Front Suspension Control Arm Problems of Hyundai Sonata - part 2

On 17 August 2015, I was driving my 2006 Hyundai Sonata at 75 mph in the left lane of I-64 near nitro, wv. As I passed a tractor trailer while entering a slight curve to the left, without warning my car violently fishtailed causing the rear end of my car to momentarily go under the tractor trailer while my front end was headed toward a four foot high concrete median. By the grace of god I was able to steer out of the situation without hitting either the truck or the wall. Corrosion of the steel cross member in the rear end caused the left rear control arm to detach suddenly. I had the vehicle towed to the local Hyundai dealer where I had previous routine maintenance and recall work performed. Later that evening I researched the NHTSA site for recalls on my vehicle and found the following notice which I had not received: report receipt date: Aug 12, 2013 NHTSA campaign number: 13v354000 component(s): suspension when I questioned the service personnel as to why I did not receive the notice, their records showed my vehicle as registered to the original owner. I purchased the vehicle in 2007. There appears to be gross negligence on the part of both the dealer and Hyundai in not informing me of this recall. As stated above, the dealer had performed recall work on my vehicle while it was in their shop for routine maintenance over the past 3. 5 years.

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My car currently has 83000 miles and already has bad upper control arm in the front. I should not be having this issue this early and it began when I had less mileage than 83000. I hear squeaks when going on cracked pavement.

6 alignments with tire balancing, untold tire balancing on other occasions. The car vibrates at high speeds, my first set of tires wore out through to the steel belts on the inside at 32000 miles with a a good 1/4 in of the tread on the outside left on the front two tires. I've complained the first week I had the car and multiple times since. Not hung vivible has been found. The tire alignments and balancing to the new tires didn't touch the vibration. My fear is it's a control arm or other front end suspension issue or failure that's not visible.

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03 Hyundai Sonata GLS (v6). Driving 55mph hit pothole and lost steering. Pulled over, removed rf wheel to discover control arm bolts ripped out of the subframe from rust. Heard about recall and investigated. Car was inspected for recall in 2010 passed then at dealer in marlton, NJ. Waiting for call back from different dealer to find out the procedure to file a claim. Dealers in se PA are not customer oriented so making complaint here to document incident.

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While slowing down to make a turn on side road, the lower left control arm pulled completely out of the frame. Inspection after found large hole rusted completely through the frame rail. Inspected right side and frame has same type of rusted and missing frame segments. Thankfully this happened at low speed and not on the interstate where outcome could have been very bad. Doing some research I have found that this appears to have been a known problem with this model for several years beginning with 1999 model.

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Tl-the contact owns a 2001 Hyundai Sonata. The contact received recall NHTSA campaign number: 09v124000 (suspension). The contact stated that the vehicle was repaired under recall, however he is still experiencing failures with corrosion. The contact stated that the vehicle was taken to a mechanic where the vehicle was diagnosed that the rear suspension upper control arms needed to be replaced due to corrosion. The manufacturer was made aware of the recurring failure. The failure mileage was 153,000. Mc.

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Was driving down the when I heard a pop sound that had came from the curbside of the vehicle then the car started pulling to the right side of the road and did not really think to much about because thought needed to just have alignment done to the vehicle then next Friday I had take the car to have the alignment done on the vehicle they called me and said that the sub-frame of the vehicle was rusted in half and that it was unsafe to drive. I looked up the recalls on the vehicle and seen where it had a recall for the sub-frame rusting and set up a apt . To have it taken care of but they are saying that since my car is not registered in one of the salt-belt states that they are not going to honor the recall even though the rust is there and the sub-frame is rusted in half and the lower control arm is rusted off. Ref # 645149.

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After removing the drivers front wheel I noticed the control arm attachment point severely rusted, & the sub frame cracked ready to break. I know about the recall. Unfortunately nebraska along with other states were not included. This car was well maintained by the original owner, & driven very little in salt/ snow conditions. She purchased @ approx. 80 years of age. Nhtsa should take a look at this again. Water being trapped in the sub frames is the real problem, salt may have only made the failure happened a bit sooner. I have talked with Hyundai customer assistance, & was told the car would not be covered by the recall. I live 8 miles away from iowa, which is covered by the recall. Omaha does use salt on the streets. 14 -15 years for a sub frame to rot away seems quite short. The problem is a design defect not allowing the water to get out. No states should have been left out! who doesn't wash their car regularly? how many 1999-2004 models of this car are still on the road? fortunately for our family we noticed the steering wheel significantly out of position, & both front wheels leaning in at the top. Separation of the control arm from the frame would not pretty at a higher rate of speed. People that have looked at the pictures I took of both sides on this car seem to agree, we were probably only a few more chuck holes away! will Hyundai notify current owners of any of these cars regardless of which state & remedy correctly?? will Hyundai, or government put out TSB's or psa's alerting any current owners of the potentially catastrophic condition which may cost someone their life?.

