A problem with the aluminum casting process for a batch of brake calipers has negatively affected fatigue resistance in some parts, making them susceptible to fracture.
At least one customer brought their new Sonata back to the dealer because the pedal “went to the floor at stops.” A subsequent investigation determined that the caliper had fractured, and a deeper analysis of cars produced on the same date suggested approximately 2,256 calipers may be prone to the same failure.
The issue is believed to be limited to calipers manufactured during one day’s production. Caliper date codes could not be tracked to specific VINs, forcing the company to recall and inspect all vehicles produced over a seven-week span between April and June.
The caliper recall arrives less than two weeks after the company issued another recall over a defective wiring harness that can cause problems with the steering assist.
Photo by Nat Shirley.
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