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
325 reports, newest first.
Structure, Jul 23, 2009
I PURCHASED A PRE-OWNED HYUNDAI SONATA IN JANUARY 2008 FROM A DEALER. THIS PAST TUESDAY, THE FRAME OF MY CAR BROKE WHILE I WAS ON THE ROAD. LUCKILY FOR ME, I WAS NOT ON THE HIGHWAY. AFTER SOME RESEARCH I FOUND OUT THAT 1999-2002 SONATA HAD PROBLEM WITH THE CAR FRAME. I CONTACTED THE COMPANY AND WAS ASKED TO TAKE THE CAR TO A HYUNDAI DEALER WHO WOULD FIX THE FRAME FOR ME. ALTHOUGH THE COMPANY IS FIXING THE FRAME AT NO COST, I HAD TO RENT A CAR AND I STILL HAVE IT. THE TOTAL CHARGES FOR IT TILL NOW HAVE BEEN $700. I ALSO PAID TWICE FOR GETTING MY CAR TOWED. I REQUESTED THE COMPANY TO REIMBURSE ME FOR THE RENTAL CAR CHARGES WHICH THEY DENY DOING. I WOULD HAVE DRIVEN MY SONATA FOR ANOTHER 3-4 YRS. AS I AM A RECENT GRADUATE AND LOOKING FOR A JOB, I CANNOT AFFORD TO BUY A NEW CAR AND PAY HUGE RENTAL FEE. BUT AT THE SAME TIME, I AM CONCERNED ABOUT MY SAFETY EVEN AFTER THE FRONT FRAME IS FIXED. I WOULD APPRECIATE IF YOU CAN GUIDE ME ABOUT HOW TO APPROACH THIS SITUATION WITH HYUNDAI. I AM SPENDING A LOT OF MONEY ON RENTAL AND AT THE SAME TIME I WILL HAVE TO BUY A NEW CAR. I LOOK FORWARD TO HEARING FROM YOU. *TR
Structure, Jul 16, 2009
FRONT SUBFRAME RUSTING OUT. *TR
Structure, Wheels, Jun 16, 2009
TL*THE CONTACT OWNS A 2002 HYUNDAI SONATA. AFTER DRIVING 55 MPH, THE DRIVER ARRIVED AT HER DESTINATION AND DISCOVERED THAT THE WHEEL WAS AT A 45 DEGREE ANGLE. THE DRIVER HAD TO USE EXCESSIVE FORCE TO TURN THE STEERING WHEEL TO THE RIGHT. SHE NOTICED THAT THE FRAME ON THE FRONT END, WHICH HOUSES THE SUPPORTS FOR THE WHEELS, WAS RUSTED OUT COMPLETELY. THE CONTACT TOOK THE VEHICLE TO A TIRE DEALER FOR AN ALIGNMENT INSPECTION. THE RESULTS INDICATED THAT THERE WERE HOLES IN THE FRAME HOLDING THE STEERING, WHICH HAD TO BE REPLACED AT THE COST OF $1,600. THE VEHICLE WAS REPAIRED AND IS CURRENTLY ABLE TO BE DRIVEN. THE VIN WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 125,000.
