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

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

Hyundai recalling late-model sedans over braking issues [Video]

Welcome back to the recall blog.

Hyundai Motor America recently made the decision to recall nearly eighty-eight thousand late-model Azera and Sonata sedans due to concerns about their anti-lock brakes.

If moisture were to enter a powered anti-lock brake system, it could result in a short circuit that increases the risk of a fire in the engine compartment.

This can happen even when the vehicle is parked and the ignition is off.

The issue affects about 1 percent of the recalled vehicles, which includes all 2006 to 2011 model year Azeras, and 2006 model year Sonatas.

Hyundai plans to notify affected owners in late February 2018, and will advise them to return the vehicles to a dealership, where the problem will be fixed free of charge.

Thanks for watching, and check back again for more recall updates!

Ken BoydHyundai recalling late-model sedans over braking issues [Video]

Hyundai Santa Fes Recalled for Common Side Air Bag Issue

Recall Masters – December 28, 2017

Hyundai Santa Fes Recalled for Common Side Air Bag Issue

Hyundai Motor America recently issued a recall order for more than 1,200 of its Santa Fe light sport utility vehicles from the 2018 model year, citing issues with a side curtain air bag inflator diffuser, according to a defect filing made with the National Highway Traffic Safety Administration.
The issue specifically relates to the shape of the metal top-hat diffusers, which were not manufactured to specification. As such, in the event of a crash in which the side curtain air bags – on either side of the vehicles in the recall – deploy, the diffuser could detach from the inflator component.
Of the 1,201 vehicles in the recall, only 1 percent are believed to have this defect, and all affected Santa Fes were manufactured between Sept. 5 and Nov. 30, 2017 at plants operated by Hyundai Motor Manufacturing Alabama and Kia Motor Manufacturing Georgia…

Read the entire article on the Recall Masters website

Sean ReyesHyundai Santa Fes Recalled for Common Side Air Bag Issue

Hyundai Santa Fes Recalled for Common Side Air Bag Issue

 

Fountain Valley, Calif. – Dec. 28, 2017 – Hyundai Motor America recently issued a recall order for more than 1,200 of its Santa Fe light sport utility vehicles from the 2018 model year, citing issues with a side curtain air bag inflator diffuser, according to a defect filing made with the National Highway Traffic Safety Administration.

The issue specifically relates to the shape of the metal top-hat diffusers, which were not manufactured to specification. As such, in the event of a crash in which the side curtain air bags – on either side of the vehicles in the recall – deploy, the diffuser could detach from the inflator component.

Of the 1,201 vehicles in the recall, only 1 percent are believed to have this defect, and all affected Santa Fes were manufactured between Sept. 5 and Nov. 30, 2017 at plants operated by Hyundai Motor Manufacturing Alabama and Kia Motor Manufacturing Georgia.

This defect is also the subject of recalls for both Kia and Ford, with both including far more vehicles than Hyundai’s.

The Defect

Specifically, this is caused by the fact that the top-hat diffusers were not manufactured with the correct dimensions.

In certain situations in which the side curtain air bags are deployed, there is a possibility that the diffusers could detach from the air bag inflator, bringing with it two potential problems. First, the air bags might not inflate properly, and second, the metal diffuser could become a projectile launched into the vehicle. Both increase the risk of occupant injury.

To this point, Hyundai is not aware of any accidents or injuries related to the top-hat diffuser issue.

Timeline of Events

The potential issue was first spotted by the company that supplied the side curtain air bag inflator component on Nov. 18, 2017, and at that point it began production of the inflator components using properly sized top-hat diffusers.

On Nov. 27, 2017, the supplier then notified both Hyundai Motor Manufacturing Alabama and Kia Motor Manufacturing Georgia of the potential defect with the inflator diffuser.

Both had received shipments of potentially affected components, and matched lot codes to vehicle production records to identify and hold back any of the affected vehicles still on site. Further, that information was used to identify affected Santa Fes that were already in dealer inventories or had been sold.

