1991 HYUNDAI SONATA

1 recalls, 41 complaints - 15 TSBs

SEAT BELTS

Defect Description

THE MOTORIZED SHOULDER BELT CAN TRAVEL SLOWLY OR CHATTER IN THE TRACK AND MAY EVENTUALLY STOP TRACKING AND BECOME INOPERATIVE.

Consequence

SLOWING, CHATTERING, OR FAILURE OF THE MOTORIZED SHOULDERBELT MAY DISCOURAGE USE OF THE RESTRAINT SYSTEM, INCREASING THE RISK OF INJURYIN THE EVENT OF A SUDDEN STOP OR ACCIDENT.

Remedy

DEALERS WILL LUBRICATE THE TRACK ASSEMBLY AND, IF ANY SYSTEMS ARE FOUND INOPERATIVE, THE SYSTEM WILL BE REPAIRED OR REPLACED, AS REQUIRED.

100,000 vehicles affected

Manufacturer: HYUNDAI MOTOR AMERICA

Complaint Statistics

41 total complaints 3 crashes 6 fires 5 injuries

Top Reported Components

Component	Complaints
SEAT BELTS	7
POWER TRAIN:AUTOMATIC TRANSMISSION	5
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR	3
UNKNOWN OR OTHER	2
ELECTRICAL SYSTEM:IGNITION:SWITCH	2
ENGINE AND ENGINE COOLING:ENGINE	2
ELECTRICAL SYSTEM:STARTER ASSEMBLY	2
SEAT BELTS:FRONT:RETRACTOR	2
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE	2
WHEELS	1

LTR EXPRESSING HIS DISSATISFACTION WITH THE WAY NHTSA PROCESSED HIS PETITION FOR A HEARING...*MR THE CONSUMER SENT A PETITION FOR DEFECTIVE AIRBAGS. *TS. THE CONSUMER STATED THE AIR BAG RECALL WAS PERFORMED ON THE VEHICLE, HOWEVER THE AIR BAG LIGHT CONTINUED TO ILLUMINATE AND THE VEHICLE WAS SERVICE... Read more

Crash 1 injured

Incident date: Mar 1, 2001

RECALL 93 V 196 000/PASSIVE RESTRAINT BELTS: SHOULDER BELT ON DRIVER'S SIDE HAS STOP TRACKING AND BECAME INOPERATIVE. DEALER AND MANUFACTURER WERE NOTIFIED, AND INFORMED CONSUMER THAT VEHICLE WAS NOT COVERED UNDER RECALL DUE TO VIN. *AK *YH

INTERIOR SYSTEM PASSIVE RESTRAINT BELTS FAILED, PRIOR TO RECALL NO #93V196000.*ET

Incident date: Mar 20, 1997

TRANSMISSION HAS FAILED 3 TIMES SINCE OWNERSHIP! TRANSMISSION IS SLIPPING, CONDITION WORSENS WITH COLD WEATHER.*AK

Incident date: Oct 29, 1997

WHILE DRIVING AT 45 MPH TRANSMISSION BLEW OUT, CAUSING THE VEHICLE TO SLOW DOWN, AND KEEP CHANGING INTO DIFFERENT GEARS. VEHICLE HAS BEEN IN THE REPAIR SHOP THREE TIMES FOR TRANSMISSION FAILURE. *AK.

Incident date: Sep 26, 1998

WHEN DRIVING AT ANY SPEED WITHOUT ANY PRIOR WARNING THE ENGINE CHECK LIGHT CAME ON AND WILL NOT GO OFF. ALSO, ENGINE/TRANSMISSION LEAK. CONSUMER HAVE BEEN HAVING PROBLEMS EVERY SINCE DAY ONE. *AK

Incident date: Sep 26, 1998

WHEN DRIVING AT ANY SPEED WITHOUT ANY PRIOR WARNING THE ENGINE CHECK LIGHT CAME ON AND WILL NOT GO OFF. ALSO, ENGINE/TRANSMISSION LEAK. CONSUMER HAVE BEEN HAVING PROBLEMS EVERY SINCE DAY ONE. *AK