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The contact owns a 2002 Hyundai Sonata. While driving approximately 33 mph, the contact's vehicle struck a pothole. As a result, the contact veered to the right and crashed into another vehicle. The air bags deployed. The contact sustained a neck injury that required medical attention. A police report was filed. The vehicle was taken to an independent mechanic where it was diagnosed that the subframe was rusted and failed to support the control arm. The technician informed that the subframe needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and stated that the VIN was included in NHTSA campaign number: 09v124000 (suspension). The failure mileage was 105,000.

The contact owns a 2007 Hyundai Sonata. The contact stated that while driving approximately 40 mph, the vehicle began shaking violently. The vehicle was taken to the dealer for diagnosis where the technician stated that the front control arm would need to be replaced. The vehicle was included in and repaired under NHTSA campaign number: 13v354000 (suspension) for the rear control arm but the recall did not cover the front control arm. The manufacturer was made aware of the failure. The vehicle was not repaired. The approximate failure mileage was 132,195.

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Why didn't Hyundai alert the nthsb of a new recall regarding lower control arm assembly for 2011 Sonata ltd?.

See all problems of the 2011 Hyundai Sonata 🔎.

Noticed a shimmy vibration louder than normal while driving to work on highway, upon exiting on main road heard very loud thump bang on left rear drivers side. I assumed it was a blow out as I couldn't steer the car (pulling to right) but managed to make into parking lot off the main. Upon inspection left rear tire still on car not flat, but on a total slant approx 45 degree. I was very glad to be off highway however still this is a major safety issue. After towing to garage, mechanic called me later and said the entire rear sub-frame rotted and broke from car needing to replace everything suspension sub-frame, including control arms, and would need an alignment, he also said that's why my tires wore down quicker than usual due to suspension issue. I didn't contact dealer since car no longer on warranty, after checking the internet for used parts (could not afford new parts as mechanic's estimate was already at the $1800. 00 mark) was surprised to see the hundreds of complaints already posted with this same issue. I did repair the car with a total bill (used/recycled parts) for $1567. 00. I still did not feel safe driving this car. Why would it take so long to have a recall. . . It is obvious this is a defect which could cause serious crash, fatality serious injury and should be covered by Hyundai for repair or full reimbursement.

Earlier in the day when I was driving with my nephew and sister, the esc light came on. The next time I drove it, the light did not come on and was not on at the time of this incident. I was driving in my neighborhood, turning a corner, when I heard a loud clunk from the driver rear side. I stopped and saw a large rusty metal piece had detached from the frame on that side and was dragging on the road, the wheel was tipped out wobbly. I knew it could not be driven. I called aaa and had it towed to a local garage. Due to holiday weekend, my husband saw the mechanic on Monday 7/8/13, who diagnosed it as a rear subframe corrosion and failure. He advised us to check for a recall as he was familiar with a prior front frame recall a few years ago. He had other repairs ahead of us, so we had it towed to our mechanic 15 miles away. When our mechanic got it on the lift we were told the damage was very severe: the rear end was rotted, needing removal/replacement of rear crossmember, 2 upper and 2 lower arms, l/r upper control arm and joint, with rear shocks and mounts, and alignment. We called Hyundai regional office, opened case # 5870260. The agent reported no recalls and this was not under warranty, but he stated he was "very familiar" with this type of problem in other years and models. He advised contacting the dealership, as they may be able to do something. (herb chambers of auburn, MA. ) the service manager at the dealership advised us to have it towed to them at our expense (40mi. ) his lack of empathy and telling us that Hyundai would take little or no responsibility for repairs, outside of a recall, prompted us to have our mechanic do the work. Repairs were done with Hyundai factory parts, ($2,640 including labor). We are convinced that the vehicle has a defect which could have caused a crash, serious injury, and/or death had it happened in any other circumstance.

