2001 Hyundai Santa Fe recalls and problems

IN A LETTER DATED APRIL 14, 2009, HYUNDAI-KIA AMERICA TECHNICAL CENTER, INC (HYUNDAI) NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL OF APPROXIMATELY 85,000 MODEL YEAR (MY) 2001 THROUGH 2003 HYUNDAI SANTA FE VEHICLES MANUFACTURED PRIOR TO JANUARY 27, 2003, THAT ARE REGISTERED AND OPERATED IN THE FOLLOWING SALT BELT STATES AND THE DISTRICT OF COLUMBIA:CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, AND WISCONSIN.HYUNDAI IS RECALLING THE VEHICLES TO REMEDY A CONDITION WHERE INTERNAL CORROSION OF EITHER THE RIGHT OR LEFT REAR TRAILING ARMS MAY RESULT IN FRACTURE OF THE AFFECTED ARM WHILE DRIVING, WHICH COULD RESULT IN LOSS OF VEHICLE CONTROL AND A CRASH.THE REAR TRAILING ARMS WILL BE INSPECTED IN THE RECALLED VEHICLES USING A PROCEDURE DEVELOPED BY HYUNDAI TO MEASURE METAL THICKNESS.PARTS WITH PERFORATIONS FROM CORROSION OR WITH METAL BELOW THE SPECIFIED THICKNESS WILL BE REPLACED WITH REDESIGNED TRAILING ARMS.IF THE MINIMUM METAL THICKNESS IS MET, DRAINAGE HOLES AND AND RUST PROOFING MATERIAL WILL BE ADDED TO THE EXISTING REAR TRAILING ARMS.ALTHOUGH NOT SUBJECT COMPONENTS OF THIS INVESTIGATION, HYUNDAI NOTED IT WOULD PERFORM A SIMILAR PROCEDURE FOR THE FRONT SUBFRAMES OF THE SUBJECT VEHICLES. ODI'S ANALYSIS OF COMPLAINT DATA REVEALED THAT 99% OF ALL CONSUMER COMPLAINTS RELATED TO TRAILING ARM CORROSION WERE FROM VEHIC…

IN RESPONSE TO AN INFORMATION REQUEST LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI) DURING THIS PRELIMINARY EVALUATION, HYUNDAI PROVIDED ODI WITH 15 ALLEGATIONS OF CORROSION FAILURE OF THE LEFT- AND/OR RIGHT-REAR SUSPENSION TRAILING ARM.THREE OF THE 15 CONSUMERS ALLEGED A LOSS OF VEHICLE CONTROL AS A RESULT OF A REAR TRAILING ARM CORROSION FAILURE.SIMILARLY, ODI HAS RECEIVED 12 COMPLAINTS OF REAR TRAILING ARM FAILURE (ONE IS A DUPLICATE OF A COMPLAINT FILED WITH HYUNDAI).OF THE 12 ODI COMPLAINTS, 4 CONSUMERS ALLEGE A LOSS OF VEHICLE CONTROL. IN TOTAL, ODI IS AWARE OF 26 CONSUMER ALLEGATIONS OF REAR TRAILING ARM CORROSION FAILURES AND 7 ALLEGATIONS THAT THE FAILURES AFFECTED VEHICLE CONTROL.ALL OF THESE VEHICLES HAVE BEEN OPERATED PRIMARILY IN SALT BELT STATES (CONNECTICUT, DISTRICT OF COLUMBIA, DELAWARE, IOWA, ILLINOIS, INDIANA, KENTUCKY, MASSACHUSETTS, MARYLAND, MAINE, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VIRGINIA, VERMONT, WISCONSIN AND WEST VIRGINIA).HYUNDAI IMPLEMENTED A DESIGN CHANGE IN THE MODEL YEAR 2003 PRODUCTION TO ADDRESS THE CORROSION ISSUE.THUS, THE SCOPE OF THE ENGINEERING ANALYSIS WILL BE VEHICLES MANUFACTURED IN MYS 2001 THROUGH 2003 AND SOLD IN SALT BELT STATES.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA08-023) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES OF THE ALLEGED DEFECT.

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