Last week Thursday I took my car into the dealer to have the idle fixed and have recall work completed. Specifically, one recall was to in regards to the lower control arms rusting. The dealer supposedly checked the control arms and told us they were "fine" and did not need replacing.
Well, this weekend I started working on changing the clutch. I was in process of removing the axles when I noticed the drivers side control arm has a rust hole in the top of it just above the ball joint. The hole is about 1/2 inch wide by 2 inches tall. The area around the hole is paper thin, and when tapped with a metalic object, doesn't make a metallic sound. It sounds as though it is made of cardboard.
I don't understand how the dealer could have missed this if they really looked at the control arms. The rust definatly has perforated the top of the control arm, which is specifically pointed out in the recall notice.
Needless to say, I will be calling the dealer today to have them replace the control arms. I will let them know that this is a recall issue and I should not be paying for any of the work. Also, with a hole like that, I don't really feel safe driving the car the 30minutes at highway speeds to reach the dealer. From what I've seen on other posts and other forums, it is typical for hyundai to foot the bill for a tow.
The scary part is, if I had not been changing the clutch and working on the car, I would probably have never noticed that the control arm had rusted through. At least not for a while. I feel lucky that I cought it. I just wonder how many other people have taken their car in for this recall and the dealer told them it was OK when it really wasn't.
---------- Post added 11-02-2010 at 12:36 PM ----------
Here is a picture of the rust hole in the control arm. As you can see, it is hard to miss.