I took my 2004 Sonata for inspection and was told that it would not pass due to a large hole from corrosion in front passenger subframe near control arm bolt costing $1200 to fix. After finding out that this was recalled and I was never notified, I contacted Hyundai and was told that my car was covered (I am in so-called "salt belt"). When I called the dealer back, I was told that my VIN is not included in the recall. The dealer then called Hyundai and dealer called me back stating that Hyundai would not cover. This hole can get larger and potentially cause the wheel to fall off while driving. My approx mileage is only 42k. Why is it not covered?!?!?!? I'm getting the run around.

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The original equipment tires wore uneven (cupping) producing a loud sound as speed increased. These tires were replaced with new toyo proxes tires, which eventually wore the rear tires in the same manner producing unacceptable tire noise. The current (third set) of new tires, hankook 727's, have apx. 20k miles and have started to wear the rear tires in the same (cupping) pattern. The dealer was made aware of this years ago during a maintenance visit. He suggested replacing the tires and rotating them every 5k miles. This suggestion is not a satisfactory fix. Outside of this problem the car is perfect. However, replacing tires before they're worn out is too expensive. Tire replacement off-sets the fuel efficiency rating that prompted the purchase of this car! not one of the 3 sets of tires on this car got close to the manufacturers mileage rating! a new set of tires mounted and balanced is more than $1,000. 00. Given the cost of tires, this car is more expensive to operate than my other car, a v8 performance sedan which averages 19mpg. I'm not happy with the tire wear situation and I'm considering a replacement vehicle due to this problem. There was a re-call to replace the rear lower control arms which didn't help with this problem.

2006 Hyundai Sonata. Consumer writes in regards to vehicle front control arms recall notice. The consumer was informed the control arms needed to be replaced, due to the fact the bushings were starting to separate. The consumer asked about the cause, and the dealer stated it was due to wear and tear. The consumer began to research the issue, and discovered a recall was issued for the front control arms. The consumer filed a complaint and Hyundai responded by saying they did not show any open campaigns on his vehicle. In October 2013, the consumer received a recall # 13v354000 which outlined an issue with corrosion that could result in detachment of the inboard control arm mounting points. As a result of the notice, he contacted the dealer and was told, it appeared to be related and that it would be fixed at no cost. Consequently, when he call the Hyundai dealership and was told the issue identified in the notice and his issue with the bushings that were starting to separate were two different issues and that the initial issue would not be a part of the recall. The consumer stated the only thing the dealer did, was add a corrosion kit under-coating aero and rust preventive v. The service department informed the consumer, they were not replacing the cross-member on any vehicles, they were merely using some kind of protectant to prevent further corrosion.

Upper control arms failed & were replaced 9/27/2012. This required another dealer alignment. Front tires then wore out 6,200 miles later. Tires wore down to metal belt core; could have easily blown out. I had 3 previous dealer alignments and was told by dealer in April 2013 there is no more camber/caster adjustment possible, my car is "out of specs", that I need a $650 aftermarket camber adjustment kit. Dealer told me to rotate tires every 3,500 miles which is much sooner then the factory recommended 7,500 miles. I was told tires will lose 50% or more of tread life. My April 17, 2013 dealer alignment failed, could not be done. I had dealer alignments sept 26, 2012 (with new upper control arms), Jan 22, 2010, July 29, 2010, July 29, 2009. I have good photos of the severe tire damage, steel belting clearly visible. I am original owner and have detailed repair records from the dealer.

The contact owns a 2003 Hyundai Sonata. The contact stated that while driving approximately 55 mph, the rear of the vehicle began swaying abnormally. The vehicle was taken to an independent mechanic for diagnosis where the mechanic stated that both rear struts would have to be replaced. While the repair was being performed the rear driver's side upper control arm fractured. The mechanic stated that the rear upper control arm and frame were severally corroded. The manufacturer was made aware of the failure. The vehicle was not repaired. The approximate failure mileage was 130,000. Updated 1/6/cn.

The right side sub-frame of my 02 Hyundai Sonata I just found out has rusted through and the lower control arm has separated causing the axle to pop out, this happened as I was driving and almost caused a wreck. . . I thought I need alignment but, found out that I need replace subframe. The car is very well maintained and even though it was once in a northern state (that's where I bought it. . In new york) I do not think this uneven rusting of the subframe is normal. I checked and found that there was actually a recall of this vehicle for the exact this same reason, I am planning to call Hyundai.

