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: structure
47 reports, newest first. Show all
Structure, Other or unspecified, Aug 31, 2022
The front subframe has a hole in it it rusted for some reason and upon research there was a recall on this particular issue but now there isn’t one. I went to two dealerships and they informed me that Hyundai had recalls on this issue that’s why I’m confused on why when I search by my VIN there isn’t any open recalls. Just because they isn’t any open recalls on this doesn’t mean that people aren’t still experiencing this issue.
Suspension, Service brakes, Air, Structure, Feb 9, 2022
The contact owns a 2004 Hyundai Sonata. The contact stated that while driving the vehicle, she noticed that her brakes were failing. The contact stated that she drove her vehicle to an independent mechanic who attempted to replace the brakes however, the mechanic informed her that her vehicle had a lot of corrosion on the brakes, and underneath the vehicle, which caused the brakes to fail. The contact stated that the mechanic did fabrication and installation of the brake line. The contact stated that she then took her vehicle to be inspected and was informed that the corrosion on the vehicle was too severe and the vehicle would not pass State Inspection. The vehicle was taken to the dealer and the contact was informed that the VIN was not included in NHTSA Campaign Number: 09V124000 (Suspension). The vehicle was not repaired. The manufacturer was not contacted. The approximate failure mileage was 122,000
Structure, Apr 2, 2021
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE AT THE LOCAL DEALER FAULKNER HYUNDAI (11500 ROOSEVELT BLVD, PHILADELPHIA) FOR ROUTINE MAINTENANCE, IT WAS DISCOVERED THAT THE K-FRAME HAD SUSTAINED SEVERE RUSTING AND CORROSION. THE CAUSE OF THE FAILURE WAS NOT DETERMINED AND THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 73,000.
Suspension, Structure, Wheels, Mar 20, 2019
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT NOTICED THAT THE SUBFRAME WAS RUSTED, WHICH CAUSED THE FRONT DRIVER AND PASSENGER TIRES TO DETACH. THE VEHICLE WAS TAKEN TO RELIABLE HYUNDAI (438 S INGRAM MILL RD, SPRINGFIELD, MO 65802) WHERE THEY INFORMED THE CONTACT THE VEHICLE WAS TOO OLD AND UNABLE TO BE REPAIRED. THE FRONT TIRES WERE REPLACED; HOWEVER, THE SUBFRAME REMAINED RUSTED. THE TIRES NEEDED TO BE REPLACED FOUR TIMES. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE APPROXIMATE FAILURE MILEAGE WAS 207,000.
Suspension, Structure, Aug 27, 2018
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE THE VEHICLE WAS UNDERGOING ROUTINE MAINTENANCE, AN INDEPENDENT MECHANIC DIAGNOSED THAT THERE WAS EXTENSIVE RUST AND CORROSION CONCERNING THE FRONT FRAME, REAR FRAME, NEAR THE FRONT PASSENGER SIDE TIRE, AND NEAR THE FRONT REAR TIRE TIE RODS PERTAINING TO THE SUBFRAME. THE INDEPENDENT MECHANIC ADVISED THE CONTACT TO CALL THE MANUFACTURER FOR A RECOMMENDATION. THE MANUFACTURER HAD KEY HYUNDAI OF SALEM (470 S BROADWAY, SALEM, NH 03079, (603) 841-3099) SCHEDULE AN APPOINTMENT ON AUGUST 28, 2018 TO DIAGNOSE AND REPAIR THE VEHICLE. THE CONTACT WAS NOT INCLUDED IN NHTSA ACTION NUMBER: EA08016 (SUSPENSION, STRUCTURE) AND NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE MANUFACTURER PROVIDED NO REMEDY AND ADVISED THAT THE DEALER REPAIR THE VEHICLE. THE FAILURE MILEAGE WAS NOT AVAILABLE.
Structure, Wheels, Sep 17, 2017
WORN REAR TIRES PROMPTED PURCHASE OF NEW TIRES. TIRE TECHNICIANS NOTED THAT THE FRAME WAS CRACKED AND THAT THE VEHICE IS UNSAFE TO DRIVE. BOTH REAR TIRES ARE IN JEOPARDY BUT THE REAR PASSENGER SIDE IS BY FAR THE WORSE. VEHICLE HAD BEEN MAKING ODD NOISES ESPECIALLY WHEN TURNING AND SOME VIBRATION AT SPWEDS OVER 40MPH. FORTUNATELY THE THE TIRES DIDN'T FALL OFF WHILE IN MOTION.
