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, Dec 5, 2013
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE FRONT PASSENGER'S SIDE EXTERIOR DOOR HANDLE BECAME FRACTURED WHILE THE CONTACT ATTEMPTED TO ACCESS THE DOOR. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 83,954.
Structure, Aug 16, 2013
THIN COATING OF CHROME PEELED/BROKE OFF CAUSING RAZOR SHARP EDGE. MY HAND WAS LACERATED ON THIS HANDLE. *TR
Suspension, Structure, Jun 7, 2013
I TOOK MY 2004 SONATA FOR INSPECTION AND WAS TOLD THAT IT WOULD NOT PASS DUE TO A LARGE HOLE FROM CORROSION IN FRONT PASSENGER SUBFRAME NEAR CONTROL ARM BOLT COSTING $1200 TO FIX. AFTER FINDING OUT THAT THIS WAS RECALLED AND I WAS NEVER NOTIFIED, I CONTACTED HYUNDAI AND WAS TOLD THAT MY CAR WAS COVERED (I AM IN SO-CALLED "SALT BELT"). WHEN I CALLED THE DEALER BACK, I WAS TOLD THAT MY VIN IS NOT INCLUDED IN THE RECALL. THE DEALER THEN CALLED HYUNDAI AND DEALER CALLED ME BACK STATING THAT HYUNDAI WOULD NOT COVER. THIS HOLE CAN GET LARGER AND POTENTIALLY CAUSE THE WHEEL TO FALL OFF WHILE DRIVING. MY APPROX MILEAGE IS ONLY 42K. WHY IS IT NOT COVERED?!?!?!? I'M GETTING THE RUN AROUND. *TR
Steering, Structure, Wheels, Engine, Mar 9, 2013
THE RIGHT SIDE OF THE ENGINE CRADLE BROKE (DUE TO CORROSION); THE RESULT OF THIS BROKE THE RIGHT FRONT HALF AXLE, AND DETROYED RIGHT FRONT TIRE. *TR
Suspension, Structure, Wheels, Sep 27, 2012, crash
DRIVING ON CLEAR PAVED STREET @ APPROXIMATELY 20 MPH WHEN LOUD CRACKLING NOISE OF FRONT RIGHT FELL TO PAVEMENT. NO LOSS OF CONTROL, MERELY STEERED VEHICLE OFF MAIN LANE OF STREET. NO STRUCTURE OR OBJECT FOUND ON PAVED STREET FOR APPROXIMATELY 50 YDS TO FINAL POINT OF EXITING OFF OF STREET. WITNESS IN CAR WITH DRIVER CAN ATTEST TO NO POT HOLES OR OTHER NOTED OBJECTS ANYWHERE IN AREA OF TIRE MARKINGS ON PAVED STREET. AUTO REQUIRED FULL TOW TO CLOSEST DEALERSHIP. *TR
Suspension, Structure, Sep 25, 2012
THE FRAME TO THE CAR HAS A HOLE RUSTED THRU THE LOWER CONTROL ARM BOLT AND IS NO LONGER DRIVABLE. THE CAR WAS STRANDED ON THE HIGHWAY AND SOMEONE COULD HAVE BEEN KILLED HYUNDAI SAYS ITS NOT COVERED UNDER THE RECALL BUT ITS THE EXACT SAME PROBLEM AS ALL THE REST. *TR
Structure, Sep 19, 2012
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT HE DISCOVERED INTERNAL CORROSION OF THE FRONT SUB-FRAME ON THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS BUT THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED BUT OFFERED NO ASSISTANCE. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 124,000.
Structure, Mar 11, 2012
THE CHROME ON THE INSIDE DOOR HANDLES ARE CRACKING & PEELING. I HAVE CUT MY FINGER TWICE NOW ON THE SHARP EDGES. ALSO, THE PAINT IS COMING OFF THE MOLDING AROUND THE OUTSIDE DOOR HANDLE ON THE REAR DRIVER SIDE. *TR *JS
Structure, Nov 3, 2011
+THE INTERIOR DOOR LEVERS CHROME IS PEELING OFF CAUSING THE LEVERS TO HAVE SHARP EDGES WHICH CUT YOUR FINGERS. *TR
Structure, Jun 10, 2011
THE INTERNAL FLOOR ON DRIVER SIDE SHOWS OBVIOUS EROSION FROM NORMAL SALT EXPOSURE IN THE WINTER. DEALER IGNORED MY COMPLAINT OF THE EROSION WHEN I WENT TO ADDRESS ANOTHER RECALL REGARDING SALT EROSION. ME AND A FAMILY MEMBER RECEIVED CUTS ON THE FINGER FROM PEELING COVERING ON INTERIOR DOOR HANDLE. PAINT NEAR EXTERIOR HANDLES SCRATCHES EASILY AND EVENTUALLY REVEALS THE COLOR OF THE SECOND LAYER OF PAINT WHICH IS A DRASTICALLY DIFFERENT COLOR FROM THE CAR'S EXTERIOR PAINT COLOR. *TR
Structure, Nov 7, 2010
INTERIOR CHROME DOOR HANDLE CRACK, CAUSING THE CHROME PLATING TO SEPARATE. AFTER SEPARATION THE HANDLE BECOMES EXTREMELY SHARP AND CUT MY HAND.
