2004 Hyundai Santa FE
Problems, recalls and owner-reported issues
Suspension is the leading concern among 303 owner complaints filed for this model year. This is the 9th highest complaint count among 25 Santa FE model years with reports.
Of the 2004 reports, 32 involved a crash and 7 involved a fire. 35 people were injured.
What owners report most often
Recalls and investigations
Suspension, front, springs, coil springsJul 18, 2014
Hyundai Motor Company (Hyundai) is recalling certain model Year 2001-2006 Santa Fe vehicles manufactured from March 31, 2000, through February 15, 2006, that are registered and operated, or which were originally sold and registered, in the following 20 salt belt" states and the District of Columbia: Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin. The affected vehicles may experience front coil spring corrosion from road salt, causing the coil spring to fracture and make contact with the tire.
If the front coil spring fractures due to corrosion it could cause the coil spring to make contact with the tire, possibly puncturing the tire and increasing the risk of a vehicle crash.
Hyundai will notify owners, and dealers will inspect and if necessary replace the coil spring, free of charge. The recall began on October 24, 2014. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 124.
Campaign 14V435000 on NHTSA.gov
Service brakes, hydraulic, antilock/traction control/electronic limited slip, control unit/moduleMar 16, 2004
ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH 3.5 LITER V-6 ENGINES, 4-WHEEL DRIVE AND ANTILOCK BRAKING SYSTEMS (ABS), IF THE BRAKE PEDAL IS DEPRESSED AT SPEEDS BETWEEN 3 AND 12 MPH WHEN THE BRAKE PAD FRICTION SURFACES ARE WET, A VIBRATION MAY OCCUR BETWEEN THE BRAKE DISCS AND PADS CAUSING ABS SENSOR ELECTRONIC SIGNAL NOISE TO DEVELOP. AT SPEEDS BELOW 5 MPH, THE ABS SENSOR SIGNAL NOISE MAY CAUSE THE ABS ELECTRONIC CONTROL UNIT (ECU) TO ACTIVATE THE ABS, EXTENDING THE STOPPING DISTANCE.
IF AN EXTENDED STOPPING DISTANCE OCCURS, IT COULD RESULT IN A CRASH.
DEALERS WILL REPROGRAM THE ABS ECU. OWNER NOTIFICATION BEGAN ON MARCH 24, 2004. OWNERS SHOULD CONTACT HYUNDAI AT 1-800-633-5151.
Campaign 04V131000 on NHTSA.gov
Equipment, other, labelsDec 18, 2003
CERTAIN SPORT UTILITY VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."
THE TIRE PRESSURE LABELS DO NOT CONTAIN THE INFORMATION REQUIRED BY THE STANDARD.
OWNERS WILL BE PROVIDED WITH A CORRECT LABEL AND INSTALLATION INSTRUCTIONS. OWNER NOTIFICATION BEGAN ON OCTOBER 29, 2003. OWNERS SHOULD CONTACT HYUNDAI AT 1-800-633-5151.
Campaign 03V520000 on NHTSA.gov
Representative owner complaints: fuel/propulsion system
25 reports, newest first. Show all
Fuel/propulsion system, Jun 10, 2021
This was a recall for hundai santa fe vehicles from 2001-2006. For unknown reasons I was not aware of recall. It was for 15 years or 150 miles. It is a danger as my car leaks gas. I am at 135,000 miles. But my car is a 2004. I purchased the vehicle in the last 2 years. I believe the recall should extend till the repair is complete for the reasons as follows. 1. it can explode. 2. it is a polluter 3. Hyundai acknowledges it as faulty equipment. 4. Corporations must be resonsible or they are irresponsible. 5. Cars are expensive they must maintain as least minimum safety requirements.
Fuel/propulsion system, Oct 27, 2019
BOUGHT AN USED 2004 SANTA FE IN AUGUST FROM A DEALER. TWO WEEKS AGO I STARTED NOTICING A STRONG SMELL OF GAS AROUND MY VEHICLE AND LAST WEEK I BEGAN SEEING A SMALL DISCOLORED AREA ON THE CEMENT IN THE GARAGE. MOM CHECKED MY VEHICLE AND FOUND THAT THE MY FUEL TANK IS LEAKING. THE DISCOLORATION OF THE CEMENT UNDER MY VEHICLE IS IN FACT LEAKING GAS. TANK IS CORRODED AND I WILL NEED A NEW TANK INSTALLED.
Fuel/propulsion system, Oct 5, 2018
VEHICLE FUEL TANK IS ROTTED AND LEAKING FUEL. CALL HYUNDAI AND THEY SAY ITS COVERED UNDER EXTENDED WARRANTY FOR 15 YEARS OR 150000 MILES. I AM OVER ON MILEAGE. THEY SAY NOT COVERED. WHAT DOES MILEAGE HAVE TO DO WITH CORROSION?
Suspension, Fuel/propulsion system, Apr 12, 2018
TL* THE CONTACT OWNS A 2004 HYUNDAI SANTA FE. WHILE THE VEHICLE WAS PARKED, THERE WAS AN ABNORMAL ODOR OF FUEL INSIDE AND OUTSIDE THE VEHICLE. THE CONTACT NOTICED FUEL LEAKING AND THAT THE CHECK ENGINE INDICATOR WAS ILLUMINATED. THE VEHICLE WAS TAKEN TO A LOCAL DEALER (COLUMBIA HYUNDAI, 10981 MONTGOMERY RD, CINCINNATI, OH 45249, (513) 489-2000) WHERE IT WAS DIAGNOSED THAT THE COIL SPRING AND FUEL TANK NEEDED TO BE REPLACED. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS 15 YEARS OLD AND EXCEEDED THE MILEAGE TO BE INCLUDED IN A RECALL. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 198,000.
Seat belts, Electronic stability control (ESC), Fuel/propulsion system, Jan 28, 2017
CATALYST CONVERTER CALIFORNIA
Suspension, Air bags, Fuel/propulsion system, Dec 13, 2016
IT DON'T WORK RITE WHEN I LET THE CAR WARM UP AND THEN PUT MY FEET ON THE BRAKES IT SOUND LIKE IT DON'T WANTED TO GIVE GAS I SMELL GAS BUT I DON'T SEE ANY ON THE GROUND THE END TAKE IS ALL MESS UP THE AIR BAGS DO NOT GO OFF IT STAY ON AND I KEEP EVERYTHING UP TO THE CAR JUST DON'T ACT RITE
Fuel/propulsion system, Nov 14, 2016
TL* THE CONTACT OWNS A 2004 HYUNDAI SANTA FE. WHILE THE VEHICLE WAS PARKED OR BEING DRIVEN, THERE WAS A STRONG FUEL ODOR COMING FROM THE VEHICLE. IN ADDITION, THERE WAS FUEL LEAKING FROM THE REAR OF THE VEHICLE. AN INDEPENDENT MECHANIC STATED THAT FUEL WAS LEAKING FROM THE SEAM OF THE FUEL TANK AND THE FUEL TANK NEEDED REPLACEMENT. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 138,900.