The right side sub-frame of my 02 Hyundai Sonata we just found out has rusted through and the lower control arm has separated causing the axle to pop out, this happened as I was driving and almost caused a wreck. . . The car is very well maintained and even though it was once in a northern state (that's where I bought it. . In s. Dakota) I do not think this uneven rusting of the subframe is normal. I checked and found that there was actually a recall of this vehicle for the exact this same reason, I called Hyundai and the representative lied to my ear that it was not covered by that recall and that I should take to the Hyundai dealership and pay for the repair myself. This is unconscionable and shouldn't be so. I wish I can get some help.

Tl-the contact owns a 2008 Hyundai Sonata. The contact stated that while driving approximately 45 mph, the rear of the vehicle started to become uncontrollable. The contact moved off the roadway and noticed that the rear passenger side tire was tilted awkwardly. The vehicle was later driven to an independent mechanic where they advised him that the rear passenger upper control arm was severely rusted and needed to be replaced. The vehicle was repaired. The manufacturer was contacted and they offered no assistance. The failure mileage was approximately 135,000. The current mileage was approximately 137,000. The VIN was unavailable. Kmj.

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I own a 2006 Hyundai Sonata, at 100,000 (hwy miles) the front upper control arms became squeeky and detatched from the rubber bushings, making a horrible ride and clunking sound when I would put the car into gear. This problem makes the car bouncy and unstable. There is also a knocking or loud clicking sound in the engine at crusing speeds, when I barley push the gas pedal. It sounds like the air intake control valve. It goes away when I accelerate. The radio and cruise control electornics seem to work only when they want too!.

This problem was discovered oct 26, 2012. My son noted some loss of control after hitting a road bump. I inspected the car and noted that the rear diver-side wheel was at a weird angle. The car was moved to my local repair shop on Nov 1st. They informed me that there was subframe corrosion effecting the rear control arm and making the car unsafe to drive. He advised me to have my Hyundai dealership look at it. I called garvey Hyundai, of queensbury, NY, where I purchased this vehicle. I spoke to the service manager and arranged to have the vehicle towed from my shop to garvey. He informs me that there has not been any prior problems with subframe corrosion and this model year and no recalls. He tells me that it will cost between $1350 and $2400 to repair and although Hyundai is not responsible they offered me $500 toward the repair work. I feel that this should not be an issue with a vehicle that is only a 2006 and that the repair should be covered in full by Hyundai. The car has spent winters in a garage when not driven. I have had multi issues with this vehicle, including needing to have the engine replaced (while still under warranty) I see that there has been subframe corrosion issues with prior years.

Tl-the contact owns a 2000 Hyundai Sonata. The contact stated that while the vehicle was at the local mechanic for tire maintenance the vehicle front subframe lower control arms was found corroded. The manufacturer denied assistance with the repair, because the vehicle was not included in NHTSA campaign id number: 09v124000 suspension. The vehicle was not repaired. The failure and the current mileage was 220,000. Li.

I was just getting off the interstate and was driving home when the car made this clunking noise and then I lost control of the steering. I could no longer drive the car. After I got the car home, it was looked at and I was told the control arm rotten off the sub-frame from the inside out. I did some research and found that this was a problem with the 2001-2004 Hyundai Sonatas. I contacted Hyundai and they did not seem to want to help me and told me this has not been a problem in the past. It apperas to me that if they recalled previous models that they have not fixed the problem. I am very thankful that the control arm did not brake while I was on the interstate driving at 65 mph.

The frame to the car has a hole rusted thru the lower control arm bolt and is no longer drivable. The car was stranded on the highway and someone could have been killed Hyundai says its not covered under the recall but its the exact same problem as all the rest.

I was backing my vehicle up, which was parked in front of my house, and I noticed what sounded like a cv joint noise from the left front wheel area. The problem has reoccurred several times since but the latest and loudest was after I had the vehicle inspected at the dealership on 03/21/2015. The noise took on an even louder sound that was more of a clunk like a front control arm. Therefore, I contacted Hyundai USA for a detailed explanation of TSB 10055854 but they will not go into any specifics about what the component(s) are in this campaign. I feel that this is an intentional cover up so that the NHTSA will not investigate and require a safety recall. VIN 5npec4acxch489687.

