2002 Hyundai Sonata
Problems, recalls and owner-reported issues
Structure is the leading concern among 325 owner complaints filed for this model year. This is the 14th highest complaint count among 26 Sonata model years with reports.
Of the 2002 reports, 31 involved a crash and 4 involved a fire. 54 people were injured.
What owners report most often
Recalls and investigations
Latches/locks/linkages, doors, latchAug 7, 2009
HYUNDAI IS RECALLING 82 MODEL YEAR 2002-2003 SONATA VEHICLES. REPEATED USE OF THE INTERIOR DOOR HANDLE MAY CAUSE WEAR OF THE CHROME PLATING. IF THE TOP EDGE OF THE HANDLE HAS VERY THIN CHROME PLATING THAT PORTION OF THE PLATING MAY WEAR AWAY MORE EASILY THAN MORE THICKLY PLATED AREAS AS THE DOOR HANDLE IS USED. THE WORN CHROME PLATING ON THE UPPER EDGE OF THE HANDLE MAY RESULT IN A CRACK OR SEPARATION BETWEEN THE CHROME PLATING ON THE INBOARD AND OUTBOARD SURFACES OF THE HANDLE, WHICH MAY FORM A SHARP EDGE.
A SHARP EDGE COULD LACERATE OR OTHERWISE INJURE A VEHICLE OCCUPANT.
DEALERS WILL REPAIR THE CHROME PLATED INTERIOR DOOR HANDLE FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 16, 2009. OWNERS MAY CONTACT HYUNDAI OF PUERTO RICO AT 1-787-999-3333.
Campaign 09V317000 on NHTSA.gov
Latches/locks/linkages, doors, latchMay 21, 2009
HYUNDAI IS RECALLING 91,350 MY 2002-2003 HYUNDAI SONATA VEHICLES. REPEATED USE OF THE INTERIOR DOOR HANDLE MAY CAUSE WEAR OF THE CHROME PLATE. IF THE TOP EDGE OF THE HANDLE HAS VERY THIN CHROME PLATING, THAT PORTION OF THE PLATING MAY WEAR AWAY MORE EASILY THAN MORE THICKLY PLATED AREAS AS THE DOOR HANDLE IS USED. THE WORN CHROME PLATING ON THE UPPER EDGE OF THE HANDLE MAY RESULT IN A CRACK OR SEPARATION BETWEEN THE CHROME PLATING ON THE INBOARD AND OUTBOARD SURFACES OF THE HANDLE, WHICH MAY FORM A SHARP EDGE.
THIS MAY INFLICT LACERATION INJURIES TO ANYONE USING THE DOOR HANDLE.
DEALERS WILL REPAIR THE CHROME PLATED INTERIOR DOOR HANDLE FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JUNE 2009. OWNERS MAY CONTACT HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.
Campaign 09V171000 on NHTSA.gov
SuspensionApr 16, 2009
HYUNDAI IS RECALLING 188,282 MY 2001-2004 SONATA AND MY 2001-2004 XG300 AND XG350 VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. ROAD SALT APPLIED IN THESE JURISDICTIONS DURING THE WINTER MONTHS MAY RESULT IN PROGRESSIVE, INTERNAL CORROSION OF THE FRONT SUB-FRAME ON THE VEHICLES, AND MAY RESULT IN THINNING OR PERFORATION OF THE SUB-FRAME STEEL. THE CORROSION IS FREQUENTLY VISIBLE AND OFTEN DISCOVERED DURING INSPECTION OR ROUTINE MAINTENANCE, AND OWNERS MAY ALSO HEAR NOISES OR NOTICE TIRE MISALIGNMENT AND STEERING PULL. IF THESE SIGNALS ARE UNDETECTED OR UNHEEDED, THE CORROSION MAY PROGRESS AND THE FORWARD MOUNTING OF THE LOWER CONTROL ARM MAY DETACH FROM THE SUB-FRAME.
IF THAT HAPPENS, THE VEHICLE MAY LOSE DRIVE POWER TO THE WHEELS, AND THE FRONT WHEEL MAY MAKE CONTACT WITH THE FENDER OR WHEEL WELL, THEREBY INCREASING THE RISK OF A CRASH.
