Sonata Low Pressure Fuel Pump May Overheat And Crack

re: NHTSA campaign 20V121000

Laguna Hills, CA – February 28, 2020 – 2013-2014 Hyundai Sonata low pressure fuel hose may crack and leak due to high temperatures around the engine. If the low pressure fuel pump overheats it may crack  and leak fuel, increasing the risk of fire and inhibiting the ability to operate the vehicle normally.

The potential number of affected units is 206,896.

The Defect:

Hyundai Motor America (Hyundai) has recalled over 200,000 2013-2014 Hyundai Sonatas whose low pressure fuel pumps may crack and leak fuel when subjected to high temperatures. The low pressure hose connects the low pressure fuel pump to the direct injection fuel pump. If the low pressure hose cracks, fuel may leak from the hose and cause fire. A slight fuel smell may develop if the fuel hose starts to leak, if vehicle occupants start to smell fuel they are advised to stop operation of the vehicle immediately and have the vehicle inspected. 

In November 2016, Hyundai Motor America (HMA) decided to conduct and investigation into previous reports concerning a fuel leak in certain model year 2013 Sonata vehicles. Of the previously recorded incidents, none of them indicated engine fire, smoke, or any time of burning odor. Hyundai decided to issue a Quality Information Report (“QIR”) and open an examination into the potential for the leak to cause an engine compartment fire. From December 2016 to April 2017, Hyundai continued to investigate the previously reported incidents as well as new field reports. The new incidents were similar to previously recorded ones – a fuel leak without any evidence of an engine compartment fire. In May 2017, HMA finalized their investigation and decided that the fuel leak in the low pressure fuel hose was too small to ignite a engine compartment fire. Formally closing the investigation, HMA decided to continually motor field reports from vehicle owners. In February 2020, HMA received news from Kia Motors America that they were to recall certain vehicles that were made with the same fuel pumps as the previously examined Sonata vehicles. Kia Motors America issued a safety recall in the U.S. on certain vehicles whose low pressure fuel lead line may creak and leak fuel, increasing the risk of an engine compartment fire. Although, HMA received no reports of a engine compartment fire in their vehicles, they decided on February 25, 2020 to issue a formal safety recall on 2013-2014 Sonata vehicles with cracked fuel pumps.

Solution:

The current remedy to this recall is under investigation. Most likely it will entail a patch to the crack in the lead to the fuel pump or the installation of a completely new fuel pump, but information provided by HMA is limited. Once the remedy has been decided upon, it will be performed at no charge. If customers have any further questions they are welcome to contact Hyundai customer service at 1 (800) 633-5151.

For more information on this or other recalls past or present, visit MotorSafety.org.

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About MotorSafety.org

MotorSafety.org is a not-for-profit organization dedicated to vehicle safety and assisting consumers with the identification and resolution of vehicle manufacturing recalls and defects. Through education, awareness, government relations, repair facility referrals and strategic partnerships, MotorSafety.org hopes to remove every unsafe vehicle from the road, facilitate its proper repair, and ensure its prompt return to the owner once the vehicle has met the required safety and performance standards. For more information about MotorSafety.org, please email support@motorsafety.org.

Marshall EarleySonata Low Pressure Fuel Pump May Overheat And Crack

Electrical Shorts in Hyundai ABS Modules’

Re: NHTSA Campaign 20V061000

Laguna Hills, CA – Feb 6, 2020 – Hyundai Motor America (Hyundai) is recalling certain 2006-2011 Elantra and 2007-2011 Elantra Touring vehicles citing the risk of short circuiting ABS modules. Electrical shorts within the affected ABS Modules’ may result in engine fires, even when the car is not being used. 

The estimated total of affected vehicles is 429,686

The Defect:

Over 400,000 Hyundai vehicles from 2006-2011 are under recall due to a risk of electrical shortage and increased risk of engine combustion. Hyundai Motor America received their first claim of an alleged engine fire on a 2007 Hyundai Elantra in October 2017. Hyundai Motors immediately requested all field information that could possibly related to other incidents of internal engine combustion and found two additional reports of internal fires in Elantra vehicles. On all three vehicles various fuses related to the Anti-lock Brake (ABS) Module were found open, indicating the possible origin of the three internal shorts and engine combustion. After two of the three known incident parts were received in November 2017, Hyundai Motors analyzed the recovered parts for signs of internal shorting due to exposed brake fluid or moisture contamination. By March 2018, Hyundai Motors could not properly confirm that internal shorting was caused by moisture ingress due to the extent of heat damage to the incident ABS Modules. In the remaining months of 2018, Hyundai continued to motor incidents in the field but  was made aware of only one additional incident and decided to initiate a recovery of in-use ABS modules for random inspection.