Steering, Structure, May 4, 2017
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING UNKNOWN SPEEDS, THE STEERING WAS UNSTABLE AND THE VEHICLE SHOOK. THE CHECK ENGINE INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE CRADLE HAD A LARGE RUST SPOT. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 188,000.
Structure, Dec 22, 2016
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE THE VEHICLE WAS UNDERGOING ROUTINE SERVICE, THE TECHNICIAN NOTICED THAT UNDERNEATH THE FRONT OF THE VEHICLE WAS SEVERE CORROSION AND PERFORATION THAT NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 143,000.
Suspension, Structure, Dec 6, 2016
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE VEHICLE HAD SEVERE RUST ON THE SUBFRAME. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). AFTER CONTACTING THE DEALER AND THE MANUFACTURER ON MULTIPLE OCCASIONS, THE CONTACT WAS INFORMED THAT THE REMEDY NEEDED TO REPAIR THE VEHICLE HAD NOT YET BEEN DETERMINED. THE CONTACT INDICATED THAT THE MANUFACTURER TOOK TOO LONG TO PROVIDE THE REMEDY. THE CONTACT EXPERIENCED THE FAILURE LISTED IN THE RECALL. THE FAILURE MILEAGE WAS 75,000. PARTS DISTRIBUTION DISCONNECT. *TR
Structure, Oct 25, 2016
FRONT LOWER CONTROL ARM BROKE DUE TO RUST WHILE BEING DRIVEN. PULLED OFF THE ROAD AND CALLED TOW TRUCK. OPERATOR TOLD ME TO LOOK UP SONATA RECALLS BECAUSE IT LOOKED LIKE ONE. IT WAS RECALL # 09V124000. CALLED LOCAL DEALERSHIP 6 TIMES IN TWO DAYS ALWAYS GOING TO ANSWERING MACHINE. THIRD DAY DROVE TO DEALERSHIP. THEY TOLD ME TO BRING IT IN AND THEY WOULD LOOK AT IT. TOW GUY SAID EVERY TIME IT IT WAS MOVED MORE DAMAGE WOULD BE DONE. HE DIDN'T WANT THE RESPONSIBILITY. DEALERSHIP WOULDN'T PICK IT UP. TOW GUY CALLED ANOTHER DEALERSHIP AND HE BROUGHT IT THERE (8/20/16) FIVE DAYS AFTER THE BREAKDOWN. AFTER 5 DAYS SECOND DEALERSHIP SAID IT WAS A RECALL ITEM AND SAID TO CALL HYUNDAI AMERICA. BEGAN DISCUSSIONS WITH HYUNDAI AMERICA- MANY CALLS- AND AFTER OVER 60 DAYS THEY DECIDED IT WAS BETWEEN THE DEALERSHIP AND SOME OTHER DEPARTMENT OF HYUNDAI AMERICA AND THEY COULDN'T DO ANYTHING. DEALERSHIP GAVE ME ANOTHER # TO CALL BUT THAT # HAD NO KNOWLEDGE OF MY CASE. THE EXPENSE OF BEING WITHOUT THE CAR HAS BEEN QUITE DRAINING. CASE # WITH HYUNDAI AMERICA IS 9566309. I WOULD LIKE THE CAR COMPLETELY REPAIRED BUT CAN'T GET ANYONE TO DO ANYTHING. THANKS
Suspension, Structure, Sep 26, 2016
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING 10 MPH, SUBFRAME FRACTURED. THE FAILURE CAUSED THE FRONT AXLE TO FRACTURE AND SEPARATE FROM THE VEHICLE. THE FRONT AXLE WAS CUT AWAY FROM THE SUBFRAME TO HAVE THE VEHICLE TOWED. THE VEHICLE WAS TOWED TO THE DEALER TO BE DIAGNOSED, BUT WAS NOT REPAIRED. THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 164,000.