Structure, Equipment, Sep 8, 2010
TL*THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE VEHICLE HAD WATER DAMAGED DUE TO A DEFECTIVE AIR CONDITIONING HOSE SEALANT THAT ALLOWED WATER TO PENETRATE WHICH CAUSED MILDEW TO FORM ON THE INTERIOR OF THE VEHICLE. THE DEALER STATED THAT THE INSTRUMENTAL PANEL WILL NEED TO BE REMOVED IN ORDER TO REPLACE THE DAMAGED WIRING AND SEALANT. THE CONTACT STATED THAT A YEAR AGO WATER PENETRATED THE INTERIOR OF THE VEHICLE DUE TO THE SEALANT AROUND THE BRAKE LIGHTS. THE VIN INFORMATION WASN'T AVAILABLE. THE MANUFACTURER WILL BE CONTACTED. THE FAILURE MILEAGE WAS 39,000 AND THE CURRENT MILEAGE WAS 69,000.
Structure, Aug 22, 2010
INTERIOR DOOR HANDLE CHROME PEELING OFF CAUSING SHARP METAL THAT CAN CUT FINGERS OR HANDS. *TR
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
Structure, Nov 10, 2009
RECALL ON 2004 HYUNDAI. I CALLED 5 DEALERS TO HAVE THEM INSPECT MY CAR, DUE TO THE RECALL I RECEIVED ABOUT POSSIBLE FRAME RUSTING. THE WAIT IS ANY WHERE FROM 10 DAYS TO A MONTH, JUST TO HAVE THEM LOOK AT THE FRAME. I EXPLAINED THAT MY CAR IS SHOWING THE SIGNS OF DAMAGED RUSTED FRAME. I REQUESTED THAT THEY EITHER. PAY FOR MY ROOM OR PAY FOR MY CAR RENTAL. *TR
Structure, Oct 12, 2009
RE: HYUNDAI '04 SONATA - BOUGHT NEW AT KEY HYUNDAI BRANFORD CT RECEIVED RECALL NOTICE RE RUSTING SUBFRAMES. ISSUES I'VE HAD OVER LAST 12 MONTHS: STEERING WHEEL PULLING TO ONE SIDE - ALIGNMENT WAY OFF - FIXED, PROBLEM RECURRED. INTERMITTENT NOISES COMING FROM ?WHEELS STEERING COLUMN, ESP.WHEN TURNING CORNERS - SEEMS TO BE TWO SEPARATE DISTINCT NOISES. RECENTLY STEERING WH. WITH RHYTHMIC SHIMMY, INTERMITTENT. TOOK CAR INTO KEY H.FOR INSPECTION - TOLD IT NEEDS NEW SUBFRAME (6 HR.JOB) BUT NO ALIGNMENT WILL BE DONE, NO LOANER OR RENTAL WOULD BE GIVEN. CALLED HYUNDAI CUST. CENTER. TOLD THAT AN ALIGNMENT, RENTAL "..WASN'T PART OF THE DEAL" THEY PUT THE ONUS ON NHTSA - SAYS YOU DIDN'T TELL THEM THEY HAD TO DO ANY MORE THAN REPLACE THE S.F. MY REGULAR MECHANIC SAYS THAT IT IS WORRISOME THAT NO ALIGNMENT WILL BE DONE. "HOW CAN THEY DO ALL THAT FRONT END WORK AND NOT REALIGN THE WHEELS?" REGARDING A REPLACEMENT VEHICLE FOR THE DAY, CONSIDERING THE SUBFR. HAS TURNED OUT TO BE MAJOR 'LEMON', YOU'D THINK AS A GESTURE OF GOOD WILL, HYUNDAI WOULD PAY ANOTHER $25 - 30 FOR A RENTAL. THEIR CUST. ASSIS. CENTRE IS A JOKE. THE GIRL HANDLING CALLS KNOWS NOTHING ABOUT MECHANICS, HAS NO AUTHORITY AND JUST KEEPS SAYING SHE'S SORRY BUT THIS IS NHTSA'S DEAL, NOT HYUNDAI. ANOTHER ISSUE- WITH THE S.F. RECALL NOTICE, I RECEIVED A 2ND NOTICE RE: CHROME HANDLES PEELING ON INSIDE DOOR. MINE PEELED THE FIRST YEAR I HAD THE CAR - ABRASION TO MY FINGER. I TAPED THE HANDLE AND DIDN'T COMPLAIN. THE SERVICE MANAGER LAST WEEK TOLD ME RECALL GOES TO '03 MODELS (WHY DID I GET THE NOTICE?) AND SAYS I CAN PAY $90 FOR CHROME REPLACEMENT. AND BY THE WAY, ALSO HANDED ME $2500 WORTH OF OTHER WORK I NEED - I DON'T, ACCORDING TO MY MECHANIC. GUESS H. TRYING TO RECOUP MONEY SOME WAY, SINCE THEY HAVE TO REPLACE THE S.F.FREE. BOTTOM LINE: THIS IS MY 2ND H. AND MY LAST-LOST FAITH& WORRIED THAT THEY WILL NOT DO PROPER JOB ON RECALL WORK.WILL PAY FOR RENTAL AND ALIGNMENT MYSELF. ANY SUGGESTIONS? *TR
Structure, Sep 16, 2009
CHROME COVERING IS PEELING FROM HANDLES AND SHIFTER RESULTING IN PIECES BEING STUCK IN MY HAND AND CUTS. *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
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
Structure, May 17, 2009
CHIPPING PAINT ON DOOR HANDLES ESPECIALLY ON THE ONES THAT ARE LESS USED. PAINT NOT MATCHING WHEN REPAIRS ARE DONE. *TR