By March 2019, a total of eleven new vehicles were surveyed (one new incident vehicle and ten previously in-use vehicles) but no sign of moisture ingress was apparent. From April 2019 to December 2019, Hyundai Motors continued their analysis in warranty part returns from both U.S. markets and international markets, hoping to find evidence of possible moisture interference. In this analysis Hyundai found certain recovery parts conditions that could potentially lead to increased moisture in the electrical circuit of ABS modules. Although no certain trend relating to Elantra design or manufacturing, Hyundai recommended addressing the issue by de-powering the ABS module during the ignition OFF state but ultimately decided to conduct an official safety recall on January 28, 2020.

Solution:

Although Hyundai is still looking for premature signs of moisture ingress in ABS Modules, the proper solution at the moment is to install a relay in the vehicle’s main junction box to ensure little to no risk of an ABS short-circuit. Any official Hyundai dealer will perform this recall repair free of charge. Owners will be notified by Hyundai Motor America on the official expected recall date – April 3, 2020. Until then, affected owners may contact Hyundai customer service at 1-855-371-9460 with the official recall number, 188, for more information.

For more information on this or other recalls past or present, visit MotorSafety.org.

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About MotorSafety.org

MotorSafety.org is a not-for-profit organization dedicated to vehicle safety and assisting consumers with the identification and resolution of vehicle manufacturing recalls and defects. Through education, awareness, government relations, repair facility referrals and strategic partnerships, MotorSafety.org hopes to remove every unsafe vehicle from the road, facilitate its proper repair, and ensure its prompt return to the owner once the vehicle has met the required safety and performance standards. For more information about MotorSafety.org, please email support@motorsafety.org.

Marshall EarleyElectrical Shorts in Hyundai ABS Modules’

Potential for airbag damage in Hyundai 2020 Palisades prompts recall

Laguna Hills, CA – Nov. 25, 2019 – Hyundai Motor America plans to issue a voluntary safety recall next year for over 11,000 2020 Palisade model vehicles because the mounting bolts used to secure their side curtain air bags could damage the latter upon deployment. Air bags that are damaged as a result of the defect may not properly inflate, thereby increasing the risk of injury to occupants, according to official company filings with the National Highway Traffic Safety Administration.

Specifically, 11,217 vehicles are estimated to be affected by the defect and Hyundai has announced that owners can have a protective cover installed over the mounting bolts free of charge when the recall officially begins at the beginning of 2020. Hyundai has not reported any customer crashes, injuries or other related incidents as a result of the defect.

The Defect

According to the official HMA recall report, the Palisade vehicles with defects were produced by Hyundai Motor Company in the Republic of Korea between the dates of November 21, 2018 and August 12, 2019. The Side Curtain Airbags fitted in these vehicles were done so using bolts that were “produced with sharp corners” on their hexagonal heads, which could perforate or otherwise damage the SCAPs.

Timeline of Events

The 2020 Palisade recall came about after HMC discovered a torn SCAP while a New Car Assessment Program crash test was conducted in Korea on July 15, 2019, which prompted the company to reach out to the supplier and conduct a joint investigation into the potential cause of the damage. Internal crash testing was unsuccessful in replicating the tear, although the two organizations concluded based on further review of test results that the SCAB could become damaged “due to interference with the mounting bolts.”

After the testing, HMC then notified all regional distributors of Palisades equipped with the bolts and conducted its own search of related field information. HMA’s Technical Committee convened November 1, 2019, where it made the decision to conduct a voluntary recall as a means of addressing the situation. The recall report was submitted to the NHTSA November 7, 2019.

The Solution

While bolts produced with rounded (rather than hexagonal) corners were first used in vehicle production on July 2, 2019, HMA intends to begin a recall for the affected vehicles on January 3, 2020 and will notify dealers and owners and ask them to bring their vehicles to a nearby dealer to each have protective covers installed onto the SCAP bolts. The official Hyundai recall number for this incident is 186, while it is filed at the NHTSA under the recall number 19V-802.

