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.
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
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
Wheels, Jul 21, 2009
THE PAINTED ALLOY WHEELS ON MY 2004 HYUNDAI SONATA ARE BUBBLING, PITTING AND CORRODING RESULTING IN REGULAR AND UNEXPECTED LOSS OF AIR. THE PAINT IS COMING OFF IN LARGE PIECES. THE DAMAGE IS NECESSITATING AIR FILL-UP PRIOR TO MOVING VEHICLE ON NUMEROUS OCCASIONS. NUMEROUS TRIPS TO TIRE SHOP TO "FIX FLATS" HAVE RESULTED IN "BEAD LEAKS" DUE TO THE CORROSION. DEALER ACKNOWLEDGES PROBLEMS IN THIS AREA BUT WILL NOT REPLACE WHEELS OR OFFER SOLUTION (I OFFERED TO ACCEPT REGULAR STEEL WHEELS AND WHEEL COVERS) EVEN UNDER EXTENDED WARRANTY. INSTEAD THEY GAVE ME THE NAME OF A WHEEL "REFINISHER" TO SOLVE THE PROBLEMS MYSELF. *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
Air bags, Jul 15, 2009
AIR BAG LIGHT STAYS ON WHEN DRIVING CAR. CALLED DEALERSHIP AND THEY TOLD ME IT IS NOT UNDER WARRANTY BECAUSE ITS OVER FIVE YEARS OLD AND HAS 53,704, IS THIS NOT A SAFETY ISSUE? AND COVERED BY LAW? *TR
Air bags, Jun 30, 2009, crash
WAS IN A CAR ACCIDENT ON JUNE 21, 2009. I HAD SIGNIFICANT FRONT END DAMAGE TO MY VEHICLE DUE TO SOMEONE RUNNING A STOP SIGN. HOWEVER, MY AIRBAGS DID NOT DEPLOY ON THE PASSENGER OR DRIVER SIDE. *TR
Service brakes, Hydraulic, Jun 29, 2009
DISC BRAKE PAD SEPARATION RESULTED IN SEVERE ROTOR WEAR AND LOSS OF BRAKES ON ALL FOUR WHEELS. LOW MILEAGE ON VEHICLE, 19K, ORIGINAL BRAKE PADS. REPLACED ROTORS AND BRAKE PADS, OLD PARTS AVAILABLE. *TR
Fuel system, Gasoline, Jun 24, 2009
I HAVE A 2004 HYUNDAI SONATA V6 THAT GIVES ME PROBLEMS WHEN I FILL THE GAS TANK UP. I KNOW THAT THIS MIGHT SOUND CRAZY BUT, WHEN I GO TO START THE CAR, IT WILL NOT TURN OVER. I RECENTLY HAD A MAJOR TUNE-UP DONE ON THE VEHICLE ALONG WITH CHANGING THE TIMING BELT. WHEN I FILL UP MY CAR, I HAVE TO INCLUDE AN ADDITIVE SUCH AS GAS TREATMENT, LUCAS GAS TREATMENT, FUEL CLEANER, ETC. I HAD MY MECHANIC LOOK AT THE VEHICLE FOUR TIMES AND HE HAS FOUND NOTHING WRONG WITH THE VEHICLE. I ASK FOR ASSISTANCE TO DIAGNOSE THE PROBLEM AND WOULD YOU RECOMMEND BRINGING THE CAR TO A DEALER. PLEASE HELP! THANK YOU. THE SYSTEM WOULD NOT ALLOW ME TO ENTER MY VIN NUMBER. *TR
Visibility, Jun 23, 2009
TL*THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING 15 MPH, THE REARVIEW MIRROR FELL OFF THE WINDSHIELD. THE DEALER STATED THAT THE WINDSHIELD DELAMINATED, WHICH MEANT THAT THE GLASS WAS NO LONGER ABLE TO HOLD THE MIRROR IN PLACE. THE INSURANCE COMPANY HAD TO REPLACE THE ENTIRE WINDSHIELD. THE CONTACT BELIEVES THERE IS A DEFECT IN THE WINDSHIELD BECAUSE THE VEHICLE WAS HARDLY IN ANY HEAT AND NO OBJECTS STRUCK THE WINDSHIELD. THE CURRENT AND FAILURE MILEAGES WERE 115,000. UPDATED 07/10/09. *LJ THE WINDSHIELD WAS REPLACED ON JUNE 25, 2009. UPDATED 07/10/09.*JB
Electrical system, Air bags, Jun 12, 2009
TL*THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE AIR BAG LIGHT REMAINS ILLUMINATED IN HER VEHICLE AND DOES NOT TURN OFF. THE VEHICLE WAS TAKEN TO A MECHANIC AND THE CONTACT WAS INFORMED THAT THE WIRING LOCATED UNDER THE FRONT PASSENGER SEAT WAS LOOSE OR A SHORTAGE WAS PRESENT. HYUNDAI STATED THAT THE VIN WAS NOT INCLUDED IN A RECALL. THE FAILURE MILEAGE WAS 53,700.