Fuel/propulsion system, Oct 23, 2016
MY SANTA FE STAY OVER NITE, INSIDE MY GARAGE AND I NOTICE VERY STRONG ODOR OF GASOLINE EVERY TIME I OPEN MY GARAGE AND AFTER I LOOK UNDER, I SPOT A DROP OF GASOLINE ON THE PASSENGER SIDE BETWEEN A PLASTIC COVER AND THE FUEL TANK, WHILE IS PARK OVER NITE, WHILE I AM DRIVING I AM AFRAID THAT SOMETHING HAPPEN, LIKE PEOPLE THROWING CIGARETTE BUT AND CUT MY CAR ON FLAME. AFTER I READ OTHER PEOPLE RECENT COMPLAINTS I DECIDE TO STOP USING MY SANTA FE, I THINK THIS IS A DEFECT FROM HYUNDAI TO CREATE A FUEL TANK THAT HOLDS WATER AND SALT BETWEEN THE TANK AND THE COVER. *TR
Fuel/propulsion system, Sep 4, 2016
WHEN CAR PARKED SMELL OF GASOLINE, LOOKED UNDER CAR ON DRIVE SIDE OF TANK HAS TINY DROP OFF FUEL COME FROM PLASTIC COVER OF TANK AND A DROP ON GROUND LOOKS IT WAS SPREAD BY CONTINUOUS SLOW WEEPING WHEN PARKED, DRAW FOR A WHILE CAME BACK PARKED WENT BACK AND CHECK UNDER SAME SPOT TINY DROP ON GROUND COMING FROM PLASTIC COVER DRAIN HOLE, DID NOT SEEM LOOSE MUCH GAS, PARK OVER WEEKEND FOUND DRIP SMELL AND THE DRY SPOT SEEMED ABOUT ONE FOOT IN DIAMETER AND STRONG ODOR WHEN GO NEAR BACK OF CAR, NOTICED THIS AT PARKED VEHICLE, OVER NIGHT PARKED THE SPOT IS ABOUT 6 INCHES DRIED WET ABOUT 1 INCH EVERY DAY LAST FEW WEEKS. FUEL SMELL NOTICED ALL THE TIME MAY BE 6 SIX MONTHS NOW DID NOT KNOW WHERE OR WHOSE CAR IT WAS COMING, WHEN LOOKED UNDER ON DRIVER SIDE BEFORE REAR WHEEL ABOUT 1 FOOT INWARD SAW A WET SPOT ABOUT 1 INCH, DRAW BACK CHECKED IT WAS GAS SPOT AROUND DRIED IMPRESSION WAS ABOUT FOOT THIS WAS IN MORNING AFTER OVER NIGHT PARKING, I OPEN ACCESS UNDER THE REAR DRIVER SIDE OF SEAT CAN NOT FIND ANY LEAK FROM FUEL PUMP OR TUBES I AM GOING TO CHECK ON OTHER ACCESS HOLE BUT THAT IS ON PASSENGER SIDE, LEAK IS UNDER DRIVER SIDE OF THE TANK PLASTIC COVER DRAIN HOLE.
Fuel/propulsion system, Aug 26, 2016
COMPLAINT HYUNDAI MOTOR AMERICA HAS ADMITTED DESIGN/PRODUCT DEFECTS WITH SIX YEARS (2001-06) OF THEIR SANTA FE FUEL TANKS VIA AN EXTENDED WARRANTY NOTIFICATION ISSUED 2016/Q1. THIS COMPLAINT CONCERNS HYUNDAI'S PRODUCT LIABILITY AND WARRANTY, WITH UNDERSTANDING PRECEDENT HAS BEEN ESTABLISHED WITH OTHER HYUNDAI PRODUCT DEFECTS AND RECALL/WARRANTY RESOLUTIONS VIA THE FRONT SPRING COIL CORROSION RECALL IN 'SALT BELT STATES'. DESIRED RESOLUTION HYUNDAI MOTOR AMERICA TO PROVIDE WARRANTY COVERAGE FOR MY SPECIFIC VEHICLE PER SCOPE DESCRIBED WITHIN THE EXTENDED WARRANTY NOTIFICATION. I WOULD SIMPLY LIKE TO HAVE EXTENDED WARRANTY SERVICE COMPLETED AT MY LOCAL HYUNDAI DEALERSHIP.
