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Multiple Hyundai recalls for brake lamps and rust issues affect nearly 1M units
by Michael Harley on Apr 20th 2009 at 2:20PM

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The National Highway Traffic Safety Administration (NHTSA) and Hyundai have initiated recalls on 963,305 vehicles as part of four separate campaigns. The first recall, blanketing over one half million late-model vehicles, is nationwide. The other three recalls, all corrosion-related on older vehicles, are limited to the regions of the country where salt is used to de-ice roads in the winters.

The most widespread recall, affecting up to 531,894 2005-2008 Accent, Azera, Elantra, Entourage, Santa Fe, Sonata, Tucson, and Veracruz models, is NHTSA Campaign 09V122000. It is focused on a malfunctioning stop lamp switch that may prevent brake lights from illuminating when the pedal is depressed (the same switch may also cause them to stay lit after the brakes are released).

The second recall, affecting up to 175,765 1999-2004 Sonata, XG300, and XG350 models, is NHTSA Campaign 09V124000. That recall, limited to America's so-called "Salt Belt" states, is centered around potentially excessive corrosion of the front sub-frame due to winter road salt applications. If unnoticed, the lower control arm may separate from its mount.

The third recall, affecting up to 170,610 2001-2003 Elantra and Tiburon models, is NHTSA Campaign 09V125000. Also limited to the salt-belt states, the affected component is a failed lower control arm due to excessive corrosion.

The fourth recall, affecting up to 85,036 2001-2003 Santa Fe models, is NHTSA Campaign 09V123000. Again limited to to the Salt Belt states, the recall is centered around the possible internal corrosion of the rear trailing arms in the vehicle's suspension.

In all four recalls, Hyundai dealers will inspect, repair, and replace defective or damaged parts at no cost to the owner. In some situations, rust-proofing material will be added to chassis areas to arrest the corrosion process. Owners of affected vehicles may contact Hyundai Customer Service at 1-800-633-5151, call the NHTSA Hotline at 1-888-327-4236, or visit SAFERCAR.GOV. Press releases after the jump.

[Source: NHTSA]


PRESS RELEASES:

Vehicle Make / Model: Model Year(s):
HYUNDAI / ACCENT 2006-2007
HYUNDAI / AZERA 2007
HYUNDAI / ELANTRA 2007
HYUNDAI / ENTOURAGE 2006-2007
HYUNDAI / SANTA FE 2007
HYUNDAI / SONATA 2006-2007
HYUNDAI / TUCSON 2005-2007
HYUNDAI / VERACRUZ 2007-2008

Manufacturer: HYUNDAI MOTOR COMPANY Mfr's Report Date: APR 14, 2009
NHTSA CAMPAIGN ID Number: 09V122000
PE09003

NHTSA Action Number: PE09003

Component: SERVICE BRAKES, HYDRAULIC:SWITCHES:BRAKE LIGHT
Potential Number of Units Affected: 531894

Summary:
HYUNDAI IS RECALLING 531,894 MY 2006-2007 ACCENT, ENTOURAGE, SONATA, MY 2007 AZERA, ELANTRA AND SANTA FE, MY 2005-2007 TUCSON AND MY 2007-2008 VERACRUZ VEHICLES. THE STOP LAMP SWITCH IN THE AFFECTED VEHICLES MAY MALFUNCTION. A MALFUNCTIONING STOP LAMP SWITCH MAY CAUSE THE BRAKE LIGHTS TO NOT ILLUMINATE WHEN THE BRAKE PEDAL IS DEPRESSED OR MAY CAUSE THE BRAKE LIGHTS TO REMAIN ILLUMINATED WHEN THE BRAKE PEDAL IS RELEASED. A STOP LAMP SWITCH MALFUNCTION MAY AFFECT THE OPERATION OF THE BRAKE-TRANSMISSION SHIFT INTERLOCK FEATURE SO THE TRANSMISSION SHIFTER WOULD NOT BE ABLE TO BE SHIFTED OUT OF PARK POSITION. IT MAY ALSO CAUSE THE ELECTRONIC STABILITY CONTROL (ESC) MALFUNCTION LIGHT TO ILLUMINATE, AND IT MAY NOT DEACTIVATE THE CRUISE CONTROL WHEN THE BRAKE PEDAL IS DEPRESSED.

Consequence:
THESE MALFUNCTIONS MY LEAD TO A CRASH.

Remedy:
DEALERS WILL REPLACE THE STOP LAMP SWITCH FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING APRIL 2009. OWNERS MAY CONTACT HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.

Notes:
HYUNDAI RECALL NO. 092. OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV .

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Vehicle Make / Model: Model Year(s):
HYUNDAI / SONATA 1999-2004
HYUNDAI / XG300 2001-2004
HYUNDAI / XG350 2001-2004

Manufacturer: HYUNDAI MOTOR COMPANY Mfr's Report Date: APR 14, 2009
NHTSA CAMPAIGN ID Number: 09V124000

EA08016

NHTSA Action Number: EA08016

Component: SUSPENSION
Potential Number of Units Affected: 175765

Summary:
HYUNDAI IS RECALLING 175,765 MY 2001-2004 SONATA AND MY 2001-2004 XG300 AND XG350 VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. DURING WINTER MONTHS, LARGE QUANTITIES OF SALT ARE USED TO DE-ICE ROADS IN THE SALT BELT STATES. ROAD SALT MAY RESULT IN INTERNAL CORROSION OF THE FRONT SUB-FRAME THAT IS PROGRESSIVE AND MAY RESULT IN THINNING OR PERFORATION OF THE SUB-FRAME STEEL. THE CORROSION IS FREQUENTLY VISIBLE AND OFTEN DISCOVERED DURING INSPECTION OR ROUTINE MAINTENANCE. YOU MAY ALSO HEAR NOISES OR NOTICE TIRE MISALIGNMENT AND STEERING PULL. THESE ARE INDICATIONS YOUR VEHICLE SHOULD BE SERVICED. IF THESE SIGNALS ARE UNDETECTED OR UNHEEDED, THE CORROSION MAY PROGRESS AND THE FORWARD MOUNTING OF THE LOWER CONTROL ARM MAY DETACH FROM THE SUB-FRAME. IF THAT HAPPENS, THE VEHICLE MAY LOSE DRIVER POWER TO THE WHEELS. THE FRONT WHEEL MAY MAKE CONTACT WITH THE FENDER OR WHEEL WELL.

Consequence:
SEPARATION OF THE FORWARD MOUNTING OF THE LOWER CONTROL ARM MAY INCREASE THE RISK OF A CRASH.

Remedy:
DEALERS WILL MEASURE THE THICKNESS OF THE FRONT SUB-FRAME AND INSPECT THE FRONT SUB-FRAME FOR CORROSION DAMAGE IF NECESSARY THE FRONT SUB-FRAME WILL BE REPLACED WITH A NEW SUB-FRAME THAT INCORPORATES ADDITIONAL HOLES IN THE UPPER AND LOWER PANELS. IF THE FRONT SUB-FRAME DOES NOT REQUIRE REPLACEMENT, THE DEALER WILL ADD DRAINAGE HOLES TO THE SUB-FRAME AND WILL TREAT THE SUB-FRAME WITH RUST-PROOFING MATERIAL TO ARREST THE CORROSION PROCESS. THIS PROCEDURE WILL BE PERFORMED FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING APRIL 2009. OWNERS MAY CONTACT HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.

Notes:
HYUNDAI RECALL NO. 089. OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV .

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Vehicle Make / Model: Model Year(s):
HYUNDAI / ELANTRA 2001-2003
HYUNDAI / TIBURON 2003

Manufacturer: HYUNDAI MOTOR COMPANY Mfr's Report Date: APR 14, 2009
NHTSA CAMPAIGN ID Number: 09V125000

PE09011
NHTSA Action Number: PE09011

Component: SUSPENSION:FRONT:CONTROL ARM
Potential Number of Units Affected: 170610

Summary:
HYUNDAI IS RECALLING 170,610 MY 2001-2003 ELANTRA AND MY 2003 TIBURON VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. DURING WINTER MONTHS, LARGE QUANTITIES OF SALT ARE USED TO DE-ICE ROADS IN THE SALT BELT STATES. ROAD SALT MAY RESULT IN INTERNAL CORROSION AND THINNING OF THE STEEL IN THE FRONT LOWER CONTROL ARMS. THE CORROSION MAY PROGRESS TO THE POINT WHERE THE LOWER CONTROL ARM'S UPPER AND LOWER PANELS BECOME PERFORATED. A PERFORATED FRONT LOWER CONTROL ARM MAY FRACTURE BETWEEN ITS BALL JOINT ATTACHMENT AND THE FORWARD AND REARWARD PIVOT ATTACHMENTS TO THE CHASSIS. THIS COULD AFFECT YOUR CONTROL OVER THE TIRE AND WHEEL ASSEMBLY.

Consequence:
REDUCED CONTROL OF THE FRONT WHEEL DIRECTION MAY INCREASE THE RISK OF A CRASH.

Remedy:
DEALERS WILL INSPECT THE FRONT LOWER CONTROL ARMS FOR CORROSION DAMAGE. IF SPECIFIED LEVELS OF INTERNAL CORROSION DAMAGE ARE FOUND, THE FRONT LOWER CONTROL ARMS WILL BE REPLACED WITH NEW FRONT LOWER CONTROL ARMS INCORPORATING ADDITIONAL HOLES IN THE UPPER AND LOWER PANELS. IF THE FRONT LOWER CONTROL ARMS DO NOT REQUIRE REPLACEMENT, THE DEALER WILL ADD DRAINAGE HOLES TO THE FRONT LOWER CONTROL ARMS AND WILL TREAT THE FRONT LOWER CONTROL ARMS WITH RUST-PROOFING MATERIALS TO ARREST THE INTERNAL CORROSION PROCESS. THESE PROCEDURES WILL BE PERFORMED FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING APRIL 2009 OWNER MAY CONTACT HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.

Notes:
HYUNDAI RECALL NO. 091. OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV .

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Vehicle Make / Model: Model Year(s):
HYUNDAI / SANTA FE 2001-2003
Manufacturer: HYUNDAI MOTOR COMPANY Mfr's Report Date: APR 14, 2009
NHTSA CAMPAIGN ID Number: 09V123000

EA08023
NHTSA Action Number: EA08023

Component: SUSPENSION:REAR
Potential Number of Units Affected: 85036

Summary:
HYUNDAI IS RECALLING 85,036 MY 2001-2003 SANTA FE VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. DURING WINTER MONTH, LARGE QUANTITIES OF SALT ARE USED TO DE-ICE ROADS IN THE SALT BELT STATES. ROAD SALT MAY RESULT IN INTERNAL CORROSION OF THE REAR TRAILING ARMS, WHICH COULD LEAD TO THINNING OR PERFORATION OF THE REAR TRAILING ARM STEEL. THE CORROSION IS PROGRESSIVE AND OCCURS OVER TIME. YOU MAY SEE OR FEEL SLIGHT TO MODERATE CHANGES IN VEHICLE OPERATION WHICH WILL INCREASE IF THE VEHICLE IS NOT REPAIRED. THESE CHANGES INCLUDE A LOWERING OF VEHICLE HEIGHT THAT CAN LEAD TO TIRE MISALIGNMENT AND STEERING PULL. YOU MAY ALSO NOTICE A CREAKING SOUND. IF THE CORROSION IS ALLOWED TO PROGRESS, THE REAR TRAILING ARM MAY FRACTURE WHILE DRIVING.

Consequence:
THE DEFORMATION AND LOSS OF STRUCTURAL RIGIDITY OF THE REAR TRAILING ARM MAY INCREASE THE RISK OF A VEHICLE CRASH.

Remedy:
DEALERS WILL INSPECT THE REAR TRAILING ARMS FOR INTERNAL CORROSION DAMAGE. IF SPECIFIED LEVELS OF CORROSION DAMAGE ARE FOUND, THE REAR TRAILING ARMS WILL BE REPLACED. REAR TRAILING ARMS THAT DO NOT REQUIRE REPLACEMENT WILL HAVE DRAINAGE HOLES ADDED AND WILL BE TREATED WITH RUST-PROOFING MATERIAL TO ARREST THE CORROSION PROCESS. INSPECTION, TREATMENT AND REPLACEMENT PROCEDURES WILL BE CONDUCTED AT NO COST TO OWNERS. THE RECALL IS EXPECTED TO BEGIN DURING APRIL 2009. OWNERS MAY CONTACT HYUNDAI AT CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.

Notes:
HYUNDAI RECALL NO. 090. OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

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Hyundai recalling more than 175,000 vehicles for corrosion damage

Hyundai is recalling 175,765 model year 2001-2004 Sonata and model year 2001-2004 XG300 and XG350 vehicles originally sold in or surrently registered in the states of Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and the District of Columbia.

During winter months, large quantities of salt are used to de-ice roads in the recall states. The road salt may result in damage to the sub-frame steel.

The damage is frequently visible and often can be discovered during routine maintenance. Owners of these vehicles may also hear noises or notice tire misalignment and steering pull. These are indications that the vehicle should be serviced.

The corrosion may progress and the vehicle may lose power to the wheels. The front wheel may make contact with the fender or wheel well. This could increase the possibility of a crash.

The Hyundai recall number is 089. Owners should contact the Hyundai Customer Assistance Center at 1-800-633-5151.

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