Recall 212 Brake Fluid Contamination – 2021 Hyundai Palisade

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October 27, 2021 NHTSA CAMPAIGN NUMBER: 21V840000

Brake Fluid Contamination

Reduced braking performance can extend the distance required to stop the vehicle, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V840

Manufacturer Hyundai Motor America

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 995

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2021 Palisade vehicles. The brake fluid may be contaminated, which can cause the brake master cylinder inner-cup seals to swell, and reduce braking performance.

 

Remedy

Dealers will replace the brake master cylinder, and flush the brake fluid, free of charge. Owner notification letters were mailed on December 24, 2021. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 212.

 

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

 


2021 Hyundai Palisade
2021 Hyundai Palisade

 


Description: This bulletin describes the procedure to drain brake fluid and replace the brake master cylinder on certain 21MY Palisade (LX2) models. The brake fluid in the subject vehicles may be contaminated with mineral oil causing the brake master cylinder inner cup seals to expand. Expanded brake master cylinder inner cup seals could reduce hydraulic pressure applied by the master cylinder resulting in reduced braking function at the wheels. The driver may experience longer brake pedal travel, change in pedal feel, and extended stopping distance, increasing the risk of a crash.

Applicable Vehicles: 21MY Palisade (LX2) vehicles produced from March 9, 2021 through March 31, 2021.

 

Parts Information:

PART NAME / IMAGE PART NUMBER REMARKS
Brake Master Cylinder 58510-C5070-QQH
DOT 4 Brake Fluid 00232-19053 12 bottles per QTY 1 of P/N
00232-19053
12 oz. / 355 mL per bottle
2 liters (6 bottles) required per
vehicle

 

SST Information

NAME PART NUMBER PHOTO REMARKS
Air Bleeding Tool 09580-3D100
  • Use as directed in the vehicle’s shop manual or TSB(s).
  • Previously provided to all dealers as essential tools.
  • To order a replacement contact Bosch: 1-866-539-4248
Active Hydraulic Boost (AHB) Brake Air Bleeding Tool Adapter 09580-3D200

 

Service Procedure: Flowchart Overview

 

Service Procedure: (Refer to the QR link for additional video information)

Hyundai Service Learning – Recall 212 Service Procedure

 

1. Place the vehicle on a lift with an assistant seated in the driver’s seat.

Open the hood.

 

2. Discharge as much brake fluid as possible from the system according to the steps below.

NOTICE

Perform this operation in this order:
1) Rear Right
2) Front Left
3) Rear Left
4) Front Right

 

3. Starting at the rear right caliper, remove the bleed screw cover.

 

4. Connect one end of a bleed line to the bleeder screw, and the other end into a container to collect the brake fluid.

Open the bleed screw and have the assistant inside the vehicle pump the brake pedal to discharge the brake fluid.

Continue until the caliper is completely discharged of brake fluid.

Close the bleeder screw.

 

5. Move to the next caliper (front left) and repeat step #4 to discharge the brake fluid.

 

6. Repeat step #4 on the rear left caliper, then the front right.

 

7. Lower the vehicle and fill the brake fluid reservoir to the MAX line with DOT 4 brake fluid.

CAUTION

  • Clean the area around the reservoir cap of any foreign substances before removing the cap.
  • Be careful not to contaminate brake fluid with dust or other foreign substances.
  • Do not allow brake fluid to come into contact with the vehicle body/paint. Immediately wipe any spills and flush with water if contact does occur.

 

8. Connect the air bleeding tool and adapter SST to the master cylinder.

Apply compressed air, and set the pressure to 3 bar (43.5 psi).

 

9. Connect a GDS to the vehicle and perform the HCU Air Bleeding Mode (under S/W Management → ABS/ESP).

 

10. Follow the directions for the HCU Air Bleeding Mode procedure on the GDS.

By the completion of the procedure, each caliper should have discharged fluid in these amounts:

Each front caliper: 100 mL
Each rear caliper: 150 mL

By the completion of the procedure, the master cylinder reservoir should be completely emptied of any brake fluid.

If any brake fluid remains, repeat the HCU Air Bleeding Mode procedure until completely empty.

 

11. Record the customer’s AM/FM/satellite radio station presets.

Turn the vehicle’s ignition to OFF.

Remove the battery by disconnecting the negative battery terminal, then the positive terminal, then the tie-down clamp.

Remove the air cleaner assembly according to the service manual procedures:

Engine Mechanical System → Intake and Exhaust System → Air Cleaner

 

12. Disconnect the brake fluid level sensor connector.

Remove and replace the brake master cylinder according to the service manual procedures:

Brake System → Brake System → Master Cylinder

NOTICE

The replacement master cylinder includes a new, preinstalled O-ring.

Before installing the new master cylinder, be sure to remove the original O-ring if it is left attached to the brake booster.