To find out more about product recalls, visit motorsafety.org.

Sean ReyesPotential for airbag damage in Hyundai 2020 Palisades prompts recall

Hyundai Issues Two Recalls Related to Loose Parts

Laguna Hills, CA – Oct. 28, 2019 – Hyundai Motor America, an automaker with few recalls to speak of in 2019, is issuing advisories to owners of its 2019 Ioniq Hybrid and 2020 Elantra vehicles.There are two separate issues for the 2020 Elantra, one involving the lower control arm ball joint – which may also affect the Ioniq Hybrid – and the other potentially loose wheel lug nuts on the passenger-side right-rear wheel. Either of these problems manifesting themselves raises the risk of a crash and subsequent injury.

The small-scale recall is expected to begin shortly after Christmas. Owners who receive notifications alerting them to these problems are advised to contact their nearest Hyundai dealer so the appropriate repair work can be performed, which will be free of charge.

The Defect

Hyundai is recalling a total of 792 models over performance issues that could lead to the loss of control for operators of the compromised automobiles, according to the National Highway Traffic Safety Administration. The vehicles involved are as follows:

  • 2019 Ioniq Hybrid
  • 2020 Elantra

The Ioniq Hybrid and Elantra may have lug nuts that weren’t installed snuggly enough during the manufacturing and assembly process, which are believed to be on the back-right side of the vehicle. The 2020 Elantras may also have ball joints whose fasteners could be poorly tightened, which may cause the lower control arm to detach completely.

In either of these cases, a wheel or ball joint separating from the vehicle raises crash risk concerns that may also lead to an injury for the parties involved.

Timeline of Events

Whenever safety recalls are publicized – whether mandatory or voluntary – NHTSA publishes a Part 573 Safety Recall Report. These summarize recalls by detailing vehicle information – type, body style, power train, etc. It also includes data on when the cars were assembled and a chronology that pinpoints the months that certain actions were taken, such as when precisely the automaker discovered a potential issue. This report was not available at press time, however.

Prior to these most recent Hyundai recalls, the last one occurred back in January. At the time, Hyundai removed 100,000 Santa Fe Sport and Sonata vehicles from the marketplace. This was done mainly for confirmation purposes to ensure that fuel tubes to the high-pressure pumps were installed correctly. The fuel tube recall took place originally in 2015 and 2017, according to a Hyundai press release.

During this same month, Kia Motors – an affiliate of Hyundai – recalled approximately 68,000 Optima, Sorento and Sportage models over engine fire fears resulting from defective high-pressure fuel lines.

When safety recalls are announced, automakers opt to extend the warranties in place  so they’re for more years or additional miles. Motorists affected by the most recent Hyundai recalls may want to get in touch with dealership they bought their automobiles from to find out more.

The Solution

While it’s unclear how many of the nearly 800 potentially problematic Hyundai contain the aforementioned flaws, owners should prioritize getting their vehicles checked out to know for sure. The Fountain Valley, California-based nameplate will distribute notifications by first-class mail starting Dec. 27. If appropriate, the parts in question will either be replaced or simply tightened.

For more information on these most recent Hyundai recalls or for other safety issues, visit MotorSafety.org. Enter your VIN in to determine if you may be one of the 25% of car owners who has an unaddressed recall.

Sean ReyesHyundai Issues Two Recalls Related to Loose Parts

Hyundai and Kia Recall Nearly 168,000 Vehicles for Potential Fuel Leaks and Fire Risk

 

Laguna Hills, Calif. – Jan. 26, 2019 – Hyundai Motor Co and affiliate Kia Motors Corp are recalling close to 168,000 U.S. vehicles at risk of fuel leaks. This recall comes after a previous recall in 2017 for engine fire risks. The companies will also offer software upgrades for 3.7 million vehicles. The new recall covers 68,000 various Kia Optima, Sorento and Sportage vehicles from the 2011 through 2014 model years, and also affects 100,000 2011-2014 Hyundai Sonata and 2013-2014 Hyundai Santa Fe Sport vehicles.

