Brake Disc Caliper Problems of Hyundai Santa Fe - part 1

My 2014 Santa Fe sport began shaking violently at 72 mph. I took it to a shop thinking the wheels had become unbalanced. Immediately the vehicle began shaking again. I again took it for re-balancing. Same shaking problem. I took it a third time to an auto repair shop who found that the calipers were so hot they were about to burn. You could feel and smell the heat. The shop replaced the calipers thinking the shaking was a braking issue since every time I applied the brakes, the vehicle would shake even worse. The caliper replacement did not fix the issue. Finally after replacing the brake pads, calipers, and rotors, the shop did another road test. Then the car not only shook but the engine started knocking due to tie rod failure. The vehicle continued to be dangerous to drive, so the shop had it towed to Hyundai for an engine replacement under a TSB. Hyundai replaced the engine but would not take responsibility for the caliper and braking issues, which ended up being directly related to the engine issue.

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There is a rear caliper recall on Hyundai santafe 2011 manufactured Sep. 28 - Nov. 25 2010 , my vehicle is manufactured in this time frame - Nov. 16. 2010 and have the exact same problem as described in the recall but the Hyundai reps refused the repair because my VIN is not on the "list"? NHTSA campaign number: 10v-613 Hyundai recall 098: brake calipers.

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2009 Hyundai Santa Fe. Consumer writes in regards to rear brake pads being worn. The consumer stated the vehicle was bought from the dealer under the assumption that it was street legal and safe to drive. After 5 weeks, it was discovered that the rear brake pads were worn to 0% wear and the front brake pads were at 1% wear. This caused damage to the calipers, rotors, and pads.

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While driving on interstate, 65 miles hour , smell of burning coming from rear of SUV, 2013 hyundia Santa Fe sport 56k miles got out of SUV and my left rear brake was smoking very hot, took it to dealer and they looked at the left rear brake and said it was just the brake pad, repalced pad, but did not inspect all my brakes! then next day my left and right rear brakes locked up and was smoking, again took to dealership, they said nothing wrong! I was so confused, I called the Hyundai customer service they did a complaint form, it did no good for dealership did not fix or did they do a complete brake inspection, they say it would be to costly and would take to much time! and on the check in form they put mileage of 66k miles so as to look as it was out of warranty but yet the brakes lock up! I got a call from Hyundai service rep. Dave he said he wanted to make sure I as being taken care of and would see to that my brakes get fixed. But nothing ever came of it, he does not answer my calls and did not set anything up. . . . Wow what a company. I looked up problem on the internet and yes there has been others with same problem with there brakes but nothing has ever come back from Hyundai saying that it is a problem, so I did the caliper replacement on my own and yes the calipers are shot! no good. So what good is there warranty?.

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The contact owns a 2011 Hyundai Santa Fe. While driving various speeds, the brake fluid warning indicator illuminated on the instrument panel. The vehicle was taken to the dealer where it was diagnosed that the rear brake calipers failed and would need to be replaced. The vehicle was not repaired. The VIN was not included in NHTSA campaign number: 10v613000 (service brakes, hydraulic). The manufacturer was notified of the failure. The approximate failure mileage was 97,000.

Shortly after having a complete brake overhaul (rotors, calipers, pads, shoes, etc) started experiencing the abs/trac control lights randomly coming on and off. Had to mechanic and found no fault issues. Lights continued to randomly come on and off, at different speeds and braking. Shortly thereafter, started hearing the abs motor run with and without the lights coming on. Tapping the brake pedal stopped the abs motor/pump from running and would eliminate what appeared to be eliminated the pump resetting itself. Approximately 3 months ago, the issue affected braking distances, in hat you may be stopping at a light or stop sign and the abs motor would activate, even on dry pavement and significantly increase stopping distance. This has almost caused an accident on multiple occasions, not only with other vehicles but when pulling the car into my, or a shops' garage. Having been researching I have found numerous complaints of 2002 Santa Fe's having the same issues, and have found that Hyundai has issued service bulletins that are abs associated, but there has been no action to recall or fix the issues. I do not understand why there hasn't been a recall, as there have been recalls for what appears to be the same issue on later year vehicles, so it would appear that this is a systemic problem with the Santa Fe model abs braking systems.