 

13. After installing the new master cylinder, fill the reservoir with DOT 4 brake fluid to the MAX line.

 

14. Bleed all four calipers starting with the rear right caliper. Connect a bleeding tube to the caliper bleed screw, leading to a collection container:

1. An assistant seated in the driver’s seat presses and releases the brake pedal several times, then holds the pedal depressed.
2. With the pedal depressed, open the bleeder screw to release air/fluid into the container.
3. Repeat #1 and #2 until no bubbles remain in the line.
4. Move to the next caliper and repeat the process until air is removed from all 4 lines.

NOTICE

Refer to the service manual for brake bleeding procedures:

Brake System → Brake Bleeding Procedures

 

15. Fill the brake fluid reservoir to the MAX line.

Connect the air bleeding tool and adapter SST to the master cylinder.

Apply compressed air and set the pressure to 3 bar (43.5 psi).

Connect a GDS to the vehicle and perform the HCU Air Bleeding Mode (under S/W Management → ABS/ESP).

Follow the directions for the HCU Air Bleeding Mode procedure on the GDS.

Repeat this process for all 4 calipers in the correct order.

Refill the brake fluid reservoir to the MAX line.

 

16. Using the GDS, perform a brake system pressure check:

From the starting screen, select Data Analysis.

 

17. Select ABS/ESC system.

 

18. Watch the three brake pressure parameters while gradually depressing the brake pedal:

1) Pressure Sensor – Pressure
2) Primary Pressure Sensor
3) Secondary Pressure Sensor

This operation should take about 20 seconds. Be sure to press the pedal very firmly to reach full braking pressure.

Confirm that the brake pressure values rise when gradually depressing the brake pedal.

The service procedure is complete after verification of brake pressure.

Reconnect the negative battery terminal and re-program the customer’s AM/FM/satellite radio station presets.

NOTICE

If proper brake pressure/operation is not achieved, perform the brake bleeding process again for both Normal Brake System and ESC Brake System.

Refer to the service manual for brake bleeding procedures:

Brake System → Brake Bleeding Procedures

 


Customer FAQ

Q1: What is the safety concern?

A1: Extended stopping distance could increase the risk of a crash.

 

Q2: What will be done during the recall service at the dealer?

A2: All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Hyundai dealer to have the brake fluid flushed and brake master cylinder replaced.

This remedy procedure will be performed at no charge. Hyundai will provide reimbursement to owners for repairs according to the plan submitted to NHTSA on May 16, 2018.

 

Customer Notification

Owners will be notified beginning in late December 2021/early January 2022. NHTSA has posted this recall.

 


Chronology :

September 2021
On September 2, 2021, HMC informed HMA’s NASO of an investigation being conducted in Korea involving eleven (11) Korean domestic vehicles produced from March 9, 2021 through March 31, 2021 for potential contamination of the brake fluid. NASO searched its field information databases and found three (3) unique U.S. vehicle incidents reporting a low or spongey brake pedal. NASO recovered and shipped two (2) brake master cylinder units from the identified incidents for further testing by the supplier in Korea.

On September 22, 2021, NASO shared its investigation status with NHTSA’s ODI during its recurring monthly review of safety-related topics.

October 2021
On October 14, 2021, HMC informed NASO of the parts analysis results confirming the presence of mineral oil in the brake fluid of the incident brake master cylinders and the ensuing effect on the brake master cylinder’s inner cup seal causing low braking ability due to reduced internal pressure. Based on this information, on October 19, NASO convened its North American Safety Decision Authority and decided to conduct a safety recall of vehicles produced in the subject date range for further evaluation into root cause of the brake fluid contamination. The investigation will actively continue to determine if a specific root cause and defect trend exists.

As of the date of this filing, Hyundai is not aware of any crashes, fires, or injuries related to the defect condition in the U.S.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
HYUNDAI PALISADE 2021

 


9 Associated Documents

Recall Acknowledgement

RCAK-21V840-5164.pdf 646.265KB

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Defect Notice 573 Report

RCLRPT-21V840-4115.PDF 214.168KB

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Recall 573 Report – Amendment 1

RCLRPT-21V840-2325.PDF 214.221KB

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Manufacturer Notices(to Dealers,etc) – Recall 212: BRAKE MASTER CYLINDER – Dealer Best Practice (TSB # 21-01-081H): December 22, 2021

RCMN-21V840-4364.pdf 399.582KB

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Remedy Instructions and TSB

RCRIT-21V840-5699.pdf 4327.934KB

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Owner Notification Letter(Part 577) – December 24, 2021

RCONL-21V840-2869.pdf 172.772KB

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Recall Quarterly Report #1, 2021-4

RCLQRT-21V840-8194.PDF 211.123KB

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Recall Quarterly Report #3, 2022-2

RCLQRT-21V840-8106.PDF 211.312KB

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Recall Quarterly Report #4, 2022-3

RCLQRT-21V840-9880.PDF 211.417KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V840&docType=RCL

 


 

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