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.
Air bags, Mar 13, 2014
AIR BAG LIGHT ILLUMINATED, CALLED THE DEALER TO ASK ABOUT A RECALL THEY SAID NONE WERE ISSUED, HOWEVER IT NEEDED TO GET LOOKED AT BECAUSE THERE COULD BE A DEFECT. AND THE POSSIBILITY THAT THE AIR BAGS COULD DEPLOY ON THEIR OWN AT ANY TIME OR NOT DEPLOY AT ALL IN AN ACCIDENT. THE COST TO HAVE THIS PROBLEM LOOKED AT WOULD BE AROUND $125.00 WHICH WOULD BE SUBTRACTED FROM THE COST OF THE REPAIR IF YOU CHOSE TO GET IT FIXED BY THE DEALER THE TOTAL COST COULD RUN AT LEAST $500.00 I WAS WONDERING IF THERE HAS BEEN ANY OTHER COMPLAINTS REGARDING THIS PROBLEM. *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
Electrical system, Exterior lighting, Service brakes, Mar 5, 2014
I CALLED HYUNDAI REGARDING THE BRAKE LAMP RECALL ISSUE IN MY CAR. I HAVE THE SAME ISSUE OF MY BRAKE LAMPS. WHEN YOU DEPRESS THE BRAKES THE LAMPS ARE ALWAYS ILLUMINATED IT ONLY GOES OFF WHEN THE CAR IS TURNED OFF. THIS CAUSES SEVERAL PEOPLE TO MISTAKE IF I AM BRAKING OR NOT. I HAVE READ SEVERAL PEOPLES COMPLAINTS ON THE RECALL WEBSITE, AND ALL OF US ARE TOLD THAT " THE RECALL HAS NOT AFFECTED YOUR CAR" AFTER GIVING THEM THE VIN. WELL I SAY IT IS. I HAVE THE VERY PROBLEM SPOKE OF IN THE RECALL. SECOND THE RECALL DOES NOT SAY THE CAR MUST ALSO BE UNABLE TO COME OUT OF PARK. THERE ARE THREE SEPARATE ISSUES. I WANT THIS CAR LOOKED AT HOW CAN SEVERAL CARS IN DIFFERENT STATES HAVE THE SAME PROBLEM, WITH THE SAME YEAR CAR???? *TR
Suspension, Feb 27, 2014
MY SUB FRAME IS ROTTING AWAY AND POSES A GRAVE SAFETY ISSUE TO MYSELF AND OTHER MOTORISTS ON THE ROAD IF MY ENGINE SHOULD FALL OUT OF MY VEHICLE
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.
Suspension, Oct 21, 2013
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE AT THE DEALER FOR ROUTINE MAINTENANCE, THE TECHNICIAN STATED THAT THERE WAS A HOLE CORRODED IN THE SUB FRAME. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION) BUT WAS ADVISED BY THE MANUFACTURER THAT THE VIN WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 120,000. UPDATED 11/30/13*CN
Fuel system, Gasoline, Sep 16, 2013
AFTER FILLING THE GAS TANK FULL, FOUND FUEL LEAKING FROM THE TANK ONTO THE GROUND. REMOVED THE TANK FROM THE CAR AND FOUND 13 RUST HOLES ON THE TOP AND SIDE OF THE FUEL TANK. HOLES WERE FOUND BENEATH AREAS OF SEALANT THAT HAD SEPARATED FROM THE TANK SURFACE. *TR
Structure, Aug 16, 2013
THIN COATING OF CHROME PEELED/BROKE OFF CAUSING RAZOR SHARP EDGE. MY HAND WAS LACERATED ON THIS HANDLE. *TR
Suspension, Jul 19, 2013
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN FOR STATE INSPECTION BUT DID NOT PASS BECAUSE THE SU B FRAME WAS RUSTED. THE CONTACT SPOKE TO THE MANUFACTURER REGARDING NHTSA CAMPAIGN ID NUMBER: 09V124000(SUSPENSION) AND WAS ADVISED THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL CAMPAIGN. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 78,000. *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
