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.

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.

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

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.

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.

Fountain Valley, Calif. – Oct. 13, 2017 – Hyundai Motor America has recalled more than 400 vehicles potentially equipped with defective crankshaft assemblies, according to documentation submitted to the National Transportation Safety Administration. The campaign affects 2017 Santa Fe sport utility vehicles with production dates ranging from Jan. 26, 2017 to Feb. 13, 2017. HMA estimates that 25 percent of the models named in the recall actually contain the defective parts.

The Defect

Affected vehicles could contain crankshaft assemblies featuring crankshaft pins with surface irregularities. These components may lead to premature engine bearing degradation and damage. In the event that the engine bearing becomes overly worn or flawed during operation, the vehicle could stall suddenly. This increases the likelihood of an accident and consequently poses a serious risk to occupants. That said, HMA has yet to receive field reports connecting the defective crankshaft assemblies to any accidents or injuries.

Owners operating vehicles containing the problematic parts may hear abnormal engine noises, experience reduced motive power or see the check-engine or oil-pressure warning lamps illuminate.

Timeline of Events

On May 2, 2017, HMA received a field report that described a situation in which a customer heard a knocking sound while operating his Santa Fe. HMA personnel recovered the engine from the SUV for further evaluation soon after. Engineers at the Hyundai North American Quality Center in Chino, California launched an investigation into the component. Meanwhile, HMA kept an eye on the market over the course of June, July and August in an effort to pinpoint additional occurrences of knocking. The Korean automaker gathered three field reports mentioning abnormal engine noise over this span, all of which involved Santa Fe models. Additionally, one of these reports outline an instance of sudden engine failure. On Aug. 7, HMA started recovering the engines from the vehicles in these reports.

Later that month, HMA engineers reviewed these parts, in addition to the engine from the original report. They found that all four engines showed signs of bearing seizure, a condition linked to crankshaft pins with significant surface irregularities. The car company discovered that these components were the result of ineffective production processes. Specifically, staff at the Hyundai Motor Company Asan Plant in Korea had failed to fabricate the crankshaft assemblies using proper heat treatment, a result of skewed heating coils. The facility amended its processes and corrected the problem during a tool maintenance session in January 2017.

On Sept. 13, the HMA Technical Committee met to analyze the results of the investigation into the crankshaft pins and determined that the potential operating outcomes, most notably sudden engine stalling, posed a serious threat to occupants. The group then ultimately decided to conduct a voluntary safety recall.

HMA notified dealers Sept. 27.

The Solution

The car company has directed dealers to inspect and, if necessary, replace the engines in affected vehicles free of charge, according to the NHTSA. HMA plans to notify owners via first-class mail Oct. 18. Owners in need of more immediate assistance can reach out to Hyundai customer service personnel at (855) 371-9460. Callers should use the internal recall identification number 168. Owners can also connect with the NHTSA directly through its Vehicle Safety Hotline at (888) 327-4236.

Fountain Valley, Calif. – Oct. 11, 2017 – Hyundai Motor America has recalled nearly 200 vehicles believed to contain defective front coil springs, according to documentation filed with the National Transportation Safety Administration. The campaign affects 2018 Hyundai Santa Fe Sport sport utility vehicles with production dates ranging from Aug. 25, 2017 to Sept. 6, 2017. The Korean automaker is unsure exactly how many of the models referenced in the recall actually come equipped with the defective features.

The Defect

Affected vehicles may include front coil springs prone to fracture under heavy loads. In some instances, these features can extrude from the chassis and come into contact with – and puncture – vehicle tires. This increases the likelihood of an accident and therefore poses a serious threat to occupants. However, HMA has not received any reports connecting the defect to any accidents or injuries.

Drivers who experience coil spring fracture normally see a notable change in ride height and hear the abnormal noise created when the spring rubs against the inboard tire sidewall.

Timeline of Events

In early September 2017, Hyundai engineers conducting routine test drives at the Hyundai Motor Manufacturing Alabama facility in Montgomery operated two vehicles that suffered coil spring fractures mid-drive. Quality assurance staff at the plant notified HMA officials via a Sept. 5 internal report. Upon receiving this documentation, the automaker reviewed records to search for customer complaints referencing the problem – none were found. However, HMA did pinpoint approximately 1,700 vehicles originating from the assembly plant in Montgomery that could include the defective coil springs.

The automaker determined that approximately 196 of these models had been shipped to dealers. It also learned, via an internal investigation, that the defective coils installed in these SUVs were the result of ineffective production processes involving malfunctioning coil spring forming equipment.

The Mando Corporation, based in Opelika, Alabama, oversaw the operation that produced the defective parts. The parts provider repaired its coil-forming tool to prevent the production of additional defective features. It launched the overhauled equipment since Sept. 6.

On Sept. 13, the HMA Technical Committee convened to review all information collected on the fracture-prone coil springs and eventually decided to conduct a voluntary safety recall. The automaker notified dealers and owners Sept. 27.

The Solution

HMA has directed dealers to replace the coil springs in affected vehicles free of charge, according to a recall acknowledgment document from the NHTSA. Owners should have received notification via first-class mail. Those who have not or need additional assistance can contact HMA customer service at (855) 371-9460. Callers should reference the internal recall identification number 167. Owners can also reach out to the NHTSA using its Vehicle Safety Hotline at (888) 327-4236.