Incident date: Sep 26, 1998

WHEN DRIVING AT ANY SPEED WITHOUT ANY PRIOR WARNING THE ENGINE CHECK LIGHT CAME ON AND WILL NOT GO OFF. ALSO, ENGINE/TRANSMISSION LEAK. CONSUMER HAVE BEEN HAVING PROBLEMS EVERY SINCE DAY ONE. *AK

Incident date: Mar 31, 1998

DRIVER NOTICED SMOKE COMING FROM CAR, TURNED OFF IGNITION, RESTARTED THE CAR AND THE KEY GOT STUCK IN THE IGNITION AND WOULD NOT TURN. A FEW MINUTES LATER, THE CAR CAUGHT ON FIRE IN THE ENGINE COMPARTMENT. OWNER WAS ABLE TO PUT OUT FIRE, BUT THE KEY WOULD NOT COME OUT OF THE IGNITION. THE VEHCLE I... Read more

Fire

Incident date: Feb 26, 1998

STARTER FAILED TWICE/REPLACED DUE TO A DESIGN FLAW. *AK

PREMATURE WEAR OF PISTON RINGS, CAUSING ENGINE FAILURE.

Incident date: May 16, 1997

STEERING RACK FAILED.

Incident date: Aug 4, 1997

COMPLETE TRANSMISSION FAILURE, CAUSING FLUID TO LEAK ALL OVER EXHAUST SYSTEM CREATING SMOKE AND SMALL FIRE.

Fire

Incident date: Apr 10, 1991

TRANSMISSION FAILED.

THE DRIVER'S SIDE SEAT BELT RETRACTOR STOPPED WORKING, CONSUMER HAD IT LUBRICATED UNDER RECALL, BUT STILL NOT WORKING, RECEIVED RECALL LETTER # 93V196000 . PLEASE DESCRIBE. *AK

Incident date: Mar 1, 1996

WINDSHIELD WIPER MOTOR FAILED.

Incident date: Jan 1, 1993

MOTORBELT STUCK IN TRACK, CAUSING MOTOR TO BURN OUT.

Incident date: Jan 1, 1996

IGNITION STUCK IN START POSITION, CAUSING STARTER TO BURN OUT/CATCH FIRE.

Fire

Incident date: Apr 1, 1996

CONVERTER HANGER FELL APART.

Incident date: Apr 1, 1996

OIL PAN RUSTY, CAUSING IT TO LEAK.

Incident date: Apr 1, 1996

RADIATOR PROBLEMS.

Incident date: Feb 1, 1996

STARTER FAILED.

Incident date: Jan 1, 1996

BATTERY FAILED.

Incident date: Jun 1, 1995

SPEEDOMETER CABLE LOOSE, CAUSING SPEEDOMETER TO FAIL.

Incident date: Nov 1, 1994

IGNITION COIL FAILED.

FAILURE OF THE DRIVER SIDE SEAT BELT RETRACTOR, WHEN DRIVING THE SEAT BELT WILL NOT RETRACT.*AK

Incident date: Jul 23, 1995

ROSENAU AND GLASSMEN HYUNDAI 93V196. DRIVER SEAT BELT BROKE. RECALL ORDER DID NOT REMEDY THE PROBLEM. *AK *JB

Incident date: Jun 24, 1996

CAR CAUGHT FIRE AT A COMPLETE STOP. PLEASE DESCRIBE. *AK

Fire

Incident date: Mar 25, 1996

WHILE DRIVING HIGHWAY, ACCELERATOR STUCK; TRIED TO STOP; LOST CONTROL; SPUNOUT 6 TIMES; LURCHED BACKWARDS/FORWARDS ACROSS HIGHWAY; HIT 2 TREES; SPEED 80 MP. *AK

