MyCarTSB

2004 Hyundai Sonata Suspension Problems

48 owner-reported suspension complaints from NHTSA data

48
Complaints
1
Recalls
1
Crashes
Jan 2011Dec 2016
Date Range

Data sourced from NHTSA public database. For informational purposes only. Always consult a qualified mechanic.

Suspension Recalls (1)

RECALLCampaign #09V124000

SUSPENSION

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.

Fix: 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.

Owner Complaints (48)

criticalSUSPENSION,WHEELS,UNKNOWN OR OTHER
Filed: Aug 2025

Your 2004 Sonata's rear end feels like it's swerving uncontrollably, especially on the freeway, and your front right tire goes flat randomly. A mechanic confirmed it's a suspension problem but couldn't pinpoint which part. The issue has gotten worse over time—even at low speeds like 35 mph, hitting a pothole or turning the steering wheel causes severe swerving and loss of control, creating a serious safety risk. The suspension system likely needs professional diagnosis and repair to identify and replace the failing component.

NHTSA #: 11681163
criticalSUSPENSION
Filed: Oct 2022

Your car's suspension sub-frame has become severely corroded, which caused abnormal sounds and shuddering while driving at 35 MPH, making you nearly lose control of the vehicle. A mechanic was unable to complete a wheel alignment because of this corrosion. The dealer told you that your vehicle's VIN wasn't covered under the recall program and refused to repair it at no cost.

NHTSA #: 11491277
criticalSUSPENSION,SERVICE BRAKES, AIR,STRUCTURE
Filed: Feb 2022

Your brakes failed while driving due to severe corrosion on the brake components and underneath your vehicle. A mechanic discovered the corrosion was so extensive that the brake lines needed to be fabricated and replaced, and your vehicle failed state inspection because of the damage. The dealer confirmed your vehicle wasn't covered under a suspension recall, so the manufacturer didn't address the issue.

Parts you may need:

As an Amazon Associate, MyCarTSB earns from qualifying purchases.

NHTSA #: 11451154
highSUSPENSION
Filed: Feb 2026

During a routine oil change inspection, a mechanic discovered that the front passenger side of your vehicle's subframe has rusted through in multiple places. This is a structural component that supports your suspension, and significant rust can compromise vehicle safety. There is an open safety recall issued in 2009 for this exact issue on your 2004 Sonata, and you should contact a Hyundai dealership to see if they can perform the recall repair, even though it was issued years ago.

NHTSA #: 11718609
highSUSPENSION
Filed: Jun 2024

Your 2004 Sonata's sub-frame has severely deteriorated due to rust, which you believe is related to Kansas's salt-heavy winters. Hyundai has declined to help, stating your state doesn't qualify for their salt-belt recall coverage. You're concerned about safety and frustrated that this appears to be a known issue affecting multiple Sonatas that weren't included in recalls. Addressing sub-frame rust typically requires professional welding, reinforcement plating, or full sub-frame replacement depending on the extent of damage.

NHTSA #: 11592697
highSUSPENSION
Filed: Apr 2023

Your car shudders and makes creaking and cracking sounds from the front suspension when you accelerate, especially around 30 MPH. A mechanic diagnosed that your front subframe, lower control arms, and lower suspension panels need to be replaced. The problem has been getting worse over time, and this issue may be related to a known suspension defect affecting some 2004 Hyundai Sonatas.

NHTSA #: 11518068
highSUSPENSION
Filed: Nov 2022

Your car's shocks and suspension have worn down significantly, making the ride unstable and causing you to nearly have accidents. The suspension is no longer providing proper support and handling. The fix will likely involve replacing the worn shock absorbers and possibly other suspension components.

Parts you may need:

As an Amazon Associate, MyCarTSB earns from qualifying purchases.

NHTSA #: 11494053
highSUSPENSION
Filed: Sep 2022

Your Sonata's subframe (the metal frame that supports the suspension) has severely corroded, which a mechanic identified as related to a known manufacturer issue. This corrosion can compromise the structural integrity of your suspension system. Addressing this typically involves inspecting the extent of the corrosion and either treating it with rust prevention products or replacing corroded sections of the subframe.

