2004 Hyundai Sonata
Problems, recalls and owner-reported issues
Suspension is the leading concern among 202 owner complaints filed for this model year. This is the 17th highest complaint count among 26 Sonata model years with reports.
Of the 2004 reports, 22 involved a crash and 2 involved a fire. 32 people were injured.
What owners report most often
Recalls and investigations
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
Representative owner complaints: latches/locks/linkages
12 reports, newest first. Show all
Latches/locks/linkages, Aug 22, 2011
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE CHROME HANDLE ON THE REAR PASSENGER DOOR PEELED AND CAUSED THE CONTACT TO CUT HIS HAND. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED HIS VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 09V171000 ( LATCHES/LOCKS/LINKAGES: DOORS: LATCH). THE MANUFACTURER WAS CONTACTED CONFIRMED THAT THE VEHICLE WAS NOT UNDER RECALL AND OFFERED NO OTHER ASSISTANCE. THE FAILURE MILEAGE WAS 73,500.
Structure, Latches/locks/linkages, Aug 19, 2010
INSIDE DOOR HANDLES THIN COVERING (APPEARS TO BE ALUMINUM) IS PEELING APART AND I HAVE CUT MY HAND ON THE SHARP EDGE WHICH CAME APART. DEALER WILL NOT REPLACE THE HANDLE BECAUSE HYUNDAI HAS NOT RECALLED THE 2004 MODELS WHICH HAS THE ***SAME PROBLEM**AS THE 2003 MODEL. *TR
Structure, Latches/locks/linkages, Aug 1, 2010
CHROME IS PEELING OFF THE INTERIOR DOOR HANDLES CAUSING CUTS TO HANDS/FINGERS ON MY 2004 HYUNDAI SONATA. *TR
Structure, Latches/locks/linkages, Mar 14, 2010
2004 HYUNDAI SONATA. BUILT IIN FEBRUARY 2004, THE CHROME PLATING OF THE INTERIOR DOOR HANDLE CAME LOOSE. OUR HANDS HAVE BEEN CUT SEVERAL TIMES BY THE SHARP EDGES OF THE CHROME THAT IS PEELING BACK. FINALLY HAD TO PEEL THE CHROME OFF AND SAND THE EDGES. *TR
Exterior lighting, Latches/locks/linkages, Dec 14, 2009
EMERGENCY FLASHERS BEGAN FLASHING FOR NO APPARENT REASON AND WOULD NOT BE TURNED OFF. THEN TRYING TO USE THE KEYLESS ENTRY DOOR OPENER, THE LOCKS BEGAN LOCKING AND UNLOCKING. WHEN THE CAR WAS RUNNING THIS STOPPED. WE TOOK IT TO THE DEALER AND THEY REPLACED THE ETAC MODULE, THEN THE ENTIRE FUSE BOX. AFTER RETURNING HOME, THE HAZARD LIGHTS AGAIN BEGAN FLASHING WHILE THE CAR WAS PARKED. THIS WOULD STOP AND BEGIN AGAIN INTERMITTENTLY. RETURNED TO THE DEALER AND LEFT THE CAR FOR SEVERAL DAYS. FINALLY A SWITCH WAS REPLACED AND THE PROBLEM CEASED. *TR
Latches/locks/linkages, Dec 3, 2009
I HAVE A 2004 HYUNDAI SONATA - SAME PROBLEM AS WITH THE 2002-2003 LISTED BELOW - THIS SHOULD NOT HAVE BEEN CLOSED. RECALL CAMPAIGN 09V171000 HAS 1 RELATED INVESTIGATION(S) NHTSA ACTION NUMBER: PE08071 VEHICLE MAKE / MODEL: MODEL YEAR(S): HYUNDAI / SONATA 2002 MANUFACTURER: HYUNDAI MOTOR COMPANY COMPONENT: LATCHES/LOCKS/LINKAGES:DOORS:LATCH DATE INVESTIGATION OPENED: DECEMBER 15, 2008 DATE INVESTIGATION CLOSED: MAY 29, 2009 SUMMARY: THE MANUFACTURER HAS ISSUED A SAFETY RECALL NOTIFICATION AS A RESULT OF THIS INVESTIGATION. THE RECALL AFFECTS 91,202 MY 2002-2003 SUBJECT VEHICLES PRODUCED FROM JANUARY 28, 2002, THROUGH MARCH 22, 2003. THE VEHICLE RECALL POPULATION WAS DEFINED BY THE MANUFACTURER'S USE OF A NEW SUPPLIER FOR THE CHROME PLATING PROCESS BEGINNING IN JANUARY 2002, AND A PRODUCTION CHANGE IN MARCH 2003 TO IMPROVE ADHESION OF THE PLATING TO THE DOOR HANDLE. VEHICLES BEING RECALLED REPRESENT 59 PERCENT OF THE TOTAL MY 2002-2003 PRODUCTION, BUT ACCOUNT FOR 91 PERCENT OF THE CONSUMER COMPLAINTS RECEIVED. THE PROCESS CHANGE FOR MY 2002 VEHICLES RESULTED IN A DRAMATIC INCREASE IN COMPLAINTS (1200 PERCENT ON A PER UNIT RATE BASIS). MY 2003 VEHICLES BUILT AFTER MARCH 2003 PRODUCTION CHANGE SHOWED A SIMILAR DECLINE IN THE COMPLAINT RATE. BASED ON THE MANUFACTURER'S ACTION, THIS INVESTIGATION HAS BEEN CLOSED. *TR
Latches/locks/linkages, Oct 30, 2009
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. IN FEBRUARY 2009, THE TOP EDGE OF THE INTERIOR DOOR HANDLE DEVELOPED CRACKS. AS A CONSEQUENCE SHE INJURED HERSELF WHILE OPENING THE DOOR. SHE TOOK THE VEHICLE TO THE DEALERSHIP TO BE INSPECTED AND WAS TOLD THAT THE PART FOR THE REPAIR WOULD COST $70.00. THE VEHICLE HAD NOT BEEN REPAIRED TO-DATE. HER MODEL YEAR WAS EXCLUDED FROM RECALL# 09V171000 & 09V317000 (LATCHES/LOCKS/LINKAGES:DOORS:LATCH). THE CURRENT MILEAGE WAS APPROXIMATELY 36,000. THE FAILURE MILEAGE WAS APPROXIMATELY 34,000.
Latches/locks/linkages, Sep 30, 2009
THE CHROME PLATING ON THE PASSENGER SIDE DOOR HANDLE AS WORN TO THE POINT WHERE IT HAS CRACKED AND LEFT A SHARP EDGE ON MY 2004 HYUNDAI SONATA. THIS CAUSED A RECALL OF 2002-2003 HYUNDAI SONATAS 09V-171. *TR
Structure, Latches/locks/linkages, Aug 31, 2009
2004 HYUNDAI SONATA - INTERIOR DOOR HANDLE CAUSED HAND LACERATION BY PEELING CHROME PLATING /CRACK IN DOOR HANDLE ASSEMBLY. *TR
Latches/locks/linkages, Aug 30, 2009
2004 HYUNDAI SONATA - THE INTERIOR HANDLES HAVE DEVELOPED VERY SHARP EDGES WHICH WE DID NOT NOTICE UNTIL I SLICED MY MIDDLE FINGER OPEN YESTERDAY WHILE TRYING TO OPEN THE DOOR. UPON CLOSER INSPECTION, BOTH FRONT DOOR HANDLES HAVE RAZOR-SHARP EDGES IN PLACES. I HAVE NOT YET HAD THE OPPORTUNITY TO CONTACT HYUNDAI. *TR
Structure, Latches/locks/linkages, Aug 17, 2009
SEEMS TO BE A DEFECT IN THE DOOR HANDLES...WE HAVE FLAKING OF THE CHROME FINISH ON OUR 2004 SONATA AS WELL, PRIMARILY DRIVER'S DOOR. *TR
Latches/locks/linkages, Jul 17, 2009
ON MY 2004 HYUNDAI SONATA, THE CHROME DOOR HANDLE HAS BEEN PEELING AWAY SINCE 2007, RESULTING IN A SHARP, JAGGED EDGE THAT I HAVE CUT MY HAND ON NUMEROUS TIMES. I NOTICE THAT THERE IS ALREADY A RECALL ORDER FOR THE 2003 SONATAS FOR THIS SAME ISSUE UNDER ACTION #PE08071, BUT IT APPEARS THAT THE 2004 MODEL IS DOING THE SAME THING, AND I WOULD LIKE FOR THAT MODEL TO BE ADDED TO THIS RECALL AS WELL. *TR