Then, on Dec. 5, Hyundai completed a review of the information and decided to initiate a recall of the affected vehicles.

The Solution

Hyundai will notify owners about the risk related to the recall and ask them to bring the SUVs to local Hyundai dealers, where both the driver and passenger side curtain air bags will be inspected and – if necessary – replaced free of charge. Owners who already incurred any repair costs as a result of this top-hat diffuser issue will also be reimbursed by the automaker.

The company informed dealers of the recall on Dec. 20, 2017, and plans to notify owners on or around Feb. 9, 2018.

adminHyundai Santa Fes Recalled for Common Side Air Bag Issue

Hyundai Elantras recalled due to brake pedal issue

 

Fountain Valley, California – Dec. 21, 2017 – Hyundai Motor America recently announced a recall of 320,000 of its popular Elantras from the 2013 and 2014 model years, due to issues with the brake pedal stopper pad, according to the National Highway Traffic Safety Administration.

The brake pedal stopper pad rests between the stop lamp switch (which tells the car to engage the brake lights) and the arm of the brake pedal itself, but in the affected vehicles, the stopper pad may deteriorate over time, potentially leading brake lights to be stuck in an “on” position without the driver knowing about it, as well as other potential issues that could increase the risk of crash or injury.

Of the 320,000 Elantras in the recall – including the Elantra Sedan, Elantra Coupe and Elantra GT cars – only 1 percent of them are expected to carry this defect. All were produced from May 1, 2012, to Feb. 28, 2014.

The Defect

Specifically, the affected brake pads have “insufficient polymer content” that causes them to break down over time. In addition to brake lights staying on even after the pedal has been released, other issues stemming from the defect include the traction control warning light in the dashboard remaining on, the ability to move the shift lever without pressing on the brake pedal, or the vehicle’s engine management system activating the brake pedal override.

The two signs of the issue drivers would likely be able to identify are the vehicle’s brake lights and the traction control warning lights in the dashboard remaining on.

So far, Hyundai has not seen any incidents related to the defect that led to accidents or injuries.

Timeline of Events

On July 25, 2016, Hyundai decided to begin an initial recall on brake pedal stopper pads in certain Hyundai Elantra Sedans from the 2013 model year, but also continued analysis going forward. Then, in the second quarter of 2017, such incidents began to rise for Elantras not in the original recall, especially in Elantra Coupes and GTs.

Consequently, Hyundai Motor America started to collect more brake pedal stopper pads from vehicles involved in field incidents and sent them back to Hyundai Motor Company in Korea to be analyzed. HMC identified the issue for all Elantras affected in the recall, stemming from a change in the brake pedal stopper pad’s polymer mix cycle time.

As such, on Nov. 21, HMA issued the full recall.

The Solution

Owners of affected Elantras will be asked to bring their vehicles to a local Hyundai dealership, where the brake pedal stopper pads will be replaced free of charge with those that had additional polymer mix cycle time. Owners who previously paid for such repairs out of their own pockets will be reimbursed.

Dealers will receive formal recall notifications starting Feb. 8, 2018, the same day as owners begin receiving them. However, owner notification is expected to be completed Feb. 22, 2018.

adminHyundai Elantras recalled due to brake pedal issue

Hyundai recalls vehicles with defective seat belts [Video]

Hello, and welcome to another vehicle recall update.

Hyundai Motor America has recalled more than four-hundred and forty-three thousand vehicles possibly equipped with defective seat belt assemblies. The campaign affects 2011-2014 Hyundai Sonata and 2011-2015 Hyundai Sonata Hybrid sport utility vehicles.

These models feature front seat belt assemblies with pretensioner components that may not fasten properly, posing a serious safety hazard to occupants.

Hyundai has directed dealers to inspect and, if necessary, repair the pretensioner parts in these models. The automaker will reimburse owners for any required work. Individuals affected by this recall should have received notification via first-class mail on or around October twelfth, two-thousand and seventeen.

Stay tuned for more vehicle recall breaking news.

adminHyundai recalls vehicles with defective seat belts [Video]