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
202 reports, newest first.
Service brakes, Jul 6, 2015
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING 5 MPH, THE BRAKE PEDAL WAS DEPRESSED TO THE FLOOR BUT THE BRAKES FAILED. THE VEHICLE STOPPED WHEN THE EMERGENCY BRAKE WAS APPLIED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE HYDRAULIC REAR BRAKE LINE AND REAR CYLINDERS WERE CORRODED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 95,000. THE VIN WAS NOT AVAILABLE.
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.
Air bags, Apr 1, 2015
THE AIR BAG WARNING LIGHT STARTED OUT INTERMITTENTLY FOR ABOUT 15 STARTS IT WAS OFF AND ON. THEN AROUND 03/11/2004 IT CAME ON AND STAYED ON. *TR
Air bags, Mar 27, 2015
AIRBAG LIGHT STAYS ON. AN INTERNET SEARCH INDICATES THAT THIS IS A CHRONIC PROBLEM WITH 2014 SONATAS, BUT HYUNDAI HAS FAILED TO ISSUE A RECALL. THERE IS, HOWEVER, A RECALL FOR THE 2013 SONATAS. DON'T UNDERSTAND WHY THERE IS NOT A RECALL. I PURCHASED MY CAR EARLY IN 2004 YEAR. MANY PARTS ARE CARRYOVERS FROM THE PREVIOUS YEAR. *TR
Suspension, Mar 25, 2015
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE VEHICLE BECAME VERY DIFFICULT TO CONTROL WHILE DRIVING. THE VEHICLE WAS TAKEN TO THE DEALER AND IT WAS DETERMINED THAT THE FRONT SUBFRAME NEEDED TO BE REPLACED. THE DEALER INFORMED THE CONTACT OF NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION), BUT THE VEHICLE WAS NOT INCLUDED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 100,000.
Electrical system, Exterior lighting, Mar 2, 2015
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE HEADLIGHTS FAILED TO ILLUMINATE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO REPLACED BOTH THE DRIVER AND THE PASSENGER BULBS ON FOUR OCCASIONS, BUT THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE. UPDATED 04/08/15*LJ
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
Electrical system, Air bags, Jan 29, 2015
TL*THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE DRIVER SIDE AIR BAG LIGHT ILLUMINATED WHILE THE SEAT WAS OCCUPIED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 110,000.
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
Air bags, Other or unspecified, Dec 31, 2014, crash
WE OWN A 2004 HYUNDAI SONATA (109,000 MILES) WE HAD A FRONT END COLLISION WITH SIGNIFICANT DAMAGE. ME AND MY WIFE SUFFERED MINOR INJURIES AND THE AIRBAGS DID NOT DEPLOY. WE FOUND OUT ON THE INTERNET THAT THERE ARE FREQUENT COMPLAINTS IF THIS FAILURE AROUND THE NATION AND ALSO IN MANY HYUNDAI MODELS ACROSS MULTIPLE YEARS. WE ARE FILING THE COMPLAINT SINCE THE ERROR IS CRITICAL AND SEEMS TO BE SYSTEMIC IN HYUNDAI VEHICLES. WE DO NOT KNOW IF NHTSA HANDLES CARS THAT ARE OVER 100,000 MILES BUT WE FELT A COMPLAINT WAS WARRANTED SINCE THE CONSEQUENCE OF THE ERROR IS SO EXTREME. WE FEAR FOR OUR SAFETY WITH THIS VEHICLE NOW! BEING A DISABLED VETERAN, ON A FIXED INCOME, WE FIND IT DIFFICULT TO ACCEPT THAT HYUNDAI TAKES NO RESPONSIBILITY FOR THIS PROBLEM. ITS NOT EASY FOR US TO REPLACE THE CAR. *JS
Steering, Suspension, Wheels, Oct 24, 2014
I WAS DRIVING AT 35 MPH ON HIMILAYA &CAME TO A SLIGHT CURVE IN THE ROAD WHEN ALL OF A SUDDEN MY CAR PULLED HARD TO THE LEFT ALMOST HITTING THE CAR IN THE LEFT LANE NEXT TO ME, IT DROPPED TO THE GROUND AND I HEARD A VERY LOUD SCRAPING NOISE.I GOT OUT OF THE VEHICLE TO FIND THE FRONT PASSENGER SIDE TIRE COMPLETELY DETACHED FROM THE LOWER CONTROL ARM & THE BOLT & PIN MEANT TO KEEP THE LOWER CONTROL ARM FROM DETACHING WAS GONE. THERE IS EXTENSIVE DAMAGE TO THE WHEEL WELL, FRONT RIGHT PANEL OF THE VEHICLE, FLUID IS LEAKING & THE CAR IS NO LONGER OPERATIONAL/CAPABLE OF DRIVING. MY VEHICLE WAS MANUFACTURED IN MARYLAND WHICH IS ONE OF THE STATES INCLUDED IN RECALL #09V124000. *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.