Crash 2 injured

Incident date: Feb 1, 1996

ALTENATOR AND STARTER ARE DEFECTIVE, RESULTING IN ENGINE FIRE. *AK

Fire

Incident date: Aug 10, 1995

REAR BRAKES STICK/WON'T RELEASE. *SKD

BOTH DRIVER AND PASSENGER SIDE SEAT BELT RETRACTOR SLOWS DOWN NOW THE DRIVER SIDE SEAT BELT STICKS . TT

Incident date: Jul 7, 1995

CATALYTIC CONVERTER FAILURE, IT CAME APART INSIDE. *AK

Incident date: Feb 13, 1995

BRAKES FAILED, CAUSING ACCIDENT/LOSS OF CONTROL/INJURIES. *AW

Crash 2 injured

Incident date: Jul 1, 1994

DRIVER AND PASSENGER AUTOMATIC SEATBELTS HAVE FAILED PRIOR TO RECALL (93V196). TT

Incident date: May 27, 1995

THE AUTOMATIC TRANSMISSION WITH GEAR CHANGES AND IT HAPPENS WHEN THE CAR HAS NOT BEEN DRIVEN IN AWHILE. PLEASE EXPLAIN. TT

Incident date: May 16, 1995

MOTORIZED SHOULDER BELT HUNG UP IN MIDDLE OF FRAME ABOVE SHOULDER; WIRE THAT RUNS INSIDE TRACK CAME THROUGH FRAME WORK BETWEEN THE TWO WINDOWS; WIRE OFF TRACK.

Incident date: Mar 1, 1995

WHEN DRIVING THE WHEEL LOCK UP. TT

Incident date: Feb 1, 1995

TRANSMISSION COOLANT LINE DEVELOPED A LEAK AND SPRAYED FLUID ONTO THE EXHAUST SYSTEM, CAUSING A FIRE. TT

Fire

THE DEALERSHIP REFUSES TO FIX A PROBLEM ON THE CAR THAT WAS RECALLED. PLEASE DESCRIBE RECALL FURTHER. TT

Incident date: Jan 11, 1995

DEALERSHIP REFUSED TO PERFORM RECALL REPAIRS DUE TO DATE OF VEHICLE, LATER RETRACTED STATEMENT, STILL NOT FIXED. TT

EPA Fuel Economy, 1991 HYUNDAI SONATA

Trim / Engine	City MPG	Highway MPG	Combined MPG	Fuel Type	Annual Fuel Cost
2.4L 4-cyl, Automatic 4-spd (Front-Wheel Drive)	18.0	24.0	20.0	Regular	$3,100
2.4L 4-cyl, Manual 5-spd (Front-Wheel Drive)	18.0	26.0	21.0	Regular	$2,950
3.0L 6-cyl, Automatic 4-spd (Front-Wheel Drive)	16.0	22.0	18.0	Regular	$3,400

CO2 Emissions: -1.0 g/mile (Midsize Cars)

Source: U.S. Environmental Protection Agency (EPA). Actual fuel economy may vary based on driving conditions.

Technical Service Bulletins, 1991 HYUNDAI SONATA

15 manufacturer communications from 11 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
061000 ENGINE AND ENGINE COOLING:ENGINE	2
350000 EQUIPMENT	2
063140 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR	1
105300 POWER TRAIN:DRIVELINE:DRIVESHAFT	1
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	1
270000 LANE DEPARTURE	1
280000 BACK OVER PREVENTION	1
110000 ELECTRICAL SYSTEM	1

130000 VISIBILITY

This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside th

060000 ENGINE AND ENGINE COOLING

This bulletin provides the inspection procedure and repair guidelines for certain vehicles listed below.

350000 EQUIPMENT

This bulletin provides the inspection procedure and repair guidelines for certain vehicles listed below.

030000 BRAKES (PWS)

This bulletin describes the procedure to inspect and identify fluid which may appear around the brake caliper area.