NHTSA #: 11483656
highSUSPENSION,ELECTRICAL SYSTEM
Filed: Feb 2021

Your car has conflicting information about a suspension recall — the HAS Buddy app says you have one, but your dealer says you don't. You're also experiencing electrical issues where your doors lock randomly, your seat moves forward and backward on its own, and your speakers aren't working. Additionally, when you hit bumps, you feel like your tires might come loose.

NHTSA #: 11397102
highSUSPENSION,UNKNOWN OR OTHER
Filed: Jan 2021

Your 2004 Sonata's suspension subframe has rusted and deteriorated, preventing a mechanic from replacing a control arm. Hyundai has acknowledged a recall for this issue on some 2004 Sonatas, but the company told you your specific vehicle (based on its VIN) is not covered by the recall, despite having the same problem. Fixing this will likely require a complete subframe replacement.

NHTSA #: 11386396
mediumSUSPENSION
Filed: Aug 2020

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT HE RECENTLY PURCHASED THE VEHICLE USED IN 07 OF 2020. THE CONTACT INSPECTED UNDERNEATH THE VEHICLE AND SAW RUSTED HOLES AND CORROSION IN THE SUB FRAME. THE CONTACT RESEARCHED AND SAW NUMEROUS INCIDENCES OF THE SAME ISSUE IN THAT MODEL VEHICLE. THE DEALER (D'ARCY HYUNDAI 2521 W JEFFERSON ST, JOLIET, IL 60435 (815) 725-5200) SAID THERE WAS NOTHING THEY COULD DO. DUE TO THE AGING OF THE VEHICLE, MILEAGE AND AN EXPIRED WARRANTY. THE DEALER ADVISED HIM NOT TO FIX THE SUB FRAME. THE MANUFACTURER GAVE A CASE NUMBER TO THE CONTACT AND REFERRED HIM TO THE DEALER. THE VEHICLE WAS CURRENTLY AT THE DEALER STILL UNREPAIRED. THE FAILURE MILEAGE WAS 94,727. *BF *AS

NHTSA #: 11351359
mediumSUSPENSION
Filed: Aug 2020

I WAS DRIVING MY CAR WHEN I STARTED HEARING NOISES AND THE CAR STARTED STEERING TO THE RIGHT. WHEN I GOT MY CAR HOME , I DISCOVERED THAT THE FRONT SUSPENSION CROSS MEMBER SUBFRAME HAD COME LOOSE BECAUSE THE BOLTS HAD COMPLETELY RUSTED OUT AND THE CROSS MEMBER HAD RUSTED. I DISCOVERED THAT MY VEHICLE HAD A RECALL #XG350 IN JULY 2009. I PURCHASED MY HYUNDAI IN THE FALL OF 2009, BUT DID NOT RECEIVE ANY RECALL NOTICE. IS MY HYUNDAI STILL ELIGIBLE FOR RECALL REPAIR? WE LIKE OUR HYUNDAI AND IT HAS BEEN ONE OF THE BEST CARS WE HAVE OWNED. THE BODY AND MOTOR ARE STILL IN GOOD SHAPE. WHAT DO I DO NEXT?

NHTSA #: 11350788
mediumSUSPENSION
Filed: Feb 2020

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE HAVING A ROUTINE CHECK AT AN INDEPENDENT MECHANIC, THE MECHANIC NOTICED THE FRONT SUB FRAME WAS SEVERELY CORRODED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE DEALER SUPERIOR HYUNDAI NORTH 5665 DIXIE HWY, FAIRFIELD, OH 45014 (513) 870-9800, WAS CONTACTED AND INFORMED OF THE ISSUE. THE CONTACT WAS INFORMED THAT THE VIN WAS NOT SUBJECTED TO A RECALL. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 09V124000 SUSPENSION AS A POSSIBLE SOLUTION TO THE FAILURE. THE MANUFACTURER WAS CONTACTED AND INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS 101,000.

NHTSA #: 11309137
mediumSUSPENSION
Filed: Nov 2019

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE STEERING WHEEL HAD TO BE SLIGHTLY TURNED TO THE LEFT IN ORDER FOR THE VEHICLE TO DRIVE STRAIGHT. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE CONTACT WAS INFORMED THAT THE A-ROD WAS RUSTED. THE VEHICLE WAS NOT REPAIRED. THE VEHICLE WAS NOT TAKEN TO A DEALER FOR DIAGNOSTIC TESTING OR REPAIRS. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN ANY OPEN RECALLS. THE FAILURE MILEAGE WAS APPROXIMATELY 200,000.