The Defect

According to Reuters, engine replacements during the prior recall could have involved a high-pressure fuel pipe that may have been damaged or improperly installed. The faulty installation could increase the risk of fire. Hyundai and Kia now also state that the high-pressure fuel line may have been damaged, misaligned, or improperly adjusted during the engine replacement procedure. That could allow fuel to leak and increase the risk of fire.

Timeline of Events

According to Reuters, in 2015, Hyundai recalled 470,000 U.S. Sonata sedans. The reason for the recall was given as a possibility of engine failure that could result in a vehicle stall, increasing the risk of a crash. Kia did not recall its vehicles, which share the same “Theta II” engines, at that time.

In 2016, a South Korean whistleblower reported concerns regarding this design flaw to NHTSA. The U.S. agency had been investigating the timeliness of three U.S. recalls, and the number of vehicles recalled.  In March 2017, Hyundai expanded the recall to include an additional 572,000 Sonata and Santa Fe Sport vehicles with “Theta II” engines, claiming a small amount of manufacturing debris was responsible for potential engine stall, and Kia recalled 618,000 Optima, Sorento and Sportage vehicles with the same engine at the same time.

According to Consumer Reports, in May 2017, the National Highway Traffic Safety Administration (NHTSA) opened a formal investigation into the recalls. The Center for Auto Safety (CAS), a consumer watchdog group, filed a formal petition with the NHTSA in June 2018 to investigate multiple fire complaints.

The Solution

Authorized dealers will inspect the connection between the high-pressure fuel pipe and the fuel pump outlet. If leaking fuel is detected, the dealer will replace the fuel pipe and properly install a new one, at no charge to owners.

In addition to the recall, both automakers have announced a software update and warranty extension. This announcement affects approximately 2 million 2011-2018 Hyundai Sonata sedans and 2013-2018 Hyundai Santa Fe Sport SUVs, and about 1.6 million 2011-2018 Kia Optima sedans, 2012-2018 Kia Sorento SUVs, and 2011-2018 Kia Sportage SUVs. The software update is reported to protect the engine from damage that could lead to vibrations or stalling. Kia and Hyundai will also extend engine warranties to 10 years and 120,000 miles for owners of affected vehicles who contact their dealer for a free software update.

Hyundai and Kia will notify owners of the recall details via first-class mail. Owners of affected vehicles may call Hyundai at 800-633-5151 or Kia at 800-333-4542. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Sean ReyesHyundai and Kia Recall Nearly 168,000 Vehicles for Potential Fuel Leaks and Fire Risk

Hyundai Recalls More Than 8,000 Santa Fe Vehicles for Faulty Airbags

Laguna Hills, CA – October 29, 2018 – Hyundai Motor America (Hyundai) is recalling certain 2019 Hyundai Santa Fe vehicles. The Side Curtain Air Bag (SCAB) mounting bolts may interfere with and damage the air bags during deployment. The number of units affected by this recall is 8,204, with a 100% estimated affected rate.

The Defect

According to the NHTSA Recall Safety Report, this safety recall involves subject vehicles which are equipped with Side Curtain Airbags (“SCAB”) that were installed using bolts that could interfere with and damage the airbags during deployment. The bolts were produced with sharp corners on the hexagonal bolt head, increasing the risk of interference with the SCAB during installation. If the SCAB becomes damaged during deployment, the air bag may not inflate properly during a crash, increasing the risk of injury.

Timeline of Events

On August 8, 2018, Hyundai Motor Company (“HMC”) discovered a torn Side Curtain Airbag (“SCAB”) during an NCAP crash test conducted in Europe. The initial investigation revealed the SCAB could have become damaged due to interference with the bolts which were used to install the airbag and connect them to the body of the vehicle. HMC searched through past crash test records and did not find any previous instances of a deployed, torn SCAB.

On September 3, 2018, HMC conducted internal crash testing. This test successfully replicated the damage to the SCAB and confirmed that it was caused by interference from the mounting bolts. HMC immediately notified all regional distributors of vehicles using these specific bolts, and subsequently convened its Technical Committee on October 2, 2018 and began voluntary safety recall to address the condition in the subject vehicles. Hyundai has not, to date, been made aware of any incidents, crashes, or injuries related to this defect.

The Solution

Hyundai will notify owners, and dealers will install a protective cover over the SCAB installation bolts, free of charge. The recall is expected to begin November 30, 2018. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 177.

Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-715.

Sean ReyesHyundai Recalls More Than 8,000 Santa Fe Vehicles for Faulty Airbags

Hyundai Recalls Over 10,000 Hybrid Vehicles Due to Fire Hazard

Laguna Hills, CA – Hyundai Motor America (Hyundai) is recalling certain 2017-2018 Hyundai Ioniq Hybrid and 2018 Ioniq Plug-In Hybrid vehicles due to an electric defect that causes a fire hazard. The potential number of units affected by this recall is 10,575.

The Defect

According to the NHTSA Recall Safety Report, the subject vehicles contain a Power Relay Assembly (“PRA”) which is located underneath the rear seat. The PRA is equipped with a main relay, which may have been installed too loosely during assembly.

If the PRA operates in this condition, a loose connection between the main power relay contacts could increase electrical resistance. This electrical resistance can generate excessive heat and increase the risk of a fire. Drivers may see illumination of the HEV warning light while driving and/or experience an inability to start their vehicle, which is an indicator of this problem in affected vehicles.

Timeline of Events

On March 7, 2018, HMC received a report indicating that heat damage had occurred on the rear seat of model year 2017 Kia Niro sold in the Korean market. HMC immediately began testing under various driving conditions and maneuvers to determine the cause of the damage, but as of June 2018, was unable to replicate the damage and thus began to focus its investigation on component testing with the supplier.

This testing concluded in August 2018 and again the damage could not be replicated by component bench testing alone. However, HMC conducted additional testing independently, and did manage to replicate the damage on September 18, 2018. Upon inspection of the test vehicle’s damaged rear seat, it was discovered that the damage was caused by increased heat generated by the PRA. The PRA was subsequently examined, and it was discovered that the main relay was loosely connected. This indicated that the heat was the result of increased electrical resistance caused by a loose contact between the main relay terminals.

HMC also noted that the main relay had lower manufacturing specifications for terminal tightening torque and contact pressure, due to being coerced from a former supplier, and that the current supplier was providing main relays which had been produced with higher specifications for terminal tightening torque and contact pressure. The vehicles potentially affected by the former batch of relays was identified via production and supplier delivery records.

All regional distributors of the affected vehicles have informed of these findings, and October 2, 2018, HMC decided to conduct a voluntary safety recall to address the condition in the subject vehicles. Hyundai is unaware of any incidents, crashes, or injuries related to the faulty relays.

The Solution

Hyundai will notify owners, and dealers will inspect the Power Relay Assembly (PRA) for damage. If no damage is found, the main relay will be replaced. If damage is found, the PRA will be replaced. These repairs will be performed free of charge. The recall is expected to begin November 30, 2018. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 178.

Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-704.