190000 TIRES

This bulletin provides tire vibration service procedures, including how to optimize vehicle vibration performance. For all wheel/tire balance claims, the a??Tire Balance Data Sheeta?? must be fully completed including imbalance and Road For

200000 WHEELS

110000 ELECTRICAL SYSTEM

This bulletin provides information on identifying dealer stock vehicles with either: a?? A Battery SOC alert - low Battery State of Charge (SOC) at or below 50%. a?? A 30 Day alert - vehicle has not started and reported an SOC in 30 days.

350000 EQUIPMENT

270000 LANE DEPARTURE

The Blind Spot Detection (BSD) or Blind-Spot Collision Warning (BCW) is a system that measures the speed of and distance from the following vehicles by using two magnetic wave radar sensors attached in the rear bumper. The BSD/BCW detects v

280000 BACK OVER PREVENTION

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

THIS BULLETIN PROVIDES INFORMATION ON COMPONENTS, ATTRIBUTES, AND PRECAUTIONS OF THE 7-SPEED DRY-TYPE DUAL CLUTCH TRANSMISSION (DCT).

061000 ENGINE AND ENGINE COOLING:ENGINE

PROVIDED PROCEDURES FOR THE INSTALLATION OF A BLOCK HEATER. *YC

061000 ENGINE AND ENGINE COOLING:ENGINE

SHOP MANUAL CORRECTION ON CYLINDER HEAD BOLT TORQUE SPECIFICATION. *YC

105300 POWER TRAIN:DRIVELINE:DRIVESHAFT

SHIFT CONDITION CAUSED BY SHORT CIRCUIT IN INHIBITOR SWITCH. *TW

063140 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR

1991 CALIFORNIA SPECIFICATION SONATA CATALYTIC CONVERTER EMISSION CAMPAIGN (23). *TW

NHTSA Safety Investigations, HYUNDAI SONATA

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

PE, Closed , Model Year: 2011

Air bags may be disabled during crash

The Office of Defects Investigation (ODI) opened PE18-003 on 3/16/18 to investigate incidents involving crashes, resulting in significant collision related damage, where the frontal airbags failed to deploy. ODI reviewed complaint data, available design, test, and field data on the model year (MY) 2... Read more

PE, Closed , Model Year: 2013

Front Passenger Seat Belt Anchor Failure

The Office of Defects Investigation (ODI) opened this investigation on December 27, 2016 based on two ODI consumer complaints reporting a failure of the front passenger seat belt to remain connected to the seat belt anchor and pre-tensioner during a crash.On March 8, 2017 Hyundai Motor America (Hyun... Read more

PE, Closed , Model Year: 2016

Electronic Parking Brake

The Office of Defects Investigation opened this investigation on September 3, 2016 based on four reports alleging the rear brakes locked or applied while driving without brake pedal application. One of the reports alleged a fire in the right rear wheel area.The vehicles subject to the investigation ... are equipped with an optional Electronic Parking Brake (EPB). In this system, an electric motor applies the parking brake by moving the rear brake pads (pads) against the brake rotors (rotors) when activated by the EPB control switch. The EPB is released by the control switch or by selecting a drive gear with the transmission shifter when the ignition is on.If the EPB has not been used within 1000 kilometers (621 miles) the system is designed to perform an Automatic Adjustment Function (AAF) of the pads to check for proper clearance. This function is a pad adjustment only and is preformed with the vehicle in park with the ignition off. It does not set the parking brake or turn the brake indicator light on. Hyundai has identified an error within the EPB control logic that can cause the pads to remain in contact with the rotors at various levels of force after the AAF is completed. This condition could cause the rear brakes to drag at the next drive cycle and may generate some levels of heat and smoke. The EPB control logic error affects model year 2016 vehicles produced from the start of production through March 16, 2016.Vehicles produced from March 17, 2016 incorporate an updated EPB control logic to prevent brake pad drag. On May 11, 2016 Hyundai notified its dealer network of Service Campaign TFF to update the EPB control logic in the affected vehicle population. Dealers will reflash the EPB software to prevent brake pad drag.There are no reports of accidents or injuries as a result of this issue. The incident that alleged fire could not be confirmed as there were no repairs to the vehicle other than replacement of the rear brake rotors and pads.ODI is closing this investigation based on the manufacturer's Service Campaign of the affected vehicles and in consideration that the the effect of brake drag in this instance does not appear to present an unreasonable risk to motor vehicle safety. The ODI reports cited above can be viewed at www-odi.nhtsa/complaints under the following identification (ODI)numbers: 10820359, 10854476, 10875764, 10892736, and 10928478Read more