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
Air bags, May 15, 2009
THERE IS SOMETHING REALLY WRONG WITH THE AIR BAGS WITH THE 2004 HYUNDAI SONATA. IF YOU READ THE COMPLAINTS, I HAD THE MOST PROBLEMS. WHAT IS IT GOING TO TAKE FOR A RECALL., FOR SOMEONE TO LOSE THEIR LIFE. DO THE RIGHT THING BECAUSE PEOPLE LIVES DEPEND ON YOU. *TR
Engine and engine cooling, Dec 18, 2008
WHILE DRIVING MY 2004 HYUNDAI SONATA AT LOW SPEED, THE ENGINE SUDDENLY DIED. THIS CAUSED ME TO LOSE POWER STEERING AND POWER BRAKES. FORTUNATELY THERE WAS SPACE FOR ME TO PULL TO THE CURB AND NO ONE WAS BEHIND ME. AFTER AN HOUR OR SO OF TRYING THE CAR STARTED UP AND I DROVE IT HOME. THREE DAYS LATER IT HAPPENED AGAIN ON A BUSY STREET AT ABOUT 10 MPH. AGAIN I WAS FORTUNATE AND COULD PULL TO THE CURB. THIS TIME I COULD NOT START IT AND HAD IT TOWED TO A LOCAL REPAIR SHOP. THEY DIAGNOSED IT AS A "DEFECTIVE EVAP. SOLENOID THAT WAS CAUSING ENGINE FLOODING." THIS WAS A VERY SCARY OCCURRENCE--IF IT HAPPENED ON A HIGHWAY IT WOULD BE VERY DIFFICULT TO STEER (DUE TO LOSS OF POWER STEERING) AND MY SUDDEN SLOWING COULD CAUSE REAR-END CRASH. THE OLD PART IS NOT AVAILABLE. *TR
Power train, Dec 18, 2008, crash
I OPERATE A 2004 HYUNDAI SONATA. IT EQUIPPED WITH SHIFTRONIC FEATURE, WHERE YOU ABLE TO OVERDRIVE A REGULAR AUTOMATIC TRANSMISSION BY MANUALLY SWITCHING TO DESIRED GEAR. HOWEVER, IT HAS OWN LOGIC NOT TO ALLOW YOU TO SWITCH TO INAPPROPRIATE GEAR LEADING TO OVERSTRESS AND/OR DAMAGE ENGINE OR TRANSMISSION. WHILE DRIVING ON SLIPPERY ROAD I USED ABOVE MENTIONED FEATURE TO SLOW DOWN A CAR WHEN APPROACHING AN INTERSECTION (SO-CALLED ENGINE BRAKE). AT SAME TIME I USED REGULAR BRAKES TOO SINCE ENGINE BRAKE IS NOT SO EFFECTIVE AND IT CAN'T STOP THE CAR COMPLETELY. MY CAR HAS ALSO NO ANTI BLOCKING SYSTEM (ABS) INSTALLED. *** AT THE MOMENT, WHEN ROAD WAS TOO SLIPPERY, FRONT WHEELS WERE BLOCKED FOR SHORT PERIOD. I EASED PEDAL LIKE IT'S NORMALLY REQUIRED FOR CARS NOT EQUIPPED WITH ABS, BUT TRANSMISSION LOGIC ASSUMED THAT CAR IS STOPPED COMPLETELY AND SWITCHED TO THE FIRST GEAR AT SPEED AROUND 40 KM/H (25 MPH) WHICH LED THE FRONT WHEELS TO BLOCK PERMANENTLY AND DUE TO THAT I LOST CONTROL OF THE CAR. *** FORTUNATELY, THERE WAS NOBODY AROUND AND I ONLY ENDED UP ON THE ROAD'S RIGHT SHOULDER. I REPEATED THIS SITUATION IN UNPOPULATED AREA AND IT HAPPENED AGAIN AND AGAIN. (THE SHIFTRONIC'S LOGIC IS SWITCHING TRANSMISSION TO THE FIRST GEAR AUTOMATICALLY AFTER CAR IS STOPPED TO AVOID THE ENGINE STALL WHEN YOU START MOVING AGAIN) I THINK, THERE SHOULD BE SOME SORT OF READER AT REAR WHEELS TO DETECT THAT CAR IS STILL MOVING OR ABS SYSTEM TO BE PRESENT AS STANDARD, NOT AS OPTIONAL FEATURE. OR, MAYBE, TRANSMISSION'S BEHAVIOR SHOULD BE UPDATED. *TR