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After performing a brake inspection I notice deep grooves within the rear brake rotors. This is not only premature brake wear but this is due to the rear brake calipers locking up.

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At 32,000 mile the rear driver's side wheel smelled hot, brake dust residue visible and squealing coming from this driver's side rear wheel. Found that the driver's side rear outside brake pad was worn down to metal. Driver's side inside pad and passenger rear pads, both inside and out were fine with hardly any wear on them. . Hyundai dealer said it is normal for rear disc pad to wear this uneven and for caliper's to stick on causing this. I feel this is a defect in either design or quality of parts as other Santa Fe owners are also experiencing this at even lower mileage. Dealer wants you to pay $60 to have your disc brakes cleaned and adjusted (what is there to adjust?) why do only Hyundai Santa Fe brakes need this unheard of service? why is it only occurring on the driver's side for me and other owners? disc brakes should not act this way.

Purchased used vehicle in March of 2013 at 32700 miles. 4 mos later at 43000 miles rear brakes began grinding severely. Took it to the dealer and they informed me the rear caliper got stuck/froze and the grinding damaged the rotor. Brake pad and rotor on rear driver side must be replaced and brake pad and rotor on passenger side needs resurfacing. Also esc light has been turning off and on and dealership claims there is no recall on the brake switch despite the NHTSA having the brake switch listed as defective and causing issues with the esc.

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While driving, driver's side rear wheel generating a screeching noise and a burning smell. Checked tire and both the tire and wheel rim were red hot. Took to Hyundai dealer. Said calipers not sliding properly. They claim on Santa Fe's you have to bring them in for service (the calipers) every 10k or so, as the rear calipers have a tendency to freeze. I checked the internet, and there are numerous postings on Hyundai Santa Fe owners having similar problems. Also an article in this week's hartford courant auto section of a consumer with a similar problem. If I had not pulled the car over and checked this out thoroughly, I could have had a blowout as the hot tire would have exploded. There may be a defect in Santa Fe calipers. A safety recall may be in order.

The contact owns a 2011 Hyundai Santa Fe. The contact stated that the brake pedal exhibited an abnormal spongy feeling when depressed. Additionally, there was a reduction in braking power without warning. The vehicle was taken to a dealer where it was diagnosed that the rear calipers needed to be replaced. The manufacturer was made aware of the failure and stated that the vehicle was not included in NHTSA campaign number: 10v613000 (service brakes, hydraulic). The vehicle was not repaired. The approximate failure mileage was 20,000 and the current mileage was 30,000.

With out any warning my rear brakes failed. I had to apply as much brake pedal as I could to stop the vehicle. After that I kept my speed down to a speed that I feel that I could stop the car safetely. A short time after that the front brakes started shuddering. I was headed for my cottage in north ontario at night were there are no garages so I had to have parts sent to that location were I replaced the front and rear rotors and brake pads. If had to make an emergency stop with the brakes in that condition I would have surely had an accident. Luckily the traffic was light. The rear brake pad was so tight in the caliper that I had to hit it with a hammer to free it and I had to grind part of the new pad so that it would fit loose in the caliper. I have to assume that the front breaks had to work so hard with no back breaks that the front rotor warped from the heat since they were fine up to that time. This is definitely a design flaw in the Hyundai brakes. The fit of the brake pad to the caliper is too close and the slightest amount of rust causes them to jam. Even without rust the new rotors were so tight that any good mechanic would not install them in that condition. This is a serious faults and I am not alone with this problem. Hyundai's answer is to pay $ 200 every year and have the brakes serviced. This is not a solution since they could seize up to 6 months after service the way the Hyundai brake parts are rusting. I had check all my brakes at the end of the winter and they seemed to be fine. The pads were not worn and the car was stopping okay. Tom gibeault cet note that I live in canada but the car was purchased in buffalo.

