The unsung motorway cruiser nobody talks about
The Hyundai i40 was a D-segment saloon and estate competing against the Ford Mondeo, Vauxhall Insignia and Mazda 6, offering similar space and equipment at a significantly lower price. It targeted fleet buyers and private motorists doing high motorway mileage who wanted a refined, well-equipped cruiser without the premium price tag. Despite being well-regarded in the trade, it was always a slow seller overshadowed by more established rivals.
We track 9 known issues across the Hyundai I40 range, including 1 rated as safety-critical. Knowing which variants and configurations to approach with caution can save you from expensive surprises after purchase.
Found a Hyundai I40? Enter the reg to see which of our 9 known issues apply to that exact car, plus full MOT history and mileage checks.
VF (2011–2019) — Petrol options included the 1.6 GDI Petrol, with 1.7 CRDi Diesel, 1.6 CRDi Diesel on the diesel side. Our database flags 9 known issues on this generation, 1 of which are rated as safety-critical. The most significant concern is Steering rack free play excessive (£800–£1,200 to address).
The i40 steering rack develops excessive internal wear leading to dangerous free play at the steering wheel. MOT data shows this model fails at 27.8 times the fleet average for excessive steering wheel free play, with peak failure rates on the 1.6 petrol variant between 80,000-100,000 miles. The rack pinion or internal bushings wear prematurely, creating play that increases rapidly once started. This is a progressive fault that becomes a serious safety hazard as steering response becomes unpredictable.
Excessive steering play creates unpredictable handling and delayed response to steering inputs, particularly dangerous in emergency manoeuvres or at motorway speeds. Complete steering failure is possible if internal components detach. Steering rack replacement is required - refurbishment is rarely successful on this model.
During the test drive, check the steering for excessive play, vibration or pulling to one side. Listen for groaning or whining when turning the wheel at low speed. Power steering fluid level and condition should be checked on hydraulic systems.
The diesel particulate filter on i40 diesel variants blocks frequently, particularly on cars used primarily for short urban journeys. The DPF requires regular high-temperature regeneration cycles that cannot complete if the exhaust system never reaches operating temperature. Warning lights appear when the filter reaches 70-80% capacity, but many owners ignore these until complete blockage occurs. The 1.7 CRDi engine is particularly affected due to its combustion characteristics and the relatively small DPF fitted.
Complete DPF blockage causes the car to enter limp mode with severely restricted power and potential engine damage from back-pressure. DPF replacement is expensive and removal is illegal for road use. Cars with blocked DPFs often develop related issues including turbo failure and EGR valve problems.
Ask about the car's typical usage — short urban journeys prevent DPF regeneration. Check for DPF warning lights and ask about any previous regeneration issues. A forced regeneration at a garage costs far less than a DPF replacement.
The turbocharger on i40 diesel engines fails due to oil starvation, carbon buildup, or bearing wear. DPF issues that cause back-pressure contribute to premature turbo failure as the turbine struggles against restricted exhaust flow. Poor oil change intervals and low-quality oil accelerate bearing wear. The variable geometry mechanism on the 1.7 CRDi is particularly sensitive to carbon deposits that prevent proper vane operation, leading to boost control problems and eventual mechanical failure.
Turbo failure results in significant power loss and potential engine damage from debris if the compressor wheel disintegrates. Oil contamination from failed seals can damage the intercooler and DPF. Complete turbo replacement is typically required as reconditioning is often unsuccessful on this engine family.
During a test drive, check for hesitation, lack of power or unusual whining from the turbo area. Watch for blue or white smoke from the exhaust under hard acceleration. Check the oil condition and service history — turbos rely on clean oil.
The dual mass flywheel on i40 diesel variants fails due to internal spring breakage and damper wear. The DMF is designed to smooth diesel engine vibration but the internal springs fatigue over time, particularly on cars used for frequent stop-start driving or where the clutch has been slipped excessively. Failure typically occurs between 60,000-100,000 miles and requires clutch replacement at the same time as access requires gearbox removal.
DMF failure causes increasingly severe vibration and noise, eventually making the car difficult to drive smoothly. Complete failure can damage the clutch assembly and release bearing. Replacement requires gearbox removal and clutch renewal, making it one of the most expensive repairs on this model.
Check each gear engages smoothly without crunching. Feel the clutch bite point — very high or very low can indicate wear. Listen for bearing noise when the clutch is depressed.
The driveshaft universal joints on 1.7 diesel variants wear prematurely, with MOT data showing failure rates 13.8 times higher than the fleet average. The higher torque output of the diesel engine combined with the joint design causes accelerated wear of the needle bearings and seals. Failed joints create vibration through the drivetrain and can cause complete driveshaft separation if the joint collapses entirely.
Worn universal joints cause increasing vibration and noise. Complete joint failure results in loss of drive to one wheel and potential damage to the differential or transmission. The driveshaft may separate entirely, creating a serious safety hazard.
Listen for clunking or vibration from underneath when pulling away or changing direction. Check for play in the driveshafts by rocking the car in gear with the handbrake on. Worn CV boots are a telltale sign — look for grease splatter around the inner wheel arch.
For the full breakdown of all 9 tracked issues with repair costs, see the Hyundai I40 common problems page.
Based on 122k real DVSA MOT tests, the Hyundai I40 fails more often than average on several items. The biggest outlier is attachment of steering column defective at 72x the fleet average, followed by tyre wear or damage (19x).
When viewing a specific car, check its MOT history for recurring advisories in these categories. See the full Hyundai I40 MOT failure breakdown for data at every mileage point.
Routine servicing (oil and filter change every 10k miles) typically costs £80–£120 at an independent garage.
See the full Hyundai I40 service schedule for every interval and cost breakdown.
The Hyundai I40 has some well-documented weak points, including 1 safety-critical issue that demand careful checking. The right example, properly maintained, can still be a sound purchase — but cutting corners on the pre-purchase inspection is not advisable. 2015-2019 models are the best buy — they avoid the early clutch switch problems of 2011-2012, benefit from the 2014 water leak fix, and offer the most refined ownership experience. The 1.7 CRDi diesel is the most popular engine and suits the car's motorway cruiser character.
Before committing, check the car's full MOT history, verify the service record is complete, and if possible arrange a specialist inspection. Enter any registration into our free report to see the complete picture.
Get Car Wise maintains a database of known mechanical issues for every popular car on UK roads, tracking the faults that owners, specialists and DVSA data reveal.
When you run a report on a specific Hyundai I40, we cross-reference the exact variant, engine and age against our database of 9 known issues. Combined with full MOT history analysis, mileage verification and DVLA data, you get a complete picture before viewing.
Enter the registration for MOT history, mileage verification, known faults for that exact variant, and a Get Car Wise Score.
This guide was compiled from independent expert reviews, DVSA MOT data, specialist workshops and our own database of 9 known Hyundai I40 issues. We are not affiliated with any source listed.