DEALERS WILL MEASURE THE THICKNESS OF THE FRONT SUB-FRAME AND INSPECT THE FRONT SUB-FRAME FOR CORROSION DAMAGE AND, IF NECESSARY, THE FRONT SUB-FRAME WILL BE REPLACED WITH A NEW SUB-FRAME THAT INCORPORATES ADDITIONAL HOLES IN THE UPPER AND LOWER PANELS. IF THE FRONT SUB-FRAME DOES NOT REQUIRE REPLACEMENT, THE DEALER WILL ADD DRAINAGE HOLES TO THE SUB-FRAME AND WILL TREAT THE SUB-FRAME WITH RUST-PROOFING MATERIAL TO STOP THE CORROSION PROCESS. THIS PROCEDURE WILL BE PERFORMED FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING APRIL 2009. OWNERS MAY CONTACT THE HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.
Campaign 09V124000 on NHTSA.gov
Fuel system, gasoline, storageJul 26, 2004
CERTAIN PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 301, "FUEL SYSTEM INTEGRITY" A VALVE ON THE FUEL TANK ASSEMBLY MAY NOT CLOSE PROPERLY. IF A VEHICLE ROLLS OVER AND THE FUEL TANK ASSEMBLY VALVE IS NOT PROPERLY CLOSED, FUEL SPILLAGE MAY OCCUR.
FUEL SPILLAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
DEALERS WILL INSTALL AN ADDITIONAL FUEL TANK ASSEMBLY VALVE. THE RECALL BEGAN ON OCTOBER 5, 2004. OWNERS SHOULD CONTACT HYUNDAI DE PUERTO RICO AT 1-800-981-0188.
Campaign 04V369000 on NHTSA.gov
Fuel system, gasoline, storage, tank assemblyApr 9, 2004
SOME PASSENGER VEHICLES CONTAIN A FUEL TANK ASSEMBLY VALVE THAT MAY NOT CLOSE PROPERLY. IF A VEHICLE WITH A FUEL TANK ASSEMBLY VALVE THAT IS NOT PROPERLY CLOSED WERE TO ROLL OVER, FUEL SPILLAGE MAY OCCUR.
FUEL SPILLAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
DEALERS WILL INSTALL AN ADDITIONAL FUEL TANK ASSEMBLY VALVE. OWNER NOTIFICATION BEGAN ON JUNE 30, 2004. OWNERS SHOULD CONTACT HYUNDAI AT 1-800-633-5151.
Campaign 04V178000 on NHTSA.gov
Tires, temporary/emergency spare tireMar 17, 2003
ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH A TRACTION CONTROL SYSTEM (TCS), IF THE T125/70D-15 COMPACT SPARE TIRE IS INSTALLED ON A FRONT WHEEL POSITION, THE TCS MAY INADVERTENTLY ACTIVATE BEGINNING AT SPEEDS OF 20 MPH.
INADVERTENT ACTIVATION OF THE TCS WILL CAUSE AUTOMATIC APPLICATION OF THE BRAKE AT THE WHEEL WHERE THE COMPACT SPARE TIRE IS INSTALLED. INADVERTENT BRAKE APPLICATION COULD CAUSE OVERHEATING AND DAMAGE TO THE BRAKE, AND MAY PREVENT THE VEHICLE FROM BEING DRIVEN AT SPEEDS ABOVE 20 MPH, WHICH COULD RESULT IN A CRASH.
DEALERS WILL REPLACE THE SPARE TIRE WITH A NEW LARGER DIAMETER T125/80R-15 COMPACT SPARE TIRE AND A NEW TIRE PRESSURE LABEL WILL BE INSTALLED ON THE DRIVER'S DOOR TO PROVIDE INFORMATION APPLICABLE TO THE T125/80R-15 COMPACT SPARE TIRE. VEHICLES PRODUCED FROM NOVEMBER 15, 2002 THROUGH DECEMBER 16 2002, ALREADY CONTAIN T125/80R-15 COMPACT SPARE TIRES, WILL ONLY REQUIRE NEW TIRE PRESSURE LABELS. OWNER NOTIFICATION BEGAN JUNE 30, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HYUNDAI AT 1-800-633-5151.