PE, Closed , Model Year: 2006

Seat Belt Buckle Electrical Malfunction

On July 22, 2014 the Office of Defects Investigation (ODI) opened a preliminary evaluation to further analyze allegations of seat belt pretensioner malfunctions on model year (MY) 2006-2008 Hyundai Sonata vehicles.ODI received 131 unique reports alleging a failure within the seat belt pretensioner s... ystem, which was typically preceded by SRS light illumination.ODI requested more information from Hyundai in order to understand the nature of the failure and how the airbag deployment algorithm, the seat belt pretensioners, and/or the airbag function may be affected. In response to ODI?s information request (IR), Hyundai submitted 764 unique consumer and field reports and 19,847 warranty claims related to a failure in the front seat belt buckle assembly potentially causing a malfunction of the seat belt pretensioners.In it's response, Hyundai advised that if the resistance specifications for the seat belt buckle pretensioner circuit, located in the seat belt stalk, exceed the nominal range, a diagnostic trouble code will be set and the SRS warning indicator lamp will illuminate.The presence of this stored code will not affect the ability of the SRS Control Module (SRSCM) to detect a collision and command deployment of the pretensioners and airbags, if warranted.In fact, the wiring harness connector may be unplugged from the seat belt buckle pretensioner, and the signal to deploy the pretensioner will still be commanded and recorded.MY 2006-2008 Sonata?s utilize a dual pretensioner system by incorporating pretensioners into both the driver and front passenger seat belt retractor and the seat belt buckle assembly.The retractor pretensioner is located inside the B-pillar and winds (pretensions) the seat belt webbing back into the retractor housing during a collision, helping to remove seat belt slack and restrain the upper torso and hips.In contrast, the buckle pretensioner is located within the stalk of the seat belt assembly and acts to supplement lower limb protection.Both pretensioners are controlled by the SRSCM but utilize separate wiring and connectors.The seat belt retractor pretensioner circuitry and operation is independent of the seat belt buckle pretensioner connector and circuitry.Hyundai produced analysis indicating that increased resistance in the seat belt pretensioner which occurs in vehicle service does not result in a loss of buckle pretensioner.Hyundai further advised that in the unlikely event that a seat belt buckle pretensioner may not deploy due to increased resistance, the retractor pretensioner would still activate.Hyundai advised that the subject vehicles maintain their 5 STAR NHTSA safety rating using the retractor based pretensioner only.ODI notes that MY 2009-10 Sonatas reverted back to a single pretensioner system, and do not utilize seat belt buckle pretensioners. Hyundai advised its intention to initiate a warranty extension program to address concerns with the seat belt buckle prentensioner faults in MY 2006-2008 Hyundai Sonata vehicles.This action will extend the warranty coverage for this issue for 15 years or 250,000 miles, whichever occurs first.Given Hyundai's action and the minimal safety consequence this issue presents, further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor the issue and reserves the right to take further action if warranted by the circumstances. The ODI complaints cited above can be reviewed at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID, seRead more

PE, Closed , Model Year: 2011

Steering Shaft Separation

The Office of Defects Investigation (ODI) is aware of 7 complaints and field reports and 10 warranty claims on the subject vehicles that allege the intermediate steering shaft became loose or in some cases separated from the upper steering column and/or the steering gearbox, causing (or potentially ... Read more