NHTSA #: 11280202
mediumSUSPENSION
Filed: Jul 2019

SUSPENSION: I HAVE CHANGED BOTH LOWER CONTROL ARMS AND NOW MY STRUTS AND SHOCKS ARE OUT I CALLED AND HAVE BEEN TOLD MY VIN NUMBER IS NOT PART OF THE RECALL BUT I DONT UNDERSTAND HOW THAT IS WHEN I HAVE A 2004 SONATA AND THAT IS THE CAR PART OF THE RECALL

NHTSA #: 11233469
mediumSUSPENSION
Filed: Jul 2019

SEVERE SUBFRAME CORROSION FOUND DURING INSPECTION OF CAR THAT WAS ORIGINALLY FROM ILLINOIS.

NHTSA #: 11231708
mediumSUSPENSION,STRUCTURE,WHEELS
Filed: Mar 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.

NHTSA #: 11190203
mediumSUSPENSION,ELECTRICAL SYSTEM,UNKNOWN OR OTHER
Filed: Mar 2019

SUB FRAME ON FRONT PASSENGER RUSTED AND CORRODED. CAUSED DAMANGE TO CV AXLE ON SAME SIDE. CAUSED ALIGNMENT ISSUES ON FRONT END. CAUSES TIRES TO WEAR QUICKLY, WITHIN A WEEK. ANTI THEFT SYSTEM LOCKS THE CAR WHILE DRIVING AND CAUSES ALARM TO SOUND WHILE DRIVING AND MUST OPEN OTHER DOORS AND STOP DRIVING TO STOP THE ALARM FROM GOING OFF, HEADLIGHTS AND DASH LIGHTS AND TAIL LIGHTS COME ON WHEN BRAKE IS PRESSED AND GO OFF WHEN BRAKE IS RELEASED BUT THIS PROBLEM ONLY HAPPENS WHEN HEADLIGHTS ARE NOT IN USE

NHTSA #: 11185120
mediumSUSPENSION,STRUCTURE
Filed: Aug 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.

NHTSA #: 11122831
mediumSUSPENSION
Filed: Aug 2018

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING 30 MPH, THE VEHICLE BEGAN TO WOBBLE VIOLENTLY AND AN ABNORMAL SQUEALING SOUND WAS HEARD. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE CONTACT LOST CONTROL OF THE VEHICLE AS IT CAME TO A STOP BY THE CURB. THE VEHICLE WAS DRIVEN TO THE CONTACT'S RESIDENCE. THE CONTACT CALLED INVER GROVE HYUNDAI AT (888) 706-5928 (LOCATED AT 1290 50TH ST E, INVER GROVE HEIGHTS, MN 55077), BUT NO ASSISTANCE WAS PROVIDED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND NO ASSISTANCE WAS PROVIDED. THE FAILURE MILEAGE WAS 175,000.

NHTSA #: 11118768
mediumSUSPENSION
Filed: Apr 2018

THERE IS A RECALL ON THE 2004 HYUNDAI SONATA NHTSA VEHICLE SAFETY RECALLS RECALL NUMBER 09V124000 BUT, HYUNDAI SAYS MY CAR MISS BY 2 WEEKS CUT OFF IS NOV. 20 2003, MY VEHICLE DATE IS DEC. 19 2003

NHTSA #: 11090796
mediumSUSPENSION
Filed: Apr 2018

MY CAR HAS FAILED THE STATE SAFETY INSPECTION DUE TO A RUSTED SUB-FRAME. HYUNDAI HAS RECALLED MAY OF THESE CARS (SAME YEAR, MAKE AND MODEL) DUE TO THIS ISSUE YET REFUSES TO COVER MINE AS THEY SAY IT WAS NOT PART OF THE RECALL. IT HAS THE SAME EXACT ISSUE AS THOSE THAT WERE RECALLED. I HAVE TRIED TWICE UNSUCCESSFULLY TO HAVE THEM CORRECT THIS SAFETY ISSUE. THERE ARE 2 CASE NUMBERS, 11190286 & 100927.