Fuel/propulsion system, Mar 8, 2016
A STRONG ODOR OF GASOLINE WAS NOTICEABLE UPON ENTERING MY GARAGE. FURTHER INSPECTION REVEALED GAS LEAKING FROM MY '04 HYUNDAI SANTA FE. THE SERVICE STATION DETERMINED THAT A FUEL TANK AND CENTER HEAT SHIELDING REPLACEMENT WAS NECESSARY AS BOTH WERE DEFECTIVE, LEAKING FUEL, AND POSED A VERY HIGH RISK OF DANGER. NEEDLESS TO SAY, I WAS STUCK PAYING A VERY HEFTY BILL TO THE REPAIR CENTER RATHER THAN WORRYING ABOUT BLOWING UP MYSELF, MY PASSENGERS, OR MY HOUSE. I SEE THAT THERE HAVE BEEN OTHER COMPLAINTS ABOUT THE SAME PROBLEM WITH THIS MAKE AND MODEL OF HYUNDAI.
Electrical system, Engine, Fuel/propulsion system, Feb 12, 2016
CAR STALLS WITHOUT WARNING WHILE DRIVING. FIRST OCCURRENCE WAS OVER A YEAR AGO. I WAS DRIVING DOWN I5 GOING 70 MPH WHEN THE CAR SUDDENLY DIED. I LOST MY POWER STEERING AND BRAKES. I MANAGED TO COAST TO THE NEXT EXIT. IT STARTED AFTER SITTING A FEW MINUTES. AND I WAS ABLE TO MAKE IT HOME. I'VE RECEIVED CODES FOR CAMSHAFT SENSOR, MISFIRES, LOW CATALYST. I'VE CHANGED THE CAM AND CRANK SENSORS, COILS, SPARK PLUGS, TIMING BELT AND ASSEMBLY, FUEL PRESSURE REGULATOR AND FUEL PUMP OVER THE PAST YEAR. STILL HAVING THE ISSUE. CAR DRIVES FANTASTIC FOR ABOUT 10 MILES AND STALLS OUT. AFTER WAITING ABOUT 5 MIN. IT CAN BE DRIVEN FOR ANOTHER FEW MILES BEFORE STALLING OUT AGAIN. CHECK ENGINE LIGHT DOES NOT TURN ON WHEN IT STALLS NOW. VERY DANGEROUS WHEN TRYING TO DRIVE IN TOWN OR ATTEMPTING TO MERGE INTO TRAFFIC. YOU NEVER KNOW WHEN IT WILL STALL OUT.
Fuel/propulsion system, Feb 10, 2016
TL* THE CONTACT OWNS A 2004 HYUNDAI SANTE FE. AFTER THE VEHICLE WAS REFUELED, THE CONTACT NOTICED FUEL LEAKING FROM THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 180,000.
Vehicle speed control, Fuel/propulsion system, Nov 28, 2015
WHEN I PUT GAS IN MY CAR IT WILL NOT START AFTERWARD. FIRST IT STARTED ONLY WHEN MY CAR WAS TURNED OFF. WHEN I LEFT MY CAR RUNNING IT WAS OK. NOW IT TURNS OFF WHEN MY CAR IS RUNNING ALSO. THE MECHANIC SAID, IT MAY BE A BAD FUEL PUMP, COST $350 TO REPLACE, BUT CAN'T GUARANTEE THIS WILL FIX THE ISSUE. I SEE I AM NOT THE ONLY ONE WITH THIS ISSUE. WHY IS THIS NOT A RECALL?? I GOOGLE IT AND THERE ARE SO MANY PEOPLE WITH SAME PROBLEM. ALSO WITH THE CAR ACCELERATING BY ITSELF. I THOUGHT I WAS CRAZY. I SEE NOW THAT OTHERS ARE HAVING THIS PROBLEM AS WELL. EVERYONE SAID I IMAGINED IT. WHY IS THIS NOT A RECALL?
Fuel/propulsion system, Oct 29, 2015
TL* THE CONTACT OWNS A 2004 HYUNDAI SANTA FE. IMMEDIATELY AFTER REFUELING THE VEHICLE, IT WOULD SUDDENLY STALL. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE PURGE VALVE FAILED AND THE FUEL TANK WOULD NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 92,000.