PE, Closed , Model Year: 2002

INTERIOR DOOR HANDLE LACERATION HAZARD

THE MANUFACTURER HAS ISSUED A SAFETY RECALL NOTIFICATION AS A RESULT OF THIS INVESTIGATION.THE RECALL AFFECTS 91,202 MY 2002-2003 SUBJECT VEHICLES PRODUCED FROM JANUARY 28, 2002, THROUGH MARCH 22, 2003.THE VEHICLE RECALL POPULATION WAS DEFINED BY THE MANUFACTURER'S USE OF A NEW SUPPLIER FOR THE CHRO... Read more

PE, Closed , Model Year: 1999

FRONT SUB-FRAME CORROSION

THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED PRELIMINARY EVALUATION, PE08-029, ON APRIL 22, 2008, BASED ON 40 CONSUMER COMPLAINTS ALLEGING FRONT SUB-FRAME CORROSION IN MODEL YEAR (MY) 1999 THROUGH 2002 HYUNDAI SONATA VEHICLES.COMPLAINTS DESCRIBE SEVERE CORROSION OF THE VEHICLE SUB-FRAME IN THE A... REA WHERE THE RIGHT-FRONT LOWER CONTROL ARM IS ATTACHED.IN SOME VEHICLES, SUB-FRAME CORROSION HAS CAUSED COMPLETE OR PARTIAL DETACHMENT OF THE CONTROL ARM, RESULTING IN WHEEL COLLAPSE OR SEPARATION. IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER FOR PE08-029, HYUNDAI PROVIDED OWNER COMPLAINTS, FIELD REPORTS, AND WARRANTY CLAIM DATA FOR APPROXIMATELY 197,906 MY 1999 THROUGH 2002 SUBJECT VEHICLES SOLD OR LEASED IN THE UNITED STATES.THE BASE WARRANTY FOR THE SUBJECT VEHICLES IS 60 MONTHS OR 60,000 MILES, WHICHEVER OCCURS FIRST.ACCORDING TO HYUNDAI, PROLONGED EXPOSURE TO THE ROAD SALTS MAY RESULT IN CORROSIVE DAMAGE TO THE SUBFRAME.HYUNDAI REDESIGNED THE SUB-FRAME EARLY IN THE MY 2004 PRODUCTION (NOVEMBER 2003) TO ADDRESS PROBLEMS WITH PREMATURE CORROSION OF THE CROSSMEMBER NEAR THE RIGHT-FRONT SUSPENSION ATTACHMENT. ODI'S ANALYSIS OF BOTH COMPLAINT AND WARRANTY DATA FOR THE MY 1999 THROUGH 2002 SONATA VEHICLES SHOWS THAT THE FAILURE RATES ARE SIGNIFICANTLY HIGHER IN SALT BELT STATES, WHICH ACCOUNT FOR APPROXIMATELY 50 PERCENT OF VEHICLE SALES AND OVER 90 PERCENT OFCOMPLAINTS AND WARRANTY CLAIMS RELATED TO THE ALLEGED DEFECT (NOTE:FOR PURPOSES OF THIS INVESTIGATION THE SALT BELT INCLUDES CONNECTICUT, DELAWARE, THE DISTRICT OF COLUMBIA, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA AND WISCONSIN).ACCORDING TO HYUNDAI, THE ALLEGED DEFECT RESULTS IN A PROGRESSIVE LOSS OF STRUCTURAL INTEGRITY OF THE SUBFRAME AND THERE IS AMPLE OPPORTUNITY FOR THE PROBLEM TO BE DETECTED (BY INSPECTION, STEERING FEEL OR TIRE WEAR ANOMALIES) AND REPAIRED BEFORE IT REACHES A STATE WHERE A SAFETY RELATED INCIDENT MAY OCCUR.HYUNDAI IDENTIFIED 4 ALLEGATIONS OF VEHICLE DISABLEMENT AND 1 ALLEGATION OF A CRASH; WHERE THE LOWER CONTROL ARM BROKE FROM THE VEHICLE WHILE DRIVING AT 55 MPH AND THE DRIVER LOST CONTROL AND DROVE INTO A YARD.THERE WERE NO REPORTED INJURIES.ODI RECEIVED A SEPARATE ALLEGATION OF A CRASH, WHERE THE COMPLAINANT ALLEGED 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.AGAIN, NO INJURIES WERE REPORTED.APPROXIMATELY ONE-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.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA08-016) COVERING MY 1999 THROUGH EARLY-2004 HYUNDAI SONATA VEHICLES IN SALT-BELT STATES AND EQUIPPED WITH THE SUBJECT SUB-FRAME DESIGN TO FURTHER ASSESS THE FREQUENCY AND SAFETY CONSEQUENCES OF THE ALLEGED DEFECT.Read more