Campaign 03V097000 on NHTSA.gov
Air bags, side/windowMay 24, 2002
ON CERTAIN PASSENGER VEHICLES, THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SIDE IMPACT AIR BAG SATELLITE SENSORS MAY BE TOO SENSITIVE TO SOME LATERAL ACCELERATIONS THAT ARE NOT CAUSED BY SIDE IMPACTS TO THE VEHICLE, SUCH AS FORCEFULLY SLAMMING A DOOR CLOSED.
INADVERTENT DEPLOYMENT OF A SRS SIDE IMPACT AIR BAG WHEN A SIDE IMPACT CRASH HAS NOT OCCURRED COULD INCREASE THE RISK OF INJURY TO THE SEAT OCCUPANT.
DEALERS WILL REPLACE THE SIDE IMPACT AIR BAG SATELLITE SENSORS. OWNER NOTIFICATION BEGAN JULY 8, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HYUNDAI AT 1-800-633-5151.
Campaign 02V145000 on NHTSA.gov
Representative owner complaints: structure
88 reports, newest first. Show all
Suspension, Structure, Tires, Jul 17, 2008
MY RIGHT FRONT WHEEL DIDN'T FEEL RIGHT , TOOK IT TO A SERVICE STATION TO BE LOOKED AT. THEY BROUGHT ME IN TO SEE THAT THE WHOLE FRAME UNDER THE CAR IS RUSTED. THE BOLTS THAT HOLD UP THE AXLE AND SUSPENSION WERE COMPLETELY GONE AND THERE WAS A HOLE IN THE UNDER CARRIAGE. THE WHEEL WAS TILTED AND THE INSIDE OF THE TIRE WAS WORN ALL THE WAY DOWN . THERE WAS NOTHING THERE TO SUPPORT THE WHEEL. *TR
Structure, Jul 17, 2008
DURING AN ANNUAL SAFETY INSPECTION A LARGE HOLE WAS FOUND IN THE FRONT SUB FRAME. THE MECHANIC BELIEVED IT WAS CAUSED BY THE OUTFLOW OF WATER FROM THE AIR CONDITIONING UNIT WHICH RAN OVER THAT AREA. *TR
Structure, Jul 2, 2008
TL*THE CONTACT OWNS A 2002 HYUNDAI SONATA. UPON TAKING THE VEHICLE IN FOR INSPECTION, THE MECHANIC DISCOVERED THAT THE SUBFRAME WAS RUSTED IN SEVERAL PLACES. THE CONTACT WAS ADVISED NOT TO DRIVE THE VEHICLE. THERE WERE NO RECALLS FOR THIS FAILURE. THE CURRENT AND FAILURE MILEAGES WERE 85,000.
Structure, Jun 27, 2008
PURCHASED A 2002 HYUNDAI SONATA IN 2006. ON 6/25/2008 I RECEIVED AN OIL CHANGE AND WHEN INSPECTING THE UNDERCARRIAGE IT WAS NOTED OF A SERVER RUST HOLE ON THE SUB FRAME ASSEMBLY ON THE FRONT OF THE CAR. THE RUST HOLE (WHILE ONLY ABOUT 1/4 TO 1/8 OF AN INCH ACROSS) STRETCHES ACROSS THE WHOLE BOTTOM OF THE SUB-FRAME ASSEMBLY. THIS IS A VERY SERIOUS PROBLEM WITH A VEHICLE IF THE SUB-FRAME IS DAMAGED.