Suspension, Jun 6, 2013
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 55 MPH, SHE NOTICED A VIBRATION FROM THE FRONT END OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS. THE MECHANIC STATED THAT THE FRONT SUSPENSION WAS CORRODED. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION) BUT WAS ADVISED BY THE MANUFACTURER THAT THE VIN WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 90,000. *TR
Vehicle speed control, Service brakes, Engine, Fuel/propulsion system, Mar 27, 2013, crash
BACKING INTO THE GARAGE, MY FOOT ON BRAKE, THE ENGINE SUDDENLY REVVED TO HIGH RPM, THE CAR SHOT BACKWARDS, PROPELLING A HEAVY RUBBER MAT ON WHICH THE CAR IS NORMALLY PARKED OUT OF THE GARAGE AND INTO THE DRIVEWAY. THE VEHICLE THEN IMPACTED AND CRASHED THROUGH THE REAR GARAGE WALL BEFORE COMING TO A STOP. I MANAGED TO PRY THE GEAR LEVER OUT OF REVERSE, HIT DRIVE INSTEAD AND SENT THE CAR, WHEELS STILL SPINNING AND LAYING DOWN RUBBER, FORWARD OUT OF THE GARAGE. ON ITS WAY OUT THE CAR SWIPED ALONG THE RIGHT SIDE THE GARAGE DOOR POST BEFORE FINALLY COMING TO A STOP IN THE DRIVEWAY. FINAL RESULT, SERIOUS DAMAGE TO BOTH THE CAR AND THE GARAGE. FORTUNATELY THIS DID NOT OCCUR IN TRAFFIC OR WITH PEDESTRIANS IN THE AREA. ON-LINE RESEARCH HAS SINCE SHOWN ME THAT THERE HAVE BEEN NUMEROUS OTHER SIMILAR INCIDENTS WHERE HYUNDAI SONATAS HAVE SUDDENLY ACCELERATED ON THEIR OWN. SEE HTTP://WWW.CARPROBLEMZOO.COM/HYUNDAI/SONATA/CAR-ACCELERATES-ON-ITS-OWN-PROBLEMS.PHP. *TR
Air bags, Mar 16, 2013
THE AIR BAG LIGHT SUDDENLY CAME ON, AND HAS STAYED ON. LOOKED ONLINE AND FOUND MANY SIMILAR COMPLAINTS. THERE HAS ALREADY BEEN AN AIR BAG RECALL FOR THE 2003 SONATA. WE (ALONG WITH MANY OTHERS) ARE HOPING THAT ONE WILL BE ISSUED FOR THE 2004 MODEL, AS WELL. THANKS! *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
Air bags, Service brakes, Feb 27, 2013, crash
I WAS INVOLVED IN A CHAIN REACTION COLLISION ON I-10 INTERSTATE. MY VEHICLE RE-ENDED ANOTHER VEHICLE AND NEITHER THE DRIVER'S NOR THE PASSENGER'S AIR BAGS DEPLOYED. FRONT END DAMAGED AND INSURANCE HAS TOTALED MY CAR. BRAKES DID NOT SEEM TO STOP WITH SUFFICIENT FORCE. *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
Electrical system, Exterior lighting, Feb 15, 2012