NHTSA #: 11089848
mediumSUSPENSION
Filed: Aug 2017

MY WHOLE RIGHT SIDE OF MY SUBFRAME IS RUSTED I'VE RESEARCHED A LOT ON THIS AND THIS SEEMS TO BE A SAFETY ISSUE AND VERY UNCOMMON IT'S CAUSING MY WHEEL TO PULL AND I CURRENTLY CAN'T DRIVE IT

NHTSA #: 11015566
mediumSUSPENSION,POWER TRAIN,ELECTRICAL SYSTEM
Filed: Apr 2017

SUSPENSION FAILURE JULY 2016-BOTH ENGINE MOUNTS AND LOWER CONTROL ARMS FAILED. REPLACED 2016 JULY. APRIL 2017 BOTH ENGINE MOUNTS AND LOWER CONTROL ARMS FAILED AGAIN. IN ADDITION VIOLENT JERKING WHILE DRIVING,THEN LOSS OF POWER. USUALLY OCCURRED GOING UP HILLS,COMING OFF FROM MAKING A TURN OR DRIVING SPEEDS UNDER 25MPH.BRAKE LIGHTS REMAIN ON UNABLE TO INDICATE STOPPING TO OTHER CARS.UNABLE TO SAFELY DRIVE AND MANEUVER THE VEHICLE. BRAKE LIGHTS REMAIN ON WHETHER DRIVING OR IN PARK. JERKING DOES NOT OCCUR WHEN PUTTING VEHICLE IN GEAR,BUT WHILE DRIVING SPEED DECREASES RAPIDLY AND CAR BECOMES DIFFICULT TO STEER. SUSPENSION FEELS LOSE IN ADDITION THERE ARE NOISES AS IF BOLTS ARE BROKEN. PER A RECALL SEARCH CAMPAIGN 089 IS OPEN MEANING UNDER BODY ISN'T COATED. UPON FURTHER READING OF THE CAMPAIGN SUSPENSION FAILURE CAN OCCUR AND OTHER ISSUES. UNSURE IF ALL RELATED,BUT THE BRAKE LIGHTS,AND JERKING OCCURRED THE SAME TIME AS SUSPENSION FAILED,WHICH WAS PREVIOUSLY REPLACED.HUGE SAFETY ISSUES FOR THE DRIVER AND OTHER MOTORISTS AROUND,ESPECIALLY WHEN JERKING OCCURS. IT SHOULD BE NOTED,PER AN INTERNET SEARCH THESE ISSUES ARE KNOWN ISSUES WITH THIS MAKE MODEL AND YEAR. ALL ISSUES SEEN ONLINE HAPPEN WITH CARS AT OR AROUND THE 130,000 MILE MARK.

NHTSA #: 10981531
mediumSUSPENSION
Filed: Apr 2017

HYUNDAI RECALLED 2001 TO 2004 SONATAS. WHEN WE TOOK IT TO THE DEALER THEY SAID HYUNDAI DENIED THE REPAIR BECAUSE THE VIN NUMBER WAS NOT IN THE RECALL. THE DEALER SAID IT IS THE SAME PROBLEM AS THE RECALL. I WANT THE RECALL EXPANDED TO INCLUDE THIS VIN.

NHTSA #: 10980257
mediumSUSPENSION,STRUCTURE
Filed: Dec 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

NHTSA #: 10930132
mediumSUSPENSION
Filed: Nov 2016

THIS IS MY SECOND ATTEMPT SUBMITTING THE SAME COMPLAINT. THE HYUNDAI CORP HAS NOT FIXED MY CAR NOR GIVEN ME A LOANER NOR CONTACTED ME AND IT'S BEEN 3 MONTHS.

NHTSA #: 10926454
mediumSUSPENSION,STRUCTURE
Filed: Sep 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.

NHTSA #: 10909624
mediumSUSPENSION
Filed: Sep 2016

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING 55 MPH, THE VEHICLE SHOOK. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT BOTH FRONT CV AXLES WERE CORRODED. THE VEHICLE WAS NOT REPAIRED. THE CONTACT ALSO STATED THAT THE REAR PASSENGER SIDE HUB ASSEMBLY WAS BENT AND RUBBED AGAINST THE TIRE, WHICH CAUSED THE TIRE TO BLOW OUT. THE MANUFACTURER WAS MADE AWARE OF THE FAILURES. THE VIN WAS UNKNOWN. THE APPROXIMATE FAILURE MILEAGE WAS 150,000.