Air bags, Nov 14, 2008, crash
TL*THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING APPROXIMATELY 10 MPH, ANOTHER VEHICLE CRASHED INTO THE DRIVER'S SIDE OF THE CONTACT'S VEHICLE. THE DRIVER'S SIDE DOORS WERE COMPLETELY SMASHED IN AND THE FRAME WAS BENT. THE AIR BAGS FAILED TO DEPLOY. THE DRIVER OF THE VEHICLE SUSTAINED MAJOR INJURIES TO HER LEFT SHOULDER. THE PASSENGERS IN THE OTHER VEHICLE WERE UNINJURED. A POLICE REPORT WAS FILED. THE MANUFACTURER STATED THAT THE AIR BAGS OPERATED IN THE MANNER THEY WERE DESIGNED; THEREFORE, THEY WERE NOT LIABLE FOR THE REPAIRS. THE DEALER HAS NOT BEEN NOTIFIED. THE VEHICLE WAS DESTROYED. THE CURRENT AND FAILURE MILEAGES WERE 65,000.
Engine and engine cooling, Oct 25, 2008
2004 HYNDAI SONATA STALLS ON HIGHWAY. *TR
Electrical system, Sep 27, 2008, fire
DROVE CAR 3 MILES FROM POINT A TO POINT B. IT WAS PARKED AT POINT B FOR APPROX 45 MINUTES. THEN DRIVEN 300FT TO POINT C. WHEN I GOT OUT OF THE CAR, I SMELLED SOMETHING UNUSUAL BUT I THOUGHT IT WAS THE AUTO SHOP NEXT DOOR. WHEN I WENT INTO THE STORE, AN EMPLOYEE LOOKED THROUGH THE GLASS WINDOW AND SHOUTED "SOMEONE'S CAR IS ON FIRE." I LOOKED AND SAW IT WAS MY VEHICLE. THERE WAS SMOKE COMING OUT OF THE HOOD. THE CAR NO LONGER STARTS. I WILL WRITE AGAIN TO UPDATE ON DIAGNOSIS FROM HYUNDAI. *TR
Air bags, Aug 25, 2008
TL*THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING AT AN UNKNOWN SPEED, THE AIR BAG LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY STATED THAT THE AIR BAG NEEDED TO BE REPLACED. THE VEHICLE HAS BEEN DIAGNOSED SEVERAL DIFFERENT TIMES; HOWEVER, THE FAILURE IS STILL OCCURRING. THE CURRENT MILEAGE WAS 42,000 AND FAILURE MILEAGE WAS 40,000.
Air bags, Aug 18, 2008
TL*THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHEN THE IGNITION WAS TURNED ON, THE AIR BAG WARNING LIGHT WOULD ILLUMINATE ON THE INSTRUMENT PANEL. THE LIGHT REMAINED ILLUMINATED UNTIL THE ENGINE WAS TURNED OFF. THE VEHICLE WAS TAKEN TO THE AUTHORIZED DEALER AND THEY STATED THAT THE FAILURE WAS RELATED TO A MALFUNCTION WITH THE SENSOR DEVICE. THE VEHICLE WAS REPAIRED. THE VEHICLE WAS TAKEN TO THE DEALER FIVE TIMES FOR THE SAME FAILURE, BUT NO REMEDY WAS FOUND. THE FAILURE MILEAGE WAS 55,000 AND CURRENT MILEAGE WAS 80,000.