EMERGENCY FLASHERS ON MY 2004 HYUNDAI SONATA BEGAN FLASHING FOR NO APPARENT REASON AND COULD NOT BE TURNED OFF (IGNITION WAS OFF), THIS CONTINUED FOR 15-30 MINUTES FROM THE TIME IT WAS NOTICED (NEIGHBORS KNOCKED AT THE DOOR TO REPORT THAT THE FLASHERS HAD BEEN LEFT ON). THE OCCURRENCE REPEATED SEVERAL TIMES THROUGHOUT THE NIGHT AND THE NEXT DAY. ACCESSING THE VEHICLE USING THE KEYLESS ENTRY, THE DOORS RE-LOCKED THEMSELVES, AND THIS REPEATED EACH TIME I UNLOCKED THEM. THE FLASHERS STOPPED WHEN THE DOOR WAS OPEN OR THE CAR WAS TURNED ON, BUT WHEN THE DOOR WAS OPENED THERE WAS A CLICKING NOISE IN THE DASH (AT THE SAME RATE AS THE FLASHERS HAD BEEN FLASHING). WE TOOK IT TO THE DEALER FOR REPAIR AND THEY SAID IT IS THE EMERGENCY FLASHER 4-WAY SWITCH (PART #937903C000) -- WHICH IS ON NATIONAL BACK-ORDER FOR ONE MONTH! THIS PART IS APPARENTLY NOT COVERED ON THE GOLD PLUS PROTECTION PLAN! *TR
Vehicle speed control, Feb 1, 2012, crash
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 5 MPH, SHE APPLIED THE BRAKES AND THE VEHICLE SUDDENLY ACCELERATED FORWARD. THE VEHICLE CONTINUED TO ACCELERATE UNTIL CRASHING INTO THE WALL OF A BUILDING. THE AIRBAGS ONLY DEPLOYED ON THE PASSENGER SIDE. THE POLICE WERE NOTIFIED AND A REPORT WAS AVAILABLE. BOTH THE DRIVER AND PASSENEGER SUSTAINED MINOR BRUISING AND WERE TRANSPORTED TO THE HOSPITAL VIA AMBULANCE. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC AND WAS PENDING AN INVESTIGATION. THE MANUFACTURER WAS NOTIFIED VIA EMAIL AND THE CONTACT HAD YET TO RECEIVE A RESPONSE. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 30,000.
Air bags, Dec 25, 2011
8 YR. LONG CHRONIC PROBLEM WITH AIR BAG LIGHT COMING ON... BEST DESCRIPTION WE GET IS A HARNESS ISSUE UNDER PASSENGER FRONT SEAT... LAST EPISODE 12/19/11 DEALER ADVISED HYUNDAI NO LONGER HAS REPLACEMENTS PARTS FOR THIS SYSTEM... THERE ARE THOUSANDS OF THESE MODELS STILL IN SERVICE HOW CAN MFG. NOT CONTINUE TO PROVIDE CRITICAL SAFETY PART... AS OF THIS MOMENT THE LIGHT IS OFF BUT GIVEN THE HISTORY THE DEALER SAID HE EXPECTS IT TO BE BACK ON SOON ... *TR
Air bags, Dec 6, 2011, crash
WAS IN A CAR ACCIDENT ON DECEMBER 04 2011. I HAD SIGNIFICANT FRONT END DAMAGE TO MY VEHICLE DUE TO SOMEONE RUNNING A STOP SIGN. HOWEVER, MY AIRBAGS DID NOT DEPLOY ON FRONT!! ONLY ON THE DRIVER SIDE AND WAS NOT FULL OPEN , VERY CONCERN ON SAFETY! *TR
Structure, Nov 3, 2011
+THE INTERIOR DOOR LEVERS CHROME IS PEELING OFF CAUSING THE LEVERS TO HAVE SHARP EDGES WHICH CUT YOUR FINGERS. *TR
Fuel system, Gasoline, Sep 30, 2011
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE ADDING FUEL TO THE VEHICLE THE CONTACT NOTICED THERE WAS A SMALL VALVE ON THE OUTSIDE OF THE FUEL TUBE THAT FRACTURED AND POSSIBLY HAD FALLEN INTO THE FUEL TANK. THE CONTACT SMELLED A STRONG FUEL ODOR EMITTING IN THE INTERIOR OF THE VEHICLE AFTER IT WAS STARTED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND INFORMED THE CONTACT THAT THE VEHICLE WAS NOT COVERED UNDER THE WARRANTY; THEREFORE, HE WOULD BE RESPONSIBLE FOR THE DIAGNOSTIC COST. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 47,000.