Structure, Aug 23, 2016
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. UPON TAKING THE VEHICLE TO A MECHANIC FOR INSPECTION, IT WAS DIAGNOSED THAT THERE WAS INTERNAL CORROSION ON THE FRONT SUBFRAME AND THE SEAL WAS DETERIORATING. THE DEALER AND THE MANUFACTURER STATED THAT THERE WAS NO RECALL TO ADDRESS THE REPAIR. THE MANUFACTURER PROVIDED NO REPAIR SOLUTION. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 104,000.
Structure, Aug 9, 2016
PAINT IS FALLING OFF AROUND THE EXTERIOR DOOR HANDLES. PASSENGER SIDE DOOR IS RARELY USED AND THIS IS THE WORST SIDE OF IT. VEHICLES ARE SUPPOSED TO RECEIVE MULTIPLE COATS OF PAINT AT TIME OF MANUFACTURE IT APPEARS THAT THIS IS NOT THE CASE WITH MANY OF THE 2004 SONATA MODELS, I HAVE NOTICED MANY OF THE SAME MODEL CARS AROUND TOWN WITH PEELING PAINT AROUND THE DOOR HANDLES. THIS VEHICLE HAS BARELY OVER 100K MILES.
Steering, Structure, Nov 22, 2015
FRONT SUB FRAME RUSTED. CRACK IN THE SUB FRAME NEAR THE RIGHT FRONT WHEEL. CAR HAS 70,000 MILES ON IT. DANGER OF SUBFRAME BREAKING AND CONTROL ARM DISCONNECT.
Structure, Aug 27, 2015
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE A FUEL LINE WAS BEING REPLACED ON THE VEHICLE, THE TECHNICIAN NOTICED A HOLE ON THE FRONT PASSENGER SIDE SUBFRAME. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE FAILURE MILEAGE WAS 112,000.
Suspension, Structure, Jul 28, 2015
SEVERE RUST AFFECTING UNDERCARRIAGE. VEHICLE WAS PART OF RECALL FOR SUB FRAME ASSEMBLY AND HAD TO HAVE ENTIRE ENGINE CRADLE REPLACED. REMAINING SECTIONS OF UNDERCARRIAGE NOT INCLUDED IN RECALL, FUEL LINES, BRAKE LINES, SUSPENSION ARE ALSO SEVERELY CORRODED AS WELL AS LARGE PORTIONS OF THE PASSENGER REAR SIDE BODY PANELS. BRAKE LINES IN REAR PORTION OF VEHICLE CORRODED SO BADLY THEY FAILED AND HAD TO BE REPLACED. TOP PORTION OF FUEL PUMP LOCATED IN TOP OF GAS TANK ALSO SEVERELY CORRODED.
Structure, Jun 11, 2015
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THERE WAS PREMATURE RUSTING ON THE UNDERCARRIAGE AND SUBFRAME OF THE VEHICLE, WHICH PROGRESSED OVER TIME IN THE FRONT AND THE REAR. THE VEHICLE FAILED INSPECTION. THE MECHANIC FOUND HOLES, EXTENSIVE RUST, AND CORROSION TO THE POINT THAT THE FRAME COULD FRACTURE. THE FRAME NEEDED TO BE REPLACED DUE TO THE FAILURE. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS NOT AVAILABLE.
Structure, Feb 6, 2015
THE CHROME PLATING ON THE INTERIOR DOOR LATCHES IS PEELING OFF CAUSING PASSENGERS TO CUT THEIR HANDS/FINGERS WHEN OPENING THE DOOR. *JS
Steering, Suspension, Engine and engine cooling, Structure, Jan 26, 2015
TOOK CAR TO MECHANIC FOR FUEL PUMP WORK. HE INFORMED US THAT THE ENGINE CRADLE IS RUSTED BEYOND REPAIR AND IS UN-SAFE TO DRIVE. I FOUND THE RECALL ONLINE AND CALLED HYUNDAI. THEY INFORMED ME THAT REMEDIATION HAD BEEN DONE IN 2009. (A NEW HOLE FOR DRAINAGE HAD BEEN DRILLED IN THE ENGINE CRADLE FRAME AND A SEALANT APPLIED). EVIDENTLY THIS DID NOT STOP THE CORROSION OF THE FRAME AND CAUSED A WEAKENING OF THE FRAME AND A CRACK IN THE STRUCTURAL AREA OF THE FRAME. IS HYUNDAI LIABLE TO REPAIR THIS DEFECT? I CAN SUPPLY PICTURES OF THE DEFECT AND CRACK IN FRAME IF NECESSARY. *TR
Structure, Oct 8, 2014
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE FRAME OF THE VEHICLE WAS CORRODED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE FRAME NEEDED TO BE REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 90,000.