Structure, May 31, 2008
A RUSTED RIGHT FRONT SUBFRAME SEPARATION ON MY 2002 HYUNDAI SONATA CAUSED TIRE FAILURE AND A BLOWOUT. THIS HAPPENED ONE TIME AND THE CAR RAN OFF THE ROAD. THE CAR HAS BEEN TAKEN FOR REPAIR WHERE THE MECHANIC IS GOING TO TRY AND REPLACE THE FRAME IN THIS AREA. *TR
Structure, May 4, 2008
IN A RECENT VISIT TO HYUNDAI DEALER RELATED TO ANOTHER MATTER I LEARNED THAT MY 2002 SONATA WAS UNSAFE TO DRIVE DUE TO A RUSTED OUT ENGINE CRADLE ON THE PASSENGER SIDE. I HAVE YET TO GET THIS FIXED DUE TO THE PRICE (EST. $2500) AND YET AT THE SAME TIME I REALIZE THE SITUATION WILL ONLY GET WORSE. I HAVE READ ON THE INTERNET WHERE YOUR AGENCY IS INVESTIGATED THIS MATTER AND ALSO ON THE INTERNET I LEARNED OF MANY OTHER OWNERS WHO HAVE HAD ACCIDENTS DUE ENGINE CRADLE FAILURE. THE SUSPENSION GIVES WAY AND WHEELS FALL OFF, ETC. IN MY OPINION HYUNDAI USED INFERIOR METAL IN THEIR ENGINE CRADLE AND INCORRECTLY DESIGNED THE ENGINE CRADLE SYSTEM. I HAVE BEEN DRIVING FOR MORE THAN 40 YEARS AND OWNED MANY MAKES AND MODELS OF VEHICLES BUT NEVER HAVE I BEEN FACED WITH SUCH A SITUATION. I REALIZE MANY PARTS HAVE A LIMITED LIFE SPAN BUT THE ENGINE CRADLE SHOULD HAVE AN EXTENDED LIFE. MY WIFE HAS A 1999 SUBARU WITH MORE MILES THAN OUR SONATA AND WHICH HAS BEEN DRIVEN ON THE SAME ROAD CONDITIONS WITH LESS CARE THAN WE HAVE GIVEN THE SONATA AND YET HER CAR DOES NOT HAVE SUCH AN OBVIOUS AND COMMON SAFETY ISSUE. THANK YOU FOR CONSIDERING THIS IMPORTANT MATTER. I TRUST THAT YOU WILL MOVE QUICKLY TO REQUIRE HYUNDAI TO CORRECT THIS MATTER BEFORE MORE LIVES ARE PUT IN JEOPARDY AND LOST DUE TO THEIR OVERSIGHT. *TR
Structure, Apr 28, 2008
BROUGHT MY WIFE'S CAR IN FOR AN OIL CHANGE AND SHE HAD COMPLAINED THERE WAS A FUNNY NOISE THAT HAD JUST STARTED COMING FROM UNDER THE CAR. I WAS INFORMED WHEN WE WENT TO PICK IT UP THAT THE FRAME CLOSE TO THE FRONT RIGHT TIRE WAS RUSTED WITH A HOLE AND LOOKED IT WAS CRACKING. MY WIFE IS A VERY CAUTIOUS DRIVER AND WE TOLD THAT IT WAS NOT DUE TO ANY KIND IF IMPACT, BUT IT HAD JUST RUSTED AT THAT SPOT. *TR
Structure, Feb 24, 2008
ENGINE CRADLE RUSTED CAUSING AN SAFE SITUATION SHOULD IT FAIL WHILE DRIVING. *TR
Structure, Dec 25, 2006
HYUNDAI SONATA 2002 OUTSIDE AND INSIDE PAINTED DOOR HANDLE PEELING CAUSING INJURY TO HANDS. INJURY MORE CAUSE BY INSIDE DOOR HANDLES DUE TO SLIVER PAINTED DOOR HANDLES. BECOMES VERY SHARP ONCE PEELING. *NM
Structure, Aug 23, 2006
DURING VEHICLE ROUTINE MAINTENANCE OF 2002 HYUNDAI SONATA, IT WAS DISCOVERED THAT SIGNIFICANT CORROSION WAS OBSERVED IN ENGINE CRADLE. THIS CORROSION PRESENTS A SAFETY ISSUE AND HYUNDAI REFUSES TO REPLACE THE COMPONENT BECAUSE ITS OUT OF WARRANTY. *JB