Fuel/propulsion system, Oct 28, 2015
TL* THE CONTACT OWNS A 2004 HYUNDAI SANTA FE. THE CONTACT STATED THAT IMMEDIATELY AFTER REFUELING THE VEHICLE, IT WOULD SUDDENLY STALL. THE VEHICLE WAS TAKEN TO THE DEALER WHO DIAGNOSED THAT THE PURGE VALVE AND THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 92,000.
Fuel/propulsion system, Oct 2, 2015
I SMELLED GAS RECENTLY WHEN OPENING AND GETTING INTO MY 2004 SANTA FE. I TOOK IT TO A CAR REPAIR SHOP. THEY INSPECTED IT AND FOUND RUST HOLES IN THE GAS TANK WHICH GAS WAS LEAKING OUT OF! I CAN'T IMAGINE THE HOW TERRIBLE AN EVENT COULD HAVE OCCURRED IF THE LEAKING GAS HAD EXPLODED WHEN I STARTED THE CAR OR BEEN CLOSE TO AN OPEN FLAME WITH THE CAR WHEN IT WAS LEAKING. I HAVE OWNED MANY CARS IN MY LIFE AND HAVE NEVER HAD A FUEL TANK RUST OUT. I THINK THE NHTSA NEEDS TO TAKE A VERY CLOSE LOOK AT THIS PROBLEM AND POSSIBLY ISSUE A RECALL ON THE GAS TANKS OF SANTA FES AND OTHER VEHICLES THEY MANUFACTURE THAT USE THE SAME GAS TANK.
Fuel/propulsion system, Oct 2, 2014
I BROUGHT THE VEHICLE IN FOR AN OIL CHANGE. THE GENTLEMAN SAID THAT THE FUEL TANK HAS A RUST HOLE IN IT AND IS LEAKING FUEL. THIS IS CAUSED BY A PLASTIC COVER THAT RETAINS SALT AND MOISTURE AND CAUSES THE TANK TO RUST. *TR
Fuel/propulsion system, Sep 15, 2014
THE VEHICLE HAD A STRONG SENT OF GASOLINE WHEN PARKED. THE VEHICLE WAS TAKEN TO THE MECHANIC, I WAS INFORMED THAT IT WAS A GAS LEAK AND THE GAS TANK HAD TO BE REPLACED. AFTER THE GAS TANK WAS REPLACED, THE MECHANIC INFORMED ME THAT THE TANK HAD RUSTED AND THAT WAS THE REASON FOR THE LEAK. HE SHOWED ME THE GAS TANK AND THERE WAS EXTENSIVE RUST ON IT. THERE WAS A PLASTIC PART UNDER THE TANK THAT RETAINED WATER AND ROAD SALT AND CAUSED THE TANK TO PREMATURELY RUST. THERE IS NO REASON FOR A VEHICLE THAT IS GARAGED AND WASHED REGULARLY TO HAVE A RUSTED OUT GAS TANK. CLEARLY, THERE IS A DESIGN FLAW THAT ALLOWED THE PLASTIC PART UNDER THE TANK TO COLLECT WATER AND RUST. *TR
Fuel/propulsion system, Jul 1, 2014
THERE IS A STRONG SMELL OF GASOLINE COMING FROM MY VEHICLE - IT CONSUMES BOTH THE INTERIOR AND THE AROUND THE ENTIRE EXTERIOR OF THE VEHICLE. LOOKING AT ALL OF THE COMPLAINTS, THIS IS NOT THE FIRST TIME THIS HAS HAPPENED. WHY ISN'T THERE A RECALL?? HYUNDAI - ARE YOU DOING ANYTHING TO HELP YOUR CUSTOMERS????? *TR
Engine and engine cooling, Fuel/propulsion system, Jun 6, 2014
DIES IN THE MIDDLE IF ROAD! ALMOST DIE. ALL THE TIME!!!!!! DIES IN THE MIDDLE IF ROAD! ALL THE TIME!!!ALMOST DIED. *TR