Structure, Jun 16, 2009
2002 HYUNDAI SONATA SUBFRAME FAILURE. *TR
Structure, May 11, 2009
WHILE CHANGING THE BALL BEARING, THE MECHANIC NOTICED THAT THERE WAS SEVERE RUSTING ON THE FRONT RIGHT SIDE FRAME. HE WARNED THAT THE CAR WOULD JUST COLLAPSE. THERE WERE 3-4 INCH BIG HOLES IN THE FRAME. THIS COULD HAVE CAUSED FATAL INJURY. THE CAR IS LESS THAN 7 YEAR OLD FOR SUCH SEVERE RUSTING TO OCCUR. *TR
Structure, Apr 7, 2009
2002 HYUNDAI SONATA SUB FRAME CORROSION AND FRONT RT WHEEL COLLAPSED. LOCAL DEALER COVERED COST OF SUB FRAME REPLACEMENT, BUT CHARGED ME FOR A NEW SWAY BAR. FRONT FENDER WAS PUSHED AGAINST PASSENGER DOOR, WHICH HYUNDAI WOULD NOT FIX, AND CAR NOW HAS SEVERE WOBBLING WHEN DRIVEN, UNLIKE BEFORE THE CORROSION. HYUNDAI SAYS IT'S AN ALIGNMENT PROBLEM AND MY RESPONSIBILITY. I AM WONDERING WHAT RECOURSE I HAVE AGAINST HYUNDAI, AS THE CAR WAS WELL MAINTAINED AND DROVE SMOOTHLY BEFORE THIS DAMAGED OCCURRED. LUCKY NO ONE WAS HURT, SINCE THE WHEEL LET GO AT A LOW SPEED. *TR
Structure, Mar 17, 2009
MY FRAME ON MY CAR RUSTED THROUGH LEAVING MY CAR SITTING ON MY TIRES LITERALLY! WHILE DRIVING THROUGH TOWN. I HAVE CALLED THE HYUNDAI MANUFACTURER AND THEY TOOK DOWN INFORMATION, I AM NOW WAITING ON THE DECISION IF IT WILL COST ME ANYTHING OR NOT. *TR
Steering, Air bags, Mar 9, 2009
TL*THE CONTACT OWNS A 2002 HYUNDAI SONATA. THE CONTACT STATED THAT THE AIR BAG INDICATOR HAS REMAINED ILLUMINATED IN HER VEHICLE SINCE NOVEMBER OF 2007. SHE TOOK THE VEHICLE TO THE DEALER FOUR TIMES AND THEY ATTEMPTED TO REPAIR THE HARNESS IN ORDER TO REMEDY THE ISSUE. HOWEVER, THE INDICATOR ILLUMINATED AGAIN A FEW DAYS LATER. THE MANUFACTURER COULD NOT ASSIST BECAUSE THE VEHICLE WAS NO LONGER UNDER WARRANTY. THE BETTER BUSINESS BUREAU REFERRED THE CONTACT TO NHTSA. THE CURRENT MILEAGE WAS APPROXIMATELY 64,000 AND FAILURE MILEAGE WAS APPROXIMATELY 55,000. UPDATED 04-14-09 *BF THE TIE ROD WAS REPLACED. UPDATED 04/16/09.*JB
Structure, Mar 9, 2009
MY 2002 HYUNDAI SONATA LX HAS THE COMMON PROBLEM OF THE SUBFRAME ROTTING OUT ON THE PASSENGER SIDE WHERE THE CONTROL ARM MOUNTS. I NOTICED THE PROBLEM DURING AN OIL CHANGE AND HAVE TAKEN THE CAR OFF THE ROAD DUE TO SAFETY ISSUES. THE CONTROL ARM HAS NOT LET GO YET, BUT I DO NOT DARE TO DRIVE THE CAR DUE TO THE EXTENT OF THE RUST. I AM GOING TO BE CONTACTING HYUNDAI TO SEE ABOUT A WARRANTY. *TR
Suspension, Feb 25, 2009