Fuel/propulsion system, Oct 7, 2014
SPLIT FUEL TANK ON THE SIDE, 2ND FUEL TANK TO FAIL IN THE LAST 5 YEARS. HYUNDAI CLAIMS THERE IS NO PROBLEMS WITH FUEL TANKS, BUT GOOGLE THE SONATA FUEL TANKS AND THERE IS A TON OF COMPLAINTS. HYUNDAI WILL DO NOTHING ABOUT IT. NO RECALL, NO NOTHING. HOUSE AND GARAGE HAS SEVERE GAS SMELL AND A LARGE PUDDLE OF GAS ON THE FLOOR. *TR
Visibility, Sep 22, 2014
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING APPROXIMATELY 45 MPH, THE SUN ROOF FRACTURED. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 130,000.
Suspension, Sep 4, 2014
THERE WAS NOT A CRASH, HAVING MAJOR ISSUES WITH THE FRONT SUSPENSION, HAVE TAKEN TO NUMEROUS MECHANICS FOR INSPECTION AND THEY CAN NOT FIND ANYTHING WRONG..FEELS LIKE THE WHEELS ARE GOING TO FOLD UNDER AND WHEN GOING AROUND A CORNER WITH PAVEMENT LEVEL CHANGES, IT PULLED DRAMATICALLY..ITS GOING TO CAUSE AN ACCIDENT, AND SURELY CAUSE FOR RECALL. A RECALL FOR THE SUSPENSION FOR VEHICLES IN THE SALT STATES ONLY...DOES NOT MAKE SENSE WHEN IM READING SOME OF THE ISSUES FOLKS ARE HAVING ISSUES CAN BE CAUSED JUST BY FAULTY WORKMANSHIP, VERY POOR QUALITY. AND AFTER CONTACTING HYUNDAI THEY MENTIONED MINE CAN NOT BE PART OF IT CAUSE IM NOT LOCATED ON THE EAST COAST. THIS SOUNDS ODD, IM HAVING SAME ISSUES .. *TR
Electrical system, Aug 22, 2014
THE HORN STARTED SOUNDING FOR NO REASON IN OUR DRIVEWAY. THE HYUNDAI DEALERSHIP CONFIRMED THAT THE HORN SWITCH IN THE DRIVERS SIDE AIRBAG ASSEMBLY IS BROKEN AND IN THE CLOSED POSITION. THE PART COST IS A RIDICULOUS $1,000.00. ALL AIRBAG ASSEMBLIES IN ALL THE LOCAL WRECKING YARDS ALSO HAVE BROKEN HORN SWITCHES. HOW CAN THIS BE ALLOWED? THE HORN IS A VERY NECESSARY SAFETY DEVICE THAT SHOULD LAST THE ENTIRE LIFE OF A VEHICLE. WHY HASN'T A RECALL NOTICE BEEN ISSUED FOR THIS CONDITION? [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
Other or unspecified, Aug 11, 2014
THIS IS A COMPLAINT, THERE WAS NOT AN ACCIDENT. THERE IS A CLUNKING NOISE FROM THE REAR SUSPENSION AREA. I HAVE HAD THE REAR STRUTS REPLACED AND ONE BUSHING ON THE RIGHT SIDE. I HAVE HAD THE VEHICLE CHECKED BY THE DEALER AND FOUR INDEPENDENT SHOPS. THE DEALER SAYS THEY CANNOT FIND ANYTHING WRONG. THE INDEPENDENT SHOPS HEAR THE NOISE BUT CAN'T LOCATE WHERE IT IS COMING FROM. ON THE INTERNET THERE ARE MANY REFERENCES REFERRING TO THE ISSUE. I AM RELUCTANT TO TRAVEL A DISTANCE NOT KNOWING THE CAUSE OF THE NOISE. I HAVE WRITTEN TO HYUNDAI. THEY SAY THEY DO NOT HAVE ANY RECORD OF COMPLAINTS RELATING TO THIS ISSUE. I AM IN THE MARKET FOR A NEW CAR BUT WOULD NOT SELL OR TRADE IN NOT KNOWING THE CAUSE OF THIS PROBLEM.
Air bags, Jul 26, 2014
ALL OF SUDDEN THE AIR BAG ICON IS CONTINUOUSLY ON. ALL FUSES FOR AIR BAGS HAVE BEEN CHANGED AND PROBLEM STILL EXIST. THE COMPANY STATES THAT THEY HAVE NOT HEARD ABOUT THIS PROBLEM AND THERE IS NO RECALL. BUT READING INTERNET BLOGS THERE APPEARS THAT THIS PROBLEM DOES OCCUR ON THIS MODEL WHEN IT REACHES THE 100,000 MILE LIMIT. WHAT IS MY RECOURSE TO HAVE THEM CORRECT THIS PROBLEM WITHOUT FINANCIAL PROBLEM. THANKS *TR
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
Suspension, May 9, 2014
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE THE VEHICLE WAS BEING INSPECTED, THE INDEPENDENT MECHANIC DISCOVERED THAT THE FRONT PASSENGER SIDE SUSPENSION CONTROL ARM WAS CORRODED AND CRACKED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 65,000.
Air bags, May 8, 2014
THE AIR BAG LIGHT CAME ON AND WILL NOT GO OUT. AFRAID TO CALL DEALER SINCE REPAIR COULD COST CLOSE TO $500.00. *TR
Engine, Mar 24, 2014
THE CAR STARTED LOSING SPEED AND STALLED A COUPLE OF TIMES. THE CAMSHAFT SENSOR AND CRANKSHAFT SENSORS WERE REPLACED. THE PROBLEM HAPPENED 6 MONTHS LATER. *TR