My 2009 Santa Fe would squeak while driving, but the noise stopped when brakes were depressed. At the dealership I was told that the rear brakes were hanging and the rotors were rusted. My car only had 26,627 miles. I have had many cars with a lot more mileage and never had this happen. This problem was not covered and the dealership did the following: machined rear rotors and lubricated slide rails, remachined rear rotors, removed and cleaned calipers and all hardware. This was on 10/4/2011. Fast forward to the end of July 2012 and my car is making noise when depressing brake. On 08/9/12 with only 37,843 (approx 10,000 miles later) the dealership told me that my rear brakes were shot and needed to be replaced. I am now finding that these cars have numerous complaints about rear brakes but none of it is covered. I also need new tires and from what I am reading about the rear brake problems this is also contributing to the wearing out of the tires. Hyundai needs to address these problems and since the 2011 Santa Fe has brake recalls, I feel that the earlier models with these problems should be taken care of and paid for by the manufacturer. Brakes are important and could potentially cause a bodily harm. This is not something that should be ignored.

Vehicle has been owned for 35 months and has 25,968 miles. Dealership refuses to repair/replace metal to metal contact of lr brakes under warranty. This is 2nd occurrence. 1st occurrence was rr on 6/13/2011 @ 15,771 miles which was repaired under warranty. Rotor turned and new brake pads installed. A rusty (defective mfgr) rattle clip which snaps into the caliper bracket causes brake pads to hang up or not retract after applying pressure and drag excessively causing premature brake pad wear/failure at half of normal pad life expectancy. This should be a class action case nationwide. Make Hyundai replace under warranty the defective rusty part to prevent premature brake wear and/or failure. Rear disc brakes should easily last 50,000 miles or more.

Our 2007 Hyundai Santa Fe keeps having brake problems - seizing, uneven wear of pads, etc. The dealership replaces the pads which continue to wear out or wear very unevenly every few thousand miles (approx 5,000). Our understanding from an independent mechanic we hired is that the calipers and the slider brackets are poorly machined (edmonds also reports the same problems); these are the real reason the brake pads wear unevenly and constantly needing replacing every few thousand miles. Please consider a recall of all of these cars. Other model years are already under recall.

2007 Hyundai Santa Fe ~36,000 miles. Rear brakes completely replaced in may 2010. While driving on highway, loud grinding brake noise heard from rear of vehicle. Large amounts of 'brake dust' on rim of rear driver's side wheel. Brought vehicle to dealer for inspection. Determined caliper was seized up due to rust. They will not remedy via warranty b/c they determine that it is an environmental issue. (salt/road debris buildup). New brake pads/rotors were damaged as a result. This has to be a safety issue as the rim of the wheel got extremely hot during use. Could this eventually lead to a tire blow out while driving? not sure!? searching online results in a lot of consumer complaints on blog/car sites. Same problem everytime: rear driver's side caliper is stuck resulting in damage to rotors and pads.

2007 Hyundai Santa Fe. Rear brakes ( driver side ) caliper siege, causing premature wearout of brake pads on left side. Some rotor scoring. Rear brakes replaced and caliper lube and cleaned of rust. Cost $153. 58.

During normal driving the left rear disc brake began to grind metal on metal. I took the car to the dealer for repair. They found "the pads were seized in the caliper brackets due to rust". The rear pads and rotors were replaced at my expense. No indication was given that the defect that caused the pre-mature failure was fixed.

The contact owns a 2008 Hyundai Santa Fe. While driving approximately 55 mph a noise was coming from the rear passenger side wheel. Upon examining the vehicle, the contact noticed that the wheel was very hot and smelled as if it was burning. The vehicle was taken to an authorized dealer who stated that the brake calipers were covered with rust. He was also informed that he would be responsible for the repair cost. The vehicle was not repaired. The failure and current mileages were 30,731.

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Hydraulic brake problems on Hyundai Santa Fe 2007. Rear brakes on drivers side caliper siege causing to ware out brake pads and rotor. Replace them once allready. Called the Hyundai dealer they said it will not be covered. I see there are a lot of complates with the same problem with the rear left caliper and no one can help.