VIBRATION IN FRONT RIGHT WHEEL AT HIGH SPEEDS. I TOOK MY 2002 SONATA TO THE REPAIR SHOP AND THEY TOLD ME MY CRADLE THAT INVOLVES THE HALF SHAFT/CONTROL ARM IN THE SUSPENSION WAS RUSTED THROUGH WITH FIST SIZE HOLES. I TOOK IT TO THE AUTO DEALER AND THEY CHARGED ME OVER $500.00 TO REPLACE THE HALF SHAFT AND CRADLE, ALSO THEY STATED THAT IT WOULD HAVE BEEN COVERED HAD MY WHEEL FALLEN OFF. THAT WAS THE MOST RIDICULOUS THING I'VE EVER HEARD. AFTER THEY REPLACED THE HALF SHAFT, WITHIN 2 DAYS I HAD A GRINDING/RATTLE ON THE SAME RIGHT SIDE. I TOOK IT BACK TO THE AUTO DEALER AND THEY TOLD ME NOW IT WAS THE BUSHINGS IN THE SUSPENSION AND THEY WOULD HAVE TO BE REPLACED BUT IT WAS SAFE TO DRIVE.. THIS PROBLEM WAS NOT THERE UNTIL THEY WORKED ON THE CAR ORIGINALLY. IT WILL NOW COST ME OVER $300.00 TO HAVE THE BUSHINGS REPLACED. I BELIEVE THEY SHOULD HAVE DONE THIS WITH THE ORIGINAL WORK. THERE IS A FEDERAL PROBE GOING ON WITH THE NHTSA, IT IS STATED THAT THIS IS A VERY SERIOUS AND DANGEROUS SITUATION. THE MANUFACTURER OF THIS CAR SHOULD BE STANDING BEHIND THEY'RE PRODUCT, BUT INSTEAD THEY ARE REFUSING TO COVER THIS PROBLEM AND MAKE THE APPROPRIATE CHANGES THAT COULD IN TURN SAVE SOMEBODY'S LIFE IF THEIR CAR WOULD FAIL DUE TO THIS FLAW. *TR
Suspension, Feb 3, 2009
MY WIFE OWNS A 2002 HYUNDAI SONATA, AND LAST WEEK SHE NOTICED THAT THE CAR WAS PULLING HARD TO THE RIGHT. SHE DRIVES 60 MILES ROUND TRIP TO HER JOB 5 DAYS A WEEK. ONCE SHE TOLD ME ABOUT IT, I TOOK IT IN FOR SERVICE THINKING IT WAS IN NEED OF A WHEEL ALIGNMENT. MY TECHNICIANS CALLED ME BACK TO THE SERVICE AREA AND SHOWED ME WHERE THE SUB FRAME HAD RUSTED COMPLETELY THROUGH ON THE RIGHT FRONT SIDE. ALSO THE RIGHT FRONT WHEEL AS TILTED TO THE SIDE SLIGHTLY. I TOLD THEM TO BEGIN REPAIRS IMMEDIATELY, AS MY WIFE'S SAFETY IS MY TOP PRIORITY. I CALLED HYUNDAI ON 2/3/09 AND INFORMED THEM OF THE PROBLEM. I WAS GIVEN A CASE NUMBER, AND TOLD THAT THEY WOULD CONTACT ME IN 3 TO 4 BUSINESS DAYS. I EXPECT FULL REIMBURSEMENT, AS I NOW UNDERSTAND THAT THIS A COMMON PROBLEM ON THIS PARTICULAR VEHICLE. *TR
Structure, Jan 25, 2009
2002 HYUNDAI SONATA RIGHT PASSENGER SIDE WHEEL WENT SIDEWAYS WHILE DRIVING AT FULL SPEED. LUCKILY NO ONE WAS SERIOUSLY INJURED BUT THE CAR WILL NEED TO BE REPAIRED. I BELIEVE HYUNDAI SHOULD BE RESPONSIBLE FOR REPAIRS. FROM READING INFORMATION ONLINE THIS SEEMS TO BE A VERY COMMON PROBLEM. *TR
Air bags, Seat belts, Jan 22, 2009