Sean ReyesHyundai Recalls Over 10,000 Hybrid Vehicles Due to Fire Hazard

Hyundai recalls vehicles with defective clutch components

Fountain Valley, Calif. – May 10, 2018 – Hyundai Motor America has recalled more than 10,000 vehicles potentially equipped with defective hydraulic clutch actuator assemblies, according to documentation submitted to the National Highway Transportation Safety Administration. The campaign affects 2017 Hyundai Ioniq hybrid sport utility vehicles produced between Nov. 16, 2016, and Sept. 20, 2017. The South Korean automaker suspects 1 percent of the models involved in the recall contain the defective parts.
The Defect
Affected vehicles have hydraulic clutch actuator housings with abnormally rough edges. These defective features can damage the nearby oil seals, causing oil to leak and pool around the phase cap. This issue can cause electrical shorting and, in instances in which major thermal damage occurs, engine fire. As a result, the defect poses a serious risk to occupants. That said, Hyundai has yet to receive field reports linking the problematic hydraulic clutch actuator assemblies to any accidents or injuries.
Timeline of Events
A Hyundai parts provider LuK reached out to the car manufacturer in March 2017 to report that it had received hydraulic clutch actuator assemblies involved in warranty claims that seemed to exhibit signs of thermal damage near their phase caps, according to an internal chronology report given to the NHTSA. Hyundai reviewed warranty claims filed in the Korean market in response and found no reports of engine fire or thermal events of any kind. The automaker then began shipping parts from applicable warranty claims to LuK for further analysis. Within three months, the parts vendor had collected a large number of hydraulic clutch actuator assemblies whose housings featured jagged metal edges. LuK determined that these features could damage adjacent oil seals and cause leakage. Consequently, the firm implemented new production processes to eliminate the creation of jagged housing edges and installed reinforced oil seals to prevent leakage.
A Hyundai affiliate submitted a quality information report associated with the defect in December 2017. This action prompted the automaker to accelerate and expand its analysis efforts. Between January 2018 and April 2018, Hyundai combed through a significant number of hydraulic clutch actuator assemblies to gain more information on the variables contributing to failure. The car manufacturer was able to replicate an electrochemical reaction caused by oil pooling around the phase cap. It was also able to create a galvanic event that produced sparks and could cause an engine fire.
On April 16, 2018, Hyundai shared its findings with all vendors and affiliates in all markets. Then, on April 20, 2018, the automaker convened its Technical Committee, which called for a voluntary safety recall. Dealers received notification of the campaign May 4, 2018.
The Solution
Hyundai has directed dealers to inspect hydraulic clutch actuators installed in affected vehicles and, if necessary, replace these parts free of charge, according to an NHTSA recall acknowledgment document. The car manufacturer intends to reach out to owners through first-class mail June 20, 2018. Owners in need of assistance prior to the beginning of the campaign can contact Hyundai customer service personnel at (855) 371-9460. Callers should use the internal recall reference number 176. Owners can, of course, connect with the NHTSA directly via its toll-free Vehicle Safety Hotline at (888) 327-4236.
Sean ReyesHyundai recalls vehicles with defective clutch components

Hyundai recalls vehicles with defective safety features

Fountain Valley, Calif. – May 1, 2018 – Hyundai Motor America has recalled more than 580,000 vehicles potentially equipped with defective air bag and seat belt assemblies, according to documentation submitted to the National Highway Transportation Safety Administration. The campaign affects 2011-2013 Hyundai Sonata sedans produced between Dec. 11, 2009, and Aug. 31, 2012, along with 2011-2012 Hyundai Sonata Hybrid sedans produced between Dec. 2, 2010, and Aug. 23, 2012. The South Korean automaker suspects all of the vehicles referenced in the recall contain the defective parts.
The Defect
Affected models contain air bag control units powered by application-specific integrated circuits. These components are designed to trigger advanced air bag systems and seatbelt pretensioners in the event of an accident. However, the ACUs installed in the recalled vehicles feature ASICs that lack circuit-protecting diodes. Without these electrical parts, the ASICs may experience overstress and eventually fail, inhibiting ACU functionality and leaving occupants without crash protection. Consequently, this defect poses a serious hazard to owners. Hyundai has received at least five reports linking the defective part to accidents and injuries.
Timeline of Events
The automaker in February 2012 received a report outlining an instance in which the AAS in a 2011 Hyundai Sonata seemed to fail during an accident, according to an internal chronology document submitted to the NHTSA. Hyundai engineers inspected the vehicle referenced in the report in June 2012 and found that the vehicle had not recorded a crash event. The car company then reached out to the Michigan-based supplier ZF TRW, which had provided the ACU components installed in the vehicle. The vendor discovered signs of electrical overstress within the ACU’s ASIC assembly, a condition it linked to a number of aftermarket accessories that were installed on the model referenced in the report.
Hyundai in May 2015 received a report detailing another instance of AAS non-deployment. In October 2015, engineering teams inspected the vehicle, a 2011 Hyundai Sonata, and determined that the ACU was not functioning. ZF TRW reviewed the component and again found signs of electrical overstress. The vehicle did not contain aftermarket parts, indicating that the condition may not be linked to the installation of such non-standard components. As a result, Hyundai initiated a field review.
The automaker received two additional reports centered on AAS non-deployment between July and November 2016. While one was invalidated by investigators, the second involved a 2011 Hyundai Sonata sedan with potential ASIC damage linked to overstress. Hyundai launched an official investigation in response. Then, in November 2017, OSHA’s Office of Defects Investigation contacted the car company to check on the status of the inquiry. Hyundai submitted data related to the investigation and established a communication channel for updates. One month later, the automaker hired an external engineering firm to look into the ACU issue.
On February 21, 2018, Hyundai and ZF TRW met to discuss the state of the ongoing investigation, with the latter coming to the conclusion that transient charges, originating from adjacent vehicle parts, were causing electrical overstress in the ASIC assemblies and therefore affecting ACU performance. One day later, members of Hyundai’s Technical Committee convened and determined that a voluntary recall involving affected 2011 Hyundai Sonata sedans was necessary. Following this action, the automaker continued its investigation into the problematic ACU components.
ODI officials and Hyundai met in Washington D.C. March 9, 2018, to discuss the inquiry and the initial findings from the third-party engineering firm. It was during this meeting that Hyundai revealed that its external collaborator had determined that the ACU failure was the result of equipment failure – specifically a lack of circuit-protecting diodes. The automaker attested to replicating the equipment-related damage in a series of crash tests. This discovery expanded the pool of potentially affected models to include Hyundai Sonata and Sonata Hybrid sedans produced in 2012 and 2013. On April 3, 2018, the two parties met once more to review the ongoing investigation.
Between April 11, 2018, and April 12, 2018, Hyundai collaborated with ZF TRW to review the ACU damage sustained in the previously conducted crash tests. Both automaker and vendor agreed hat the ASIC assemblies in these components shorted due to lack of diodes. On April 18, 2018, the Hyundai TC decided to expand the existing recall, an action the group communicated to both dealers and owners April 20, 2018.
The Solution
Hyundai has not yet developed a viable remedy, according to an NHTSA recall acknowledgment document. Owners in need of assistance can contact Hyundai customer service personnel by calling (855) -371-9460. Callers should use the internal recall identification number 174. Owners can also reach out to the NHTSA directly using the agency’s Vehicle Safety Hotline at (888) 327-4236.
Sean ReyesHyundai recalls vehicles with defective safety features