Structure, Jul 21, 2014
WHEN HAVING MY CAR ALIGNED, A TECHNICIAN SHOWED ME THAT THE RIGHT FRONT SUBFRAME IS RUSTED THROUGH. SUPPOSEDLY HYUNDAI FIXED THIS 5 YEARS AGO, WITH ONE OF TWO FIXES: EITHER REPLACEMENT OR DRILLING DRAINAGE HOLES AND APPLY A RUST PROTECTOR. ONE CAN SEE A HOLE DRILLED ON THE LEFT SUBFRAME BUT NOT THE RIGHT SIDE. BESIDES MY CAR, ONE HAS TO ASK: DID HYUNDAI REALLY DO ANYTHING TO FIX THIS SITUATION OR DID THEY ACT LIKE THEY DID? A CAR RUSTING THROUGH THE FRAME IN FIVE YEARS IS UNHEARD OF, AND I FEAR OTHERS MIGHT HAVE THIS SAME PROBLEM. HYUNDAI DOES NOT WANT TO TALK TO ME. *TR
Air bags, Seat belts, Structure, Jul 12, 2014
MY WIFE SOMEHOW GOT HER FOOT CAUGHT IN HER SANDAL AND TRYING TO GET IT UNSTUCK HIT A CONCRETE LIGHT POLE. THE AIRBAG SHOT WHITE POWDER OUT ,LIGHT WENT ON TO SHOW AIR BAG WENT OFF BUT IT NEVER DEPLOYED. HAD IT BEEN A WORSE ACCIDENT FATAL INJURY COULD HAVE OCCURRED BECAUSE OF FAULTY AIRBAG NOT DEPLOYING YET SHOWING IT DID BY ALL SYMPTOMS SUCH AS THE LIGHT, WHITE POWDER AND THE SEAT BELT CANNOT BE MOVED AND WILL NOT OPERATE. THIS IS A SAFETY ISSUE NO MATTER IF UNDER WARRANTY OR NOT. *TR
Suspension, Structure, Jun 30, 2014
CAR FAILED PA INSPECTION BECAUSE OF RUN ON THE SUB FRAME DEALER SAYS ITS NOT COVERED UNDER RECALL. *TR
Power train, Structure, Service brakes, May 26, 2014, crash
THE CAR WAS PARKED IN A RESIDENTIAL PARKING AREA. IT HAD BEEN BACKED INTO THE SPACE. AFTER STARTING THE CAR AND PUTTING THE TRANSMISSION IN DRIVE, THE CAR ACCELERATED UNCONTROLLABLY. THIS OCCURRED SO QUICKLY THE DRIVER WAS UNABLE TO CONTROL THE VEHICLE. BRAKES DID NOT STOP THE VEHICLE. IT APPEARED THAT THE ACCELERATOR WAS STUCK. THE VEHICLE HIT A CAR IN THE NEXT ROW OF CARS. BECAUSE OF RAIN, THE CAR THEN SKIDDED 180 DEGREES AND STRUCK TWO CARS IN THE SAME LINE OF CARS FROM WHICH IT HAD DEPARTED. ONLY AT THIS TIME BY TURNING GETTING THE CAR OUT OF GEAR AND TURNING THE KEY COULD THE CAR BE STOPPED. THE DRIVER BELIEVES THIS WAS THE RESULT OF EITHER A THE ACCELERATOR STICKING ON ITS OWN OR A THICK RUBBER WINTER MAT SLID UP AND JAMMED THE ACCELERATOR. *TR
Structure, Mar 10, 2014
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE SUB FRAME WAS RUSTED ON THE PASSENGER'S SIDE. THE VEHICLE WAS TAKEN TO THE DEALER BUT WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 118,000. *TR