2005 Hyundai Sonata Body & Structure Problems

Your car's subframe—a critical structural component that supports the suspension and drivetrain—has severely rusted and may collapse, creating a dangerous safety hazard for you, your passengers, and others on the road. This is a known corrosion problem affecting certain model years of this vehicle, though you had no warning signs before inspection. The mechanic recommends replacing the subframe before driving long distances. The repair will involve removing and installing a new or reinforced subframe.

While your 2005 Hyundai Sonata was being serviced, a mechanic discovered the subframe—a structural component that supports the suspension—was completely rusted. You believe this may be related to a known Hyundai suspension issue (NHTSA campaign 09V124000). The vehicle wasn't repaired at that time. Addressing this would likely involve inspection of the subframe and potentially replacement or restoration of rusted components.

While replacing your brakes, you discovered your subframe was completely corroded with rust. A Hyundai dealership confirmed the subframe needed to be replaced, but the work wasn't completed. Fixing this will likely require removing and replacing the entire subframe, which is a major structural component underneath your vehicle.

THE FRONT SUBFRRAME IS RUST AND CORROSION VERY BAD

RUST UNDERNEATH ENGINE PART OF BODY FRONT PASSENGER SIDE I THINK THIS METAL SUPPORT BREAK ANYTIME WHILE DRIVING IN RAIN

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. WHILE THE VEHICLE WAS AT AN INDEPENDENT MECHANIC FOR ROUTINE MAINTENANCE, THE TECHNICIAN INFORMED THE CONTACT THAT THE SUBFRAME WAS RUSTED. THE VEHICLE WAS THEN TAKEN TO SUNTRUP HYUNDAI WENTZVILLE (971 WILMER RD, WENTZVILLE, MO 63385, (636) 887-8711) WHERE IT WAS CONFIRMED THAT THE SUBFRAME WAS RUSTED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND A CASE WAS FILED. THE FAILURE MILEