Some models of the Hyundai Sonata can rust so severely along the sub-frame that the front wheels collapse or separate from the vehicle, according to reports from the National Highway Traffic Safety Administration (NHTSA).
NHTSA has elevated an initial evaluation of rusting in the Korean made economy car to an "engineering analysis." The analysis could eventually lead to the recall of 197,906 Sonatas to repair the rusting frames.
The Hyundai Sonatas that are the focus of federal safety attention are the 1999 Sonata GLS, the 1999 Caribbean Sonata and the 1999 to 2004 Sonata.
The Office of Defects Investigation (ODI) at NHTSA has received 84 complaints from consumers about sub-frame rust in the Sonata. The agency reported that "approximately on-third of the complaints to ODI allege that the sub-frame corrosion resulted in a loss of control and or a vehicle disablement due to wheel collapse or separation."
There are two reports claiming Sonatas crashed because of the rusting sub-frame.
In the first report, the lower front control arm of the Sonata broke away from the frame of the car while the Korean car was traveling at 55 mph. The driver, according to the report, lost control of the vehicle and the Sonata came to rest in the yard of a house.
A second consumer claimed in a report to NHTSA, "that while driving around a slight curve at 65 mph on a freeway, the vehicle sub-frame fractured and the driver lost control of the vehicle and went off the road."
No injuries were reported to the federal safety agency in either of the crashes.
When NHTSA opened the initial inquiry of excessive rust on the Sonata sub-frame in April, the agency reported that some consumers had complained of "fist-sized holes in the frame" that could cause the suspension control arm to detach from the vehicle.
The failure could result in "wheel collapse or separation, half shaft detachment resulting in sudden vehicle disablement and or steering anomalies," NHTSA reported on its Web site. The federal agency also received reports of corrosion in the engine cradle and front cross-member of the Hyundai Sonata.
Most of the complaints arose in states where large amounts of salt are used on roads during snowy months, according to NHTSA.
The "salt belt" states according to NHTSA are 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.
NHTSA said that "there appears to be an increasing trend in failures, with 10 reported so far in 2008, 19 in 2007, 11 in 2006 and 1 in 2005."
One consumer told NHTSA that his Sonata was so badly rusted the vehicle was declared a total loss by the insurance company after the lower control arm separated from the vehicle "causing the half-shaft to detach from the transmission."
A Maryland Sonata owner recently reported to ConsumerAffairs.Com that a Hyundai service technician noticed a softball-sized hole in the front right hand side of the sub-frame of their 2002 Hyundai Sonata GLS.
"I am afraid to drive this car," the Hyundai owner said.
Another consumer reported that the sub-frame on his Sonata is so badly rusted that the sub-frame needs to be replaced and the dealer will provide no assistance.
In Fairfax, Virginia, a consumer told us that his 2000 Sonata fell apart with the "sudden collapse of the right front suspension system," while he was in a parking lot.
Santa Fe
NHTSA is also investigating excessive rust and corrosion in the Hyundai Santa Fe. Federal safety investigators reported in July that they were examining consumer complaints of suspension failure, some at high rates of speed, in the 2001 model year Hyundai Santa Fe. The investigators want to know if the Santa Fe suspension rusts to the point of breaking.
Three people have reported to NHTSA that they lost control of their Santa Fe while traveling at speeds of 55 mph or more.
The safety agency investigation of the Santa Fe is still in the "preliminary evaluation" stage.
At least one report to ConsumerAffairs.Com demonstrates the urgent need for the safety evaluation. A Michigan woman reported that her Santa Fe is "rusted so bad underneath that the frame dropped down and caused a tire to blow."
