It involved a substantial cash outlay, but Hyundai has settled its case with the federal government as it regarded two recalls, the most recent in 2017, over engine-durability issues on the 2011-2014 Sonata sedan and the 2013-2014 Santa Fe SUV. The recalls were focused on production issues that could have led to excessive bearing wear and ultimately, engine failure. In part, the settlement between Hyundai and the National Highway Traffic Safety Administration led to a warranty extension to 10 year and up to 120,000 miles, plus software updates, for the recalled vehicles. In a 2015 action, NHTSA asserted that metallic shavings and other debris may not have been fully removed during machining of the crankshaft, which could restrict oil flow to the connecting-rod bearings, leading to rod failure and an unforeseen loss of engine power.
Under the agreement, Hyundai agreed to pay a cash settlement of $54 million, invest $40 million in improved safety operations, and be subject to a possible additional $46 million deferred payment depending on compliance with the agreement’s terms. An estimated 470,000 Sonatas were involved with the 2015 recall alone. If you happen to own one of the affected Hyundais, you can go here to learn more about your options.