Hyundai recalls vehicles with defective steering assemblies

 

Fountain Valley, Calif. – March 7, 2018 – Hyundai Motor America has recalled more than 43,000 vehicles potentially equipped with defective steering assemblies, according to documentation submitted to the National Highway Transportation Safety Administration. The campaign affects two sport utility models:

  • 2018 Hyundai Santa Fe SUVs manufactured between Aug. 10, 2017, and Oct. 23, 2017.
  • 2018 Hyundai Santa Fe Sport SUVs manufactured between June 15, 2017, and Dec. 28, 2017.

The South Korean automaker suspects just 1 percent of the recalled vehicles contain the defective components.

The Defect

The recalled models feature steering assemblies that were not manufactured to specification. Specifically, the fixtures do not possess sufficient breakage strength. As a result, the steering wheel could separate from the steering column during operation. This poses a serious threat to passengers, as steering wheel separation drastically increases the likelihood of an accident. However, Hyundai has not received reports connecting the defective parts to any accidents or injuries.

Timeline of Events

Hyundai in November 2017 received a report from the American market detailing an instance in which steering wheel of a 2018 Hyundai Santa Fe separated from the steering column. The car company filed at quality information report addressing the issue in December 2017 and began monitoring the field for further instances of steering wheel separation. One month later, Hyundai received a field report from the Korean market outlining an occurrence of steering wheel separation, leading the company to recover parts from the related vehicle for further analysis. Engineering personnel learned that the recovered steering components matched those taken from the vehicle referenced in the U.S. report, indicating vendor error.

In February 2018, Hyundai initiated a joint investigation with the steering assembly supplier Dayou Autoparts. The organizations soon discovered that a batch of steering wheel hub assemblies produced June 9, 2017, were damaged during manufacture but then reworked, compromising their breakage strength. The parts were apparently harmed during the molding phase when temperatures surpassed specified standards and adversely affected the structural integrity of the steering wheel hub assemblies.

Hyundai quality assurance reviewed the matter Feb. 8, 2018, and chose to conduct a voluntary safety recall. The automaker notified dealers of the action Feb. 23, 2018.

The Solution

Hyundai has directed dealers to replace the defective steering assemblies free of charge, according to an NHTSA recall acknowledgment document. Hyundai intends to notify owners via first-class mail March 16, 2018. Those in need of more immediate assistance can contact Hyundai customer service at (855) 371-9460. The internal recall identification number for this campaign is 173. Owners can also reach out the NHTSA directly using the agency’s Vehicle Safety Hotline at (888) 327-4236.

Sean ReyesHyundai recalls vehicles with defective steering assemblies