Structure, Jan 17, 2006
DT*: THE CONSUMER STATED THE INTERIOR MATERIAL ON THE PASSENGER'S DOOR HANDLE OF THE VEHICLE CAUSED MINOR INJURIES TO A CHILD. THE VEHICLE WAS TAKEN TO THE DEALERSHIP WHERE THEY REPLACED THE DOOR HANDLES. THE CONSUMER IS NOW HAVING THE SAME TYPE OF PROBLEM WITH THE DRIVER'S SIDE DOOR. *JB UPDATED 3/9/2006 - *NM
Structure, Sep 10, 2005
ON JULY 26TH, 2005, I WAS MEETING A CO-WORKER FOR LUNCH WHEN I NOTICED THAT THE PAINT ON THE FRONT FACIA COVERING THE BUMPER ON MY 2002 HYUNDAI SONATA WAS BUBBLING AND STARTING TO PEEL. AFTER WORK THAT SAME DAY, I ATTEMPTED TO CONTACT THE SALESPERSON WHO SOLD ME THE VEHICLE AT THE DEALERSHIP. I SPOKE THE SERVICE MANAGER AND HAD HIM WALK OUT TO INSPECT THE FACIA. HIS FIRST QUESTION TO ME WAS WHETHER I HAD THE VEHICLE REPAINTED. I TOLD HIM I HAD NOT! HE THEN ASKED ME IF I HAVE EVER BROUGHT MY CAR TO A TOUCHLESS CAR WASH, WHICH I HAVE FOR MANY, MANY YEARS HERE IN TOWN. HE THEN STATED THAT BECAUSE OF THE 7500 PSI CAUSED BY THE HIGH PRESSURE WATER THAT THEY WERE NOT AT FAULT AND THAT IT WAS NOT A MANUFACTURER DEFECT. I ASKED WHY THIS WAS NOT OCCURRING ON THE BODY OF THE CAR OR ON THE REAR FACIA, AND HE STATED THAT HE DID NOT KNOW. DISSATISFIED WITH THIS RESPONSE, I CALLED HYUNDAI MOTOR AMERICA IN FOUNTAIN VALLEY, CA AT 800-633-5151 THAT EVENING (8/5/05) AND SPOKE WITH A GENTLEMAN. AFTER TELLING HIM OF THE SITUATION, HE THEN STATED THAT I SHOULD TRY TO GET THE CAR FIXED AT ANOTHER DEALERSHIP! ON MONDAY, AUGUST 8TH, I RECEIVED A PHONE CALL FROM HYUNDAI MOTOR AMERICA REPRESENTATIVE, WHO STATED THAT THE DEALERSHIP WAS NOT GOING TO REMEDY THIS SITUATION. I RECEIVED A RESPONSE FROM THE BBB AUTO LINE DATED AUGUST 30TH, STATING THAT MY VEHICLE EXCEEDED THE MILEAGE REQUIREMENTS FOR FILING WITH THEIR PROGRAM. MY VEHICLE HAD 27,500 MILES AT THE TIME OF THE COMPLAINT. APPARENTLY, THE BBB AUTO LINE AGREEMENT WITH HYUNDAI IS TO ONLY ACCEPT CLAIMS WITHIN TWO YEARS OR 24,000 MILES, WHICHEVER COMES FIRST (SEE DOCUMENT HYUNDAI-NY 8/2000). HYUNDAI WARRANTY EXPRESSLY STATES WARRANTY AGAINST PAINT DEFECTS FOR 3 YEARS, 36,000 MILES. I HAVE SUBMITTED A COMPLAINT TO THE NYS ATTORNEY GENERALS OFFICE AS OF 9/7/2005. *JB
Structure, Jun 17, 2004
WHILE OPENING THE DRIVER'S DOOR CONSUMER NOTICED THAT THE DOOR HANDLE WAS SHARP. CONSUMER'S HAND WAS CUT. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION, AND MECHANIC DETERMINED THAT THE DOOR HANDLE NEEDED TO BE REPLACED, AND HE REPLACED IT. HOWEVER, THE PROBLEM RECURRED. *AK