PE, Closed , Model Year: 2002

TIRE VALVE STEM FAILURES

THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE), PE05-059, BASED ON NINE CONSUMER COMPLAINTS OF TIRE VALVE STEM FAILURES.THE ALLEGED VALVE STEM FAILURES OCCURRED ONLY AFTER TIRE REPLACEMENT FROM THE ORIGINAL EQUIPMENT (OE) TIRE (MICHELIN 205/65R15 ENERGY MXV4 PLUS) TO ... Read more

DP, Closed , Model Year: 1999

IMPROPER FRONTAL AIR BAG PERFORMANCE

HYUNDAI HAS RECEIVED 49 REPORTS FROM CUSTOMERS STATING THE FRONTAL AIR BAGS DID NOT DEPLOY IN A CRASH FOR THE SUBJECT VEHICLES.EXAMINATION OF SUPLIMENTAL INFORMATION PROVIDED TO ODI BY THE MANUFACTURER FOR THE REPORTED CASES IT APPEARED THAT THE NECESSARY AIR BAG DEPLOYMENT THRESHOLD WAS NOT MET.THE... Read more

PE, Closed , Model Year: 1989

PASS.RESTRAINT SYSTEM FAIL

There is no summary currently available

HYUNDAI SONATA - All Years Overview

Complete safety history for the HYUNDAI SONATA across all model years (1989, 2026).

141 Total Recalls

22,246 Total Complaints

10 Investigations

1,204 Reported Crashes

689 Reported Fires

27 Reported Deaths

HYUNDAI SONATA - Year by Year

Compare recalls and complaints across model years. Click any year to see full details.

Year	Recalls	Complaints
2026	1	2	View
2025	0	20	View
2024	1	72	View
2023	2	140	View
2022	3	142	View
2021	4	179	View
2020	4	262	View
2019	0	209	View
2018	1	546	View
2017	3	1,002	View
2016	6	996	View
2015	9	1,658	View
2014	7	1,079	View
2013	9	2,650	View
2012	8	2,280	View
2011	14	4,618	View
2010	2	415	View
2009	2	612	View
2008	5	554	View
2007	7	906	View
2006	11	1,422	View
2005	1	217	View
2004	1	288	View
2003	6	249	View
2002	7	407	View
2001	3	293	View
2000	4	378	View
1999	4	187	View
1998	1	68	View
1997	2	74	View
1996	1	37	View
1995	2	93	View
1994	1	7	View
1993	1	46	View
1992	1	43	View
1991 (current)	1	41
1990	3	25	View
1989	3	18	View
1987	0	4	View

Other HYUNDAI Models

Model	Recalls	Complaints
SANTA FE	153	9,962	View
ELANTRA	133	11,853	View
PALISADE	124	2,704	View
TUCSON	95	8,074	View
SONATA HYBRID	67	1,129	View
IONIQ 5	66	1,865	View
ACCENT	64	2,745	View
SANTA FE HYBRID	57	347	View

Vehicle Safety

Consumer Safety

Infrastructure

Public Health

1991 HYUNDAI SONATA

Complaint Statistics

Top Reported Components

EPA Fuel Economy, 1991 HYUNDAI SONATA

Technical Service Bulletins, 1991 HYUNDAI SONATA

Most Affected Components

NHTSA Safety Investigations, HYUNDAI SONATA

HYUNDAI SONATA - All Years Overview

HYUNDAI SONATA - Year by Year

Other HYUNDAI Models