TL*THE CONTACT OWNS A 2002 HYUNDAI SONATA. WHILE DRIVING APPROXIMATELY 55 MPH ON NORMAL ROAD CONDITIONS, THE AIR BAG WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL UNEXPECTEDLY. THE WARNING INDICATOR REMAINED LIT UNTIL THE ENGINE WAS TURNED OFF. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING, BUT THE CAUSE OF THE FAILURE COULD NOT BE DETERMINED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC ON TWO SEPARATE OCCASIONS FOR IDENTICAL FAILURES, BUT THERE WERE NO RESOLUTIONS. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS 51,000 AND THE CURRENT MILEAGE WAS UNAVAILABLE. UPDATED 03/09/09. *LJ THE CONSUMER ALSO STATED THE SEAT BELT LIGHT ILLUMINATED. UPDATED 03/11/09. *JB
Structure, Jan 13, 2009
MY 2002 HYUNDAI SONATA FAILED STARE INSPECTION DUE TO RIGHT FRONT ROT ON SUBFRAME. I CONTACTED MY LOCAL HYUNDAI DEALER AND THEY ARE GOING TO REPAIR PROBLEM. UNTIL THEN, IT WILL NOT PASS INSPECTION. I HAVE ALREADY RECEIVED A CITATION FOR IT NOT BEING INSPECTED . I AM LEFT WITH AN UNINSPECTED AND ROTTED CAR UNTIL THEY CAN TAKE IT IN. HYUNDAI DOES NOT GIVE OUT LOANER CARS! *TR
Electrical system, Dec 14, 2008
THE BATTERY IS OFTEN DRAINED AND CONTINUES TO DO SO ALL THE TIME I'VE RESEARCHED IT ON THE INTERNET AND MANY OWNERS OF THE 2002 HAVE THE SAME PROBLEM, POSSIBLY THE IGNITION SWITCH RELAY. MANY HAVE REPLACED BATTERY, ALTERNATOR AND PROBLEMS CONTINUE. MY CAR IS CURRENTLY DRAINING AND DYING ALL THE TIME I HAVE PURCHASED A JUMP STARTER FOR MY CAR. I HAVE TO JUMP MY CAR EVERY TIME I USE IT. *TR
Structure, Dec 9, 2008
VEHICLE FAILED STATE INSPECTION DUE TO THE PASSENGER SIDE FRONT SUBFRAME BEING SEVERELY RUSTED IN ON SPECIFIC AREA. FRAME FAILURE AT THAT POINT IS LIKELY TO CAUSE A WHEEL/SUSPENSION FAILURE, MOST LIKELY WHILE BEING PUT UNDER THE STRAIN OF TURNING/BRAKING. DEALER WILL NOT REPAIR WITHOUT CHARGE. I HAVE PHOTOS OF THE DEFECT IF NEEDED. *TR
Steering, Dec 3, 2008
ON 11/3/08 I FILED ODI#10248441 REGARDING ROTTED RIGHT SIDE SUB-FRAME ON MY 2002 HYUNDAI SONATA WHICH WAS REPAIRED BY DEALER ON 11/11/08 AS A 1 TIME "GOODWILL" REPLACEMENT. DURING REPLACEMENT OF SUB-FRAME DEALER DAMAGED AND REPLACED FLEXPIPE AND BOLTS. CAR WAS RETURNED AND STARTED LEAKING FLUID WHICH WAS FOUND TO BE POWER STEERING FLUID. WE MONITORED AND REPLACED FLUID BUT STEERING WAS DIFFICULT AND MADE NOISE MOSTLY ON START-UP AND TURNING CORNERS. ON 12/1/08 WE HAD TO HAVE THE CAR TOWED - WE LOST THE POWER STEERING COMPLETELY AND IT WOULD NO LONGER HOLD FLUID. DEALER STATED THAT POWER STEERING RACK MOUNT WAS COMPLETELY CRACKED AND HAD TO BE REPLACE AT A COST OF OVER $1,000. WE ARE REFUSING TO PAY FOR REPAIR STATING THAT CRACKED STEERING MOUNT IS RELATED TO ROT PROBLEM AND IS THE DEALERS RESPONSIBILITY. 12/3/08 WE OPENED A CASE WITH HYUNDAI CONSUMER COMPLAINTS . BASED ON INFORMATION RESEARCHED ON THIS SITE AND OTHER RELATED SITES THE CRACKED POWER STEERING MOUNT IS COMMON AND RELATED TO ROT PROBLEM. CURRENTLY WAITING FOR A RESPONSE FROM HYUNDAI. CAR ONLY HAS 41,400 MILES AND WE HAVE ALREADY HAD TO REPLACE BRAKES, TIRES, HEAT SENSOR, AND SUB-FRAME IN ADDITION TO NORMAL MAINTENANCE. *TR