NHTSA #: 10907097
mediumSUSPENSION
Filed: Mar 2016

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING, THE STEERING WHEEL VEERED TO THE RIGHT INDEPENDENTLY. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE SUB FRAME NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 145,000.

NHTSA #: 10852679
mediumSUSPENSION
Filed: Nov 2015

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING AT VARIOUS SPEEDS, THERE WAS AN ABNORMAL NOISE COMING FROM THE REAR OF THE VEHICLE. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE SUBFRAME WAS SEVERELY CORRODED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE FAILURE MILEAGE WAS APPROXIMATELY 70,000.

NHTSA #: 10795087
mediumSUSPENSION
Filed: Sep 2015

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING APPROXIMATELY 30 MPH, THE FRONT END FRAME OF THE VEHICLE FRACTURED. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FRONT END SUBFRAME NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND STATED THAT THE VIN WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE FAILURE MILEAGE WAS 68,400.

NHTSA #: 10763108
mediumSUSPENSION,STRUCTURE
Filed: Jul 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.

NHTSA #: 10744092
mediumSUSPENSION
Filed: Mar 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.

NHTSA #: 10701636
mediumSUSPENSION
Filed: Sep 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

NHTSA #: 10630646
mediumSUSPENSION,STRUCTURE
Filed: Jun 2014

CAR FAILED PA INSPECTION BECAUSE OF RUN ON THE SUB FRAME DEALER SAYS ITS NOT COVERED UNDER RECALL. *TR

NHTSA #: 10606892
mediumSUSPENSION
Filed: May 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.

NHTSA #: 10587402
mediumSUSPENSION
Filed: Feb 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

NHTSA #: 10568414
mediumSUSPENSION
Filed: Oct 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

NHTSA #: 10548712
mediumSUSPENSION
Filed: Jul 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

NHTSA #: 10525806
mediumSUSPENSION,STRUCTURE
Filed: Jun 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

NHTSA #: 10515707
mediumSUSPENSION
Filed: Jun 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

NHTSA #: 10515429
mediumSUSPENSION,STRUCTURE,WHEELS
CrashFiled: Sep 2012

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

NHTSA #: 10477342
mediumSUSPENSION,STRUCTURE
Filed: Sep 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

NHTSA #: 10476953
mediumSUSPENSION
Filed: Jan 2011

OUR CAR WAS EXCESSIVELY VIBRATING; WE WERE TOLD THAT THE HARMONIC STABILIZER NEEDED TO BE FIXED AND THAT HYUANDI CARS WERE KNOWN FOR HAVING THIS PROBLEM. *TR

NHTSA #: 10374024
mediumSUSPENSION,WHEELS
Filed: Aug 2006

18 MONTHS AFTER PURCHASING MY 2004 HYUNDAI SONATA BRAND NEW. THE REAR WHEEL BEARING SEIZED CAUSING MY TIRE TO DRAG WHILE DRIVING AND THE TIRE THEN POPPED. I WAS ABLE TO HAVE THE WHEEL BEARING REPLACED UNDER WARRANTY. HOWEVER, THEY WOULD NOT COVER THE TIRE. *JB

NHTSA #: 10164343
mediumSUSPENSION
Filed: Feb 2006

DT*: THE CONTACT STATED WHEN THE ROAD SLANTED TO THE RIGHT, THE VEHICLE PULLED TO THE RIGHT. THE DEALERSHIP WHERE THE VEHICLE WAS PURCHASED, AS WELL AS ANOTHER DEALERSHIP, ALIGNED THE VEHICLE. THIS HAS NOT REPAIRED THE PROBLEM. UPDATED 03/15/06

NHTSA #: 10150778
mediumSUSPENSION
Filed: Jan 2005

WHILE DRIVING AT HIGHWAY SPEEDS THE VEHICLE PULLED TO THE LEFT. THE DEALER STATED THE VEHICLE NEEDED A FRONT ALIGNMENT. PLEASE PROVIDE ADDITIONAL INFORMATION. *JB

NHTSA #: 10107487

Other 2004 Hyundai Sonata Issues