Electrical system, Aug 1, 2008
BATTERY, THE BATTERY WAS REPLACE IN 12/05/05, THEN AGAIN IN 10/05/06, ON 7/31/08 THE BATTERY THIS TIME DIE WITH NO WARNING, IN THE MIDDLE OF THE VERY BUSY INTERSECTION. BOTH TIME THE BATTERY WAS REPLACE BY RICK CASE HYUNDAI, STATED BAD BATTERY. *TR
Power train, Feb 19, 2008
HYUNDAI SONATA, 5 SPEED, 2005, 4 CYLINDER, 47,500 MILES, APPROXIMATELY 4 YEARS OLD. THERE WAS A LOT OF PLAY IN THE CLUTCH, BUT IT STILL ENGAGED. ONCE ENGAGED HOWEVER, THE VEHICLE WAS SLOW TO BUILD UP SPEED. TOOK IT TO KEY HYUNDAI, THE DEALER WHERE IT WAS PURCHASED. WAS IMMEDIATELY TOLD THAT THEIR 5 YEAR, 60,000 MILE BUMPER-TO-BUMPER WARRANTY WOULD NOT BE IN EFFECT BECAUSE THIS WAS DUE TO NORMAL WEAR-AND-TEAR. THEY NEVER DROPPED THE TRANSMISSION TO LOOK AT THE INTERNALS. THEY GAVE ME THE CHOICE OF $1,100 FOR REPAIRS, AND $2,500 IF A NEW FLYWHEEL WAS NEEDED. SINCE IT WASN'T COVERED BY A WARRANTY, I TOOK IT TO MY MECHANIC. HE DROPPED THE TRANSMISSION AND NOTED THAT THE FLYWHEEL CAME LOOSE FROM THE SHAFT IT WAS ATTACHED TO AND CAUSED WEAR TO THE CLUTCH ASSEMBLY HOUSING. THE FLYWHEEL AND OTHER PARTS WOULD HAVE TO BE REPLACED. THE FLYWHEEL ALONE WILL COST $1050, AND THE ENTIRE JOB ABOUT $2300. NO AFTER MARKET FLYWHEELS ARE AVAILABLE FOR THIS VEHICLE. HYUNDAI SHOULD HAVE HONORED THEIR WARRANTY. I SPOKE WITH SEVERAL PEOPLE AT KEY HYUNDAI PLUS HYUNDAI USA CUSTOMER SERVICE. KEY SAID THAT IT WAS NOT GOING TO BE WARRANTED AND CUSTOMER SERVICE WOULD ONLY REFER ME BACK TO THE DEALERSHIP. NO ONE COULD GIVE ME INFORMATION ABOUT AN AVERAGE LIFE FOR THE CLUTCH. *TR
Electrical system, Jan 2, 2008
TL*THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE WIRES UNDER THE HOOD WERE MELTING IN THE CLIMATE CONTROL ASSEMBLY. THIS IS THE SECOND TIME THAT THE CLIMATE CONTROL ASSEMBLY HAS BEEN REPLACED. AS A RESULT, THE INSULATION IS MELTING FROM THE WIRES AND CAUSING THEM TO BECOME BARE. THE CURRENT MILEAGE WAS 136,000 AND FAILURE MILEAGE WAS 98,000.
Seats, Nov 6, 2007
INCIDENT: 2004 HYUNDAI SONATA LX LEFT REAR SEAT FOLDABLE SEAT BACK RELEASE BUTTON DOES NOT SNAP BACK AFTER BEING PRESSED FOR FOLDING DOWN THE SEAT BACK. THUS, WHEN SEAT BACK IS FOLDED INTO THE UPRIGHT POSITION AGAIN, LOCK DOES NOT SNAP AND ENGAGE, LEAVING THE SEAT BACK LOOSE. IN CASE OF BREAKING OR FRONT CRASH SEAT BACK MOST CERTAINLY WILL FOLD DOWN. *TR