Suspension, Structure, Dec 2, 2008
TL*THE CONTACT OWNS A 2002 HYUNDAI SONATA. THE CONTACT TOOK THE VEHICLE TO THE REPAIR SHOP BECAUSE THE STEERING BECAME DIFFICULT TO CONTROL WHILE DRIVING 20 MPH. THE MECHANIC STATED THAT THE FAILURE WAS IN THE PASSENGER SIDE FRONT SUBFRAMES. THERE WAS A LARGE HOLE THAT RUSTED ALL THE WAY THROUGH THE FRAMES, WHICH PREVENTED THE VEHICLE FROM BEING DRIVEN. AFTER RESEARCHING THE ISSUE, THE CONTACT FOUND NUMEROUS COMPLAINTS FOR THE SAME DEFECT AND BELIEVES IT SHOULD BE RECALLED. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 100,000 AND CURRENT MILEAGE WAS 106,000. UPDATED 01/07/09. *LJ THE SWAY BAR ENDS LINKS AND BUSHINGS WERE WORN. UUPDATED 01/09/09. *JB
Tires, Nov 18, 2008
I HAVE HAD TWO VALVE STEMS ON MY 2002 HYUNDAI SONATA GO BAD. I PURCHASED NEW TIRES AT GURNEE HYUNDAI 10/23/07. THE FIRST FAILURE WAS 4 OR 5 MONTHS AGO AND THE MOST RECENT WAS ON 11/2/08. WE WERE TRAVELING IN VIRGINIA AND STOPPED FOR LUNCH WHEN THE FAILURE OCCURRED. IT COULD HAVE BEEN SERIOUS BECAUSE IT WAS THE RIGHT FRONT TIRE AND WE WERE TRAVELING AT HIGHWAY SPEEDS IN THE MOUNTAINS. *TR
Structure, Nov 11, 2008
I OWN A 2002 HYUNDAI SONATA WITH THE ENGINE CRADLE FRAME COMPLETELY RUSTING OUT. VEHICLE FAILED NH STATE INSPECTION AND IS CONSIDERED UNSAFE TO DRIVE AT THIS POINT. MILEAGE: 123,000. *TR
Structure, Nov 11, 2008
2002 HYUNDAI SONATA/4DR SEDAN/2.4L AU - RIGHT FRONT SUB-FRAME COMPLETELY ROTTED OUT. CAR WAS BEING CHECKED FOR A LEAK AND MECHANIC FOUND DAMAGE. CAR WAS TAKEN OFF THE ROAD UNTIL REPAIRED. NO INJURY OR DAMAGE TO PERSON OR PROPERTY. *TR
Steering, Nov 8, 2008
POWER STEERING HOSE RUPTURED ABRUPTLY CAUSING LOSS OF POWER STEERING AT HIGH SPEED. *TR
Structure, Nov 8, 2008
SUBFRAME RUSTED COMPLETELY THROUGH. LUCKILY THIS WAS DISCOVERED DURING A REPAIR OF A POWER STEERING FAILURE. THIS IS A COMMON COMPLAINT REGARDING THE 1999-2004 SONATA IN HIGH SALT AREAS AND HYUNDAI IS APPARENTLY REPLACING THE FRAME OUT OF WARRANT (MINE WAS UNDER AN EXTENDED WARRANTY ANYWAY). I BELIEVE THIS SHOULD BE A FULL RECALL TO PROTECT THOSE WHO ARE OTHERWISE UNAWARE OF THIS DEFECT WHICH HAS CAUSED, IN SOME CASES, WHEEL SEPARATIONS. DEALER TOLD ME THAT THE PART HAD A LARGE HOLE COMPLETELY THROUGH THE FRAME. *TR