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The contact owns a 2002 Hyundai Sonata. While driving approximately 15 mph, the vehicle unexpectedly came to a complete stop after a loud noise emitted outside of the vehicle. The contact inspected the vehicle and noticed the front driver's side collapsed with the tire positioned outwardly. The vehicle was towed to an independent mechanic who stated the sub frame and lower control arm needed to be replaced. The mechanic recommended the vehicle be repaired by an authorized dealer. The vehicle was taken to the dealer for diagnostic testing and to be repaired. There was a NHTSA recall campaign id number, 09v124000 (suspension); however the part was unavailable and the consequence occurred while waiting for the part. The manufacturer was not notified of the problem. The approximate failure mileage was 155,000. The VIN was unavailable.

2011 Hyundai Sonata. Consumer writes in regards to a sound heard when making a left turn the dealer informed the consumer the vehicle needed a left control arm and cross member assembly, including an alignment. The consumer was informed, the repairs were not covered under warranty because the vehicle had bottomed out caused by driving.

In spite of following manufacturers guidelines for tire inflation and following proper rotation timetables and having the car aligned this car eats tires. I have replaced all four tires 5 different times in less than 100,000 miles. I purchase premium, name brand tires with a mileage rating of 60,000 miles. In 2011 I took my car in for alignment at a Hyundai dealership. They informed me that "all lower control arms, cam bolts and bushings seized due to rust; can't align properly. I had a platinum extended 100,000 mile bumper to bumper warranty through Hyundai. The dealership called to advise of the extended warranty. The adjuster came and inspected and "extended warranty denied coverage as rust was the cause, they will not pay for repairs. " the dealership argued that this is the northeastern part of the us and we have snow and the roads are salted in the winter. Dealership felt this should have been covered and tried again but coverage denied. As the owner I called the about the extended warranty and was also denied. Because correct alignment is not possible due to rust issues there is a handling/stability problem in the vehicle caused from rusted alignment components. I have followed proper scheduled maintenance but due to the propensity of rusting this Hyundai Sonata has deteriorated worse than comparable automobiles therefore causing a safety concern and a resulting loss of value. It is interesting to note that this car is exposed to northern salted roads minimally. I leave the north the first of January and head south and return in early April and have done so for the past 3 winters.

See all problems of the 2009 Hyundai Sonata 🔎.

Broken left upper control arm not covered under 100,000 mile warranty, which could have adversely caused a loss of control of vehicle, per mechanic.

The contact owns a 2006 Hyundai Sonata. The contact stated the front drivers side control arm broke. The contact was traveling 65 mph when he heard a cracking sound. The contact was attempting to exit the highway when the vehicle crashed into another vehicle because the contact was unable to keep the vehicle in one lane. The vehicle was towed to the dealer to be repaired. The failure and current mileage was 153,000.

The car is not mine,I am a mechanic,a 2003 Sonata I do a lot of work on just had a rr lower control arm fail,I know thay have a subframe issue,so knowing this, how many more of thease"time bombs" are out thair,thay sell alot of these cars in the state I live in[new york], how many more major suspention components are failing due to corrosion! alot of young people buy them because of price,the elderly also,that is why im writing this car belongs to an older widow who cano't aford the repairs,the warantee should cover the repair but her late husband bought this car because of the warantee!!.

Car has bad rust out problems. On the metal frame and suspension parts. Total rust out on rear frame, also the upper control arms. The front cradle frame was repaired previously. Updated 10/20/11.

Vehicle had developed a front end alignment problem, and I scheduled an alignment. The morning before the scheduled alignment, I was pulling out of my driveway to go to work when the right inner cv joint disintegrated. Investigation revealed severe subframe corrosion resulting in the control arm mount separating from the subframe, causing the cv joint to fail and the vehicle to become inoperable. Nhtsa and Hyundai issued a recall in 2009, campaign id number: 09v124000. However, the state I reside in (nebraska) is not listed as a "salt belt" state and is not covered by the recall. Nebraska does indeed use salt on the roads, and the description of the fault and potential results matches exactly with the rust and corrosion on my vehicle's subframe and the results. I believe it likely that there are other motorists in the state of nebraska who are driving these vehicles with this hidden and potentially very dangerous fault. The Hyundai dealer has been unable to help me so far with a fault resolution per the recall.