Fuel/propulsion system, May 18, 2014
WHENEVER I GET GAS AND WHICH I DREAD , ONCE I FILL UP THE TANK OR JUST PUT A FEW GALLONS AND I TURN THE IGNITION IT GRINDS LIKE IT IS TRYING TO START . EVENTUALLY IT WILL TURN OVER OR I WILL HEAR A POP. I AM AFRAID AT SOME POINT WITH THAT POP THAT IT WILL CATCH ON FIRE. THIS HAPPENS EVERY TIME I FILL THE VEHICLE WITH GAS. COULD SOMEONE PLEASE LET ME KNOW WHAT THE RESOLUTION IS. *JS
Fuel/propulsion system, Dec 20, 2013
I HAD MY 2004 HYUNDAI SANTE FE AT THE DEALER'S FOR THE SMELL OF GASOLINE IN THE VEHICLE AND WHEN WALKING BEHIND THE CAR. IT WAS TOLD THERE WAS A SMALL LEAK IN THE GAS TANK DUE TO RUST. THE VEHICLE IS NOT 9.5 YEARS OLD HAS APPROXIMATELY 82,000 MILES ON IT - HAVE REGULAR SERVICE DONE ON THE VEHICLE. I HAVE UNDERCARRIAGE OF CAR WASHED AFTER SNOW STORMS AS I LIVE IN NEW ENGLAND AND KNOW THE SALT FROM THE ROADS CAN RUST THE CAR. I WAS QUOTED A PRICE OF $1,500 OR MORE - "CAN'T TELL UNTIL WE START TAKING THINGS APART HOW MUCH JOB WILL BE". THIS EVENING WENT TO GO TO THE STORE FOR MILK CAR STARTED RIGHT UP DROVE DOWN HILL AND CAR STARTED TO BUCK AND STOPPED. THANK GOD FOR AAA - CALLED FOR A TOW AND THE TOW TRUCK DRIVER ATTEMPTED TO START CAR - CAR STARTS BUT THEN STALLS SAID THERE MAY BE AN AIR BUBBLE IN FUEL LINE - COULD THIS HAVE HAPPENED WHEN DEALER'S SERVICE DEPARTMENT CHECKED FOR THE LEAK. (I DO NOT HAVE THE MONEY TO REPLACE A GAS TANK WHEN I DON'T KNOW EXACTLY HOW MUCH THE COST WILL BE). HAS ANYONE ELSE HAD THIS PROBLEM. THE SERVICE PERSON INFORMED ME MY CAR WAS "OLD" I DON'T THINK 9.5 YEARS WITH 81,000 MILES A GAS TANK SHOULD RUST???????? ESPECIALLY WHEN THE CAR IS TAKEN CARE OF. *TR
Fuel/propulsion system, Nov 20, 2013
TL* THE CONTACT OWNS A 2004 HYUNDAI SANTA FE. THE CONTACT STATED THAT HE SMELLED A GASOLINE FUEL ODOR WHILE STANDING NEAR THE VEHICLE. THE VEHICLE WAS EXAMINED BY AN INDEPENDENT MECHANIC, WHO STATED THAT THE FUEL TANK WAS RUSTED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 100,000.
Fuel/propulsion system, Sep 9, 2013
I BOUGHT THE HYUNDAI LESS THAN A YEAR AGO. A FEW MONTHS AFTER I BOUGHT IT, I STARTED SMELLING GAS. I TOOK IT TO THE SHOP, AND WAS TOLD THE GAS TANK WAS LEAKING. AFTER PAYING AN EXORBITANT AMOUNT TO REPLACE IT, IT WORKED FINE. NOW LESS THAN A YEAR LATER, I TOOK THE CAR INTO THE SHOP FOR A ROUTINE INSPECTION AND WAS INFORMED THAT MY NEW GAS TANK IS LEAKING AND NEEDS TO BE REPLACED. WHAT'S THE PROBLEM, HYUNDAI? THIS IS RIDICULOUS! *TR