Structure, Oct 29, 2008
MY DAUGHTER WAS DRIVING MY 2002 SONATA, WHEN IT BASICALLY JUST FELL APART. IT SOUNDED LIKE SHE WAS DRIVING ON THE TIRE RIM, BUT ALL 4 TIRES WERE STILL INFLATED. THE FRONT PASSENGER-SIDE TIRE DID LOOK TILTED OUT. IT HAD TO BE TOWED FROM THAT SITE. AN INSURANCE ADJUSTER INSPECTED IT AND STATED HE WAS SURE THAT THE CAR HAD GONE OFF THE ROAD AT SOME POINT BECAUSE THE AXLE WAS BROKEN, THAT TIRE WAS BENT AND THE ENGINE CRADLE WAS SCUFFED "SHINY". IT HAD NOT GONE OFF THE ROAD, SO MY MECHANIC TOOK A CLOSER LOOK AND FOUND THAT THE ENGINE CRADLE WAS RUSTED RIGHT THOUGH AND WHAT HAD HAPPENED (TO MY 16 YEAR-OLD DAUGHTER WHILE DRIVING ON A BUSY ROAD AT NIGHT) WAS THAT THE ENGINE CRADLE WAS SO RUSTED THAT IT CRUMBLED, CAUSING THE ENGINE AND TRANSMISSION TO FALL AND BREAK THE AXLE AND BEND THE WHEEL! THANKFULLY, SHE HAD ONLY JUST DRIVEN ONTO THE ROAD FROM A DRIVEWAY, SO SHE WASN'T GOING FAST AND THE LANE SHE ENTERED WAS CLEAR. I'D HATE TO THINK WHAT WOULD HAVE HAPPENED HAD SHE MADE IT TO THE HIGHWAY BEFORE THIS HAPPENED! WHEN WE DISCOVERED ON LINE THAT SO MANY OTHERS HAD SIMILAR PROBLEMS WITH THEIR 1999-2002 SONATAS, WE CONTACTED OUR LOCAL DEALER. HE SAID WE NEEDED TO HAVE THE CAR TOWED (15 MILES) TO HIS SERVICE DEPT WHERE THEY WOULD HAVE A HYUNDAI REP TAKE A LOOK AT IT. HE SAID HIS MANAGER HAD BEEN KNOWN TO REPLACE THE ENGINE CRADLE FREE OF CHARGE, BUT HE DOUBTED VERY MUCH THAT THEY'D PAY FOR THE AXLE, WHEEL, AND ANY OTHER DAMAGE INCURRED. AFTER READING ALL THESE OTHER SIMILAR INCIDENTS, I DON'T KNOW IF I WANT TO BOTHER GOING TO THE TROUBLE OF HAVING MY CAR TOWED TO HYUNDAI. I DEFINITELY FEEL THAT THE PUBLIC NEEDS TO BE MADE AWARE OF THIS PROBLEM AND THAT A RECALL SHOULD BE ISSUED ASAP BEFORE SOMEONE IS KILLED. (I BOUGHT THIS CAR USED FROM THE HYUNDAI DEALER IN JAN '05 WITH 50,000 MILES ON IT. I HAVE HAD IT SERVICED REGULARLY BY A REPUTABLE MECHANIC THESE PAST 3+ YEARS, AND IT NOW HAS A LITTLE OVER 100,000 MILES ON IT). *TR
Engine and engine cooling, Oct 17, 2008
I OWN A 2002 HYUNDAI SONATA WHICH HAS SEVERE PASSENGER SIDE ENGINE CRADLE RUST. IT WOULD NOT PASS VEHICLE INSPECTION. THE MECHANIC HAS SUGGESTED WELDING THE FRAME TO "BANDAGE" THE PROBLEM. I HAVE READ THE OTHER STORIES FROM OWNERS OF THE SAME CAR AND BELIEVE SOMETHING SHOULD BE DONE BEFORE THERE ARE DEATHS RELATED TO THIS DEFECT. I AM AFRAID TO DRIVE MY CAR, IT'S LIKE WAITING FOR SOMETHING TO HAPPEN. MY SON ALSO DRIVES MY CAR ON OCCASION. *TR