Back driver side caliper overheated on a 2007 Hyundai Santa Fe with 32,000 miles on it. The brake pads were ruined as the vehicle was being driven one day 3/15/2010. I drove over 200 miles before I heard the loud droning sound of the brakes. Even when the brakes were not engaged the caliper was still pressing against the brake pad. Smoke coming from the wheel as well as residue on the rims. The dealership will not fix it under warranty as per Hyundais instructions. The cost will be #300. 00-$400. 00 and they said it was caused by rust which they said they saw in other Santa Fe's. I believe this is a serious defect in the vehicle as the tire could catch fire and explode causing a dangerous accident. Hyundai doesn't see a problem with this and will not warranty this issue.

The brakes on my 2008 Santa Fe seem to rust excessively. I had lost almost all braking ability last summer when the calipers froze requiring a complete brake job. Lately the rotors are rusting so bad each night that the brakes almost fail to stop the vehicle for the first mile or so of driving.

With only 21,132 miles on the vehicle, the left rear brake caliper stuck resulting in loss of braking when pads wore out. Brakes were inspected less than 3000 miles prior to loss of braking.

Rear brake problem in a 2007 Hyundai sante fe vehicle with 29k mileage. Left rear brake caliper sticks intermittently causing high pitch squealing/scraping noise and hot wheel hub. Multiple other customers report the same issue on website forum @Hyundai sante fe carspace automotive forum. Many with much lower mileage claims. My dealer inspected and said nothing could be found wrong. Root cause analysis points to rear brake caliper assembly rusts from salt corrosion and causes the caliper to stick on the brake while driving with foot off the brake. Problem resurfaced 50 days later. Waiting for my appointment to have dealer look at the issue readdress the problem. Hyundai technical safety bulletin 08-br-002 dated 12/2008 calls for cleaning and greasing the pad contact surface of the caliper carrier to rectify the cause. This does not address the root cause of material defect of rusting on rear brake calipers.

Multiple failures of the valve cover gaskets on the 3. 3 v6. Hyundai replaced twice under recalls. Gaskets have failed again and Hyundai refuses to replace. Rear brake calipers are constantly locking up. Have been since new. Hyundai refuses to acknowledge that there is a serious safety concern with this.

My 2007 Hyundai sata fe, with 15,000 miles on the odometer-has squealing rear brakes. Dealer says,there is a corrosion problem in the calipers,and they have to be cleaned out every 8,000 thousand miles,at a cost of $90. Dollars which is ridiculous. I believe poor quality metal is being used in the brake parts , a very dangerous practice ! I got no satisfaction from Hyundai motor America, consumer assistance cntr. ,to pay for this so called "brake service". I, paid for it, myself, probably like thousands of other Hyundai owner's. Please,make them recall these unsafe vehicles, and install quality brake parts,and save the owner's from the cost of unnecessary service, on rear brakes.

The contact owns a 2007 Hyundai Santa Fe. While driving 35 mph, the contact smelled a foul odor inside the vehicle. He pulled the vehicle over and attempted to identify the source of the smell. He inspected the vehicle and noticed that the odor was coming from the passenger side rear tire. He also noticed a severe heat wave from the tire. The contact stated that the tire itself was extremely hot. He took the vehicle to the dealer and they stated that the pads were rubbing up against the rotors. The dealer cleaned and greased the calipers, which corrected the failure. Through research, the contact found numerous complaints regarding the same failure he was experiencing. He believes that a recall should be issued since the failure appeared to be a manufacturer defect. The current and failure mileages were 11,700. Updated 07/17/09 the consumer stated the odor from the overheating passenger side rear wheel was only noticed after exiting the vehicle. The dealer stated the cause was due to the pads freeing up against the rotors due to corrosion at the place where the pads set in the brake caliper. Updated 07/17/09.

My driver side rear brake started squealing. I pulled over and realized the brake was scorching hot. It happened two more times after that. I called the dealership, they said bring it in. It was frozen pads in caliper slides. I was also told I should have the brakes cleaned once a year?! I was also charged $89. 95.

The contact owns a 2007 Hyundai Santa Fe. The contact stated that the rear driver's side brakes were worn. The caliper is rusted shut and the rotors and pads were destroyed. He must purchase new calipers, rods, and rotors at the cost of $405. The manufacturer would not assist and stated that the contact must pay for the repairs, even though they are aware of the failure. The failure mileage was 30,127. Updated 06/25/09 updated 06/26/09.

Noise from drivers side rear brakes in late April 2009. Checked brakes rotors extremely hot-rear only. Front brakes fine;however, rear worn almost to metal. Made appointment with dealer for may 13. Car is only 17 mo old, 15,000 miles (mostly highway driving). Dealer will replace pads but will charge a rear brake service$150. I believe there is a brake design flaw. Dealer wants $160/axle every 15000 miles to "service" brakes- clean calipers. Brakes should last longer than 15,000 miles.

My 2007 Hyundai sante fe was experiencing brake overheating from drivers side rear brake and mild heating with passenger side rear brakes. At 28k miles I had to take it to the dealer for this situation. The brakes had failed very prematurely due to this condition. The dealer resurfaced the rotors and cleaned and lubed the brake slides, and replaced the overheated damaged pads to the tune of $389. I was advised that they were not covered under the 3yr 36k mile bumper to bumper warranty as there was an exception to this for the brakes, they were only 1 yr 12k for the warranty as I am in a "severe" operating zone in upstate NY. I have checked many other forums on this subject and have found many others to be experiencing this same premature failure with the brakes and almost always it is the drivers side rear caliper that fails. I feel this is a design problem and a severe safety problem as the brakes almost caused a fire with my vehicle. This has been going on for quite a while and has not been addressed by Hyundai America. I placed a complaint with them and was told that basically there was nothing they could do about it. I do not have the old parts as they said they disposed of them prior to my arrival. I have always serviced my vehicle myself according to manufacturer recommendations and no where does it state the brakes need to be lubricated.

2007 Hyundai Santa Fe limited 27,300 mile the rear driver side caliper is sticking to the disc brake causing burning smell and heat.

Three major complaints. At 18,000 miles the top seal of the engine had to be replaced, repaired under warranty. At 21,000 mile the rear brake calipers had to be repaired for sticking and pads replaced at owners expense. Owner told by dealership the cause was "probably from salt used to treat road surfaces during snow removal". Hyundai refused warranty claim and would not admit improper materials used for braking system. At 27,000 miles, multiple visits to dealership for repair of inoperating turn signals. Parts replaced in attempt to repair include electrical box in steering column, all bulbs,flasher unit,grounding points for system. Problem recurring and dangerous.

My 2007 Hyundai Santa Fe limited (16,600 miles) began making a very loud screeching/squealing noise after about 20 minutes of driving that goes away when you even lightly tap on the brake pedal. I took it to the natick, MA Hyundai service department, who said that they could not replicate the problem, but suggested that I pay $89 for a rear brake servicing, which they explained will clean any rust/corrosion on my rotors and will adjust the rear brakes. I asked if they saw any signs of rust or corrosion on my rear brakes when they were investigating the noise, and they couldn't answer that. I asked if it is normal to have rust or corrosion or to require an adjustment of the rear brakes in a car that is 1 year old, and they said no. I elected to skip the rear brake service, and took the car home, at which time it started making the noise again. I took it back and had the mechanic go for a drive with me and he said it sounds like the rear brake pad on the driver side slipped and needs to be fixed. He said it is very common in the 2007 Santa Fe. I left the car to be fixed, and when they called to let me know it was ready, they said it would cost $89 for the rear brake service. If my brake pads slipped and it is a known issue with this car, why was a forced to pay $89 to clean and adjust the rotors? after some internet research and speaking with an independent mechanic, I have learned that the caliper frame is machined wrong and Hyundai is cramming the brakes in, causing the brake pads to slip, or even worse, causing the brakes to seize. My car is under warranty and it is unacceptable that after a year of driving it (purchased brand new) I had to pay for what is clearly poor design and construction by Hyundai.

Front brake caliper sticks and will turn rotor a very hot red color, which causes vehicle to shake violently and increases the time needed to stop the vehicle. Dealership has had the vehicle for over 2 weeks and says the only problem is the caliper needs to be replaced, which is covered under warranty. I believe it goes deeper than just replacing a caliper, which takes about half an hour.