Three problems related to frame rust have been reported for the 2002 Hyundai Santa Fe. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2002 Hyundai Santa Fe based on all problems reported for the 2002 Santa Fe.
Right side main frame rusted threw. Can not pass state inspection. Car for all practical purposes the car is totaled and not covered by car insurance !!!.
Took vehicle in for a normal oil change, and when technician was under the car, he took some pictures of the frame in the front right corner by the front right tire. He was showing me the frame was rusting very, very badly. He warned us that if we hit a small pot hole/bump or the curb at even 5 mph the frame could bust and we could crash. The steering would shake and made chugging feeling when trying to turn, was looked at and power steering looked to be fine and fluid was full. After July 7th it made it very hard to drive and not safe for our family.
Hyundai 2002 Santa Fe began drifting during driving and developed uneven tire wear. Brought to garage - during inspection for cause, mechanic found rusted frame where front bolt of control arm is bolted to frame (frame completely gone, bolt was not attached to anything). Frame and tires replaced and alignment accomplished to fix problem - old part is available. Car was part of initial rust recall and inspected by Hyundai dealership with only action being undercoating applied.