Recall 255 – Engine Valve Springs May Break – 2024 Hyundai Palisade

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February 13, 2024 NHTSA CAMPAIGN NUMBER: 24V106000

Engine Valve Springs May Break

A loss of drive power increases the risk of a crash. A hole in the engine block increases the risk of a fire.

 

NHTSA Campaign Number: 24V106

Manufacturer Hyundai Motor America

Components ENGINE AND ENGINE COOLING

Potential Number of Units Affected 4,245

 

Summary

Hyundia Motor America (Hyundai) is recalling certain 2024 Palisade vehicles. The engine valve springs may break while driving, which can result in a loss of drive power and possibly create a hole in the engine block.

 

Remedy

Dealers will replace the engine sub-assembly, free of charge. Owner notification letters are expected to be mailed April 13, 2024. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 255.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Hyundai has a Recall

 


Safety Recall Campaign 255: Engine Valve Springs – Dealer Best Practice 

February 12, 2024

 

Document Topic Date
  • Remedy Not Available
02/14/2024

 

IMPORTANT: As required by federal law, dealers must not deliver new vehicles for sale or for lease to customers until all open recalls have been performed. Dealers must perform all open recalls on used vehicles, demo, and rental vehicles prior to placing them into customer use and whenever an affected vehicle is in the shop for any maintenance or repair.

To check vehicle specific recall applicability, access the “Vehicle Information” screen via WebDCS.

 

Recall Description

The subject vehicles contain engine valve springs that may fracture while driving due to fatigue cracking as a result of damage to the springs during manufacturing by the supplier. A fractured valve spring may result in a sudden loss of motive power. In rare cases, a hole in the engine block may occur due to a broken valve entering the combustion chamber.

 

Applicable Vehicles (Certain)

  • 2024MY Palisade (LX2) produced from 08/21/2023 – 10/12/2023 for sale in the U.S.

 

Remedy Information

This remedy is currently under development and additional information will be provided once it has been developed for release by HMA.

 

Recommended Alternative Transportation

A Service Rental Vehicle (SRC) should be provided to customers who do not feel safe operating their vehicle until a remedy is available. In addition, a SRC may be required based on any other additional work on the vehicle that may need to be addressed during customer’s visit. If a SRC is not available, other options such as a 3rd Party Rental or Rideshare may be provided.

 

Sample Customer Talk Track

“During your visit today, I checked your vehicle for any open campaigns or recalls and found that your vehicle has an open recall without an available remedy. The recall states that it is a condition relating to engine valve springs  which may crack prematurely, which may result in a sudden loss of motive power and in rare cases, a hole in the engine block. A hole in the engine block increases the risk of a fire. Once a remedy is available, Hyundai will notify you via First Class mail advising you to bring your vehicle to a Hyundai dealer to have it applied at no cost to you.”

 

Customer FAQs

Q1: What is the issue?

A1: The subject vehicles contain engine valve springs that may fracture while driving due to fatigue cracking as a result of damage to the springs during manufacturing by the supplier. A fractured valve spring may result in a sudden loss of motive power. In rare cases, a hole in the engine block may occur due to a broken valve entering the combustion chamber.

 

Q2: What are the affected vehicles?

A2: Affected vehicles include certain model year 2024 Hyundai Palisade vehicles produced 08/21/2023 – 10/12/2023 by Hyundai Motor Company (“HMC”) for sale in the U.S. market.

 

Q3: What is the safety concern?

A3: A loss of motive power increases the risk of a crash and a hole in the engine block increases the risk of a fire.

 

Q4: Have there been any accidents or injuries?

A4: As of the filing to NHTSA on February 13, 2024, there are no crashes, injuries, fires, or fatalities attributable to this condition in the U.S. or Canada.

 

Q5: Will a Dealer Stop Sale be issued?

A5: Yes, a Dealer “Stop Sale” (hold) has been issued in accordance with federal regulation for involved vehicles unsold at dealers. In addition, a Port “hold” has been issued for all involved vehicles located at ports and vehicle processing centers.

 

Q6: What will be done (planned remedy) during the recall service at the dealer?

A6: All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Hyundai dealer for replacement of the engine sub-assembly. This remedy will be offered at no cost to owners for all affected vehicles, regardless of whether the affected vehicles are still covered under Hyundai’s New Vehicle Limited Warranty. Additionally, Hyundai will provide owners of affected vehicles reimbursement for outof-pocket expenses incurred to obtain a remedy for the recall condition in accordance with the reimbursement plan submitted to NHTSA on February 24, 2022.

 

Q7: When will owners be notified?

A7: Owners of the subject vehicles will be notified via First Class mail in mid-April 2024.

 


Hyundai Recall Campaign 255

Attachment A: Requested Chronology of Events Leading Up to Decision

October- December 2023

On October 30, 2023, HMNA received a dealer Techline case regarding an engine stall condition caused by a fractured valve spring.

On December 11, 2023, HMNA’s Service Quality Department submitted a Quality Information Report to HMC regarding broken valve springs found during an engine teardown involving a model year 2024 Hyundai Palisade vehicle in the U.S. market.

 

January 2024

On January 5 and January 9, 2024, HMC informed NASO of information regarding manufacturing changepoint history provided by the valve spring and spring wire supplier(s).  NASO provided an update of U.S. market incidents for further HMC analysis.

On January 11, 2024, NASO’s Data Analysis (“DA”) team opened a case into the U.S. market condition.  The matter was escalated to the Data Review Committee (“DRC”) on January 16, 2024, and subsequently to the Technical Review Committee (“TRC”) as an open investigation on January 18, 2024.  NASO’s TRC began finalizing U.S. market field condition and severity while supporting warranty parts collection efforts to support HMC’s ongoing analysis through January-end.

On January 31, 2024, HMC informed NASO of its findings.  According to HMC, the supplier implemented a new inspection process in early January 2024 to confirm durability of newly built valve springs due to recent discovery of certain springs with surface irregularities caused by a damaged spring manufacturing die.  HMC also informed NASO of a safety recall determination made by Kia Motor America for U.S. specification vehicles containing valve springs from the suspect lot identified by the supplier.

 

February 2024

Based on HMC’s findings and confirmation of suspect lot traceability, HMA’s NASO convened its North America Safety Decision Authority on February 6, 2024, and decided to conduct a safety recall of affected Hyundai Palisade vehicles in the U.S. market.

❖ NASO has confirmed eighteen (18) unique incidents in the U.S. from October 30, 2023, through January 25, 2024. There are no crashes, injuries, or fatalities attributable to this condition in the U.S.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
HYUNDAI PALISADE 2024

 


4 Associated Documents

Defect Notice 573 Report

RCLRPT-24V106-6572.PDF 213.594KB

 


Recall Acknowledgement

RCAK-24V106-2611.pdf 645.386KB

 


Attachment A – Chronology

RMISC-24V106-7195.pdf 144.573KB

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Manufacturer Notices(to Dealers,etc)

RCMN-24V106-5122.pdf 240.207KB

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Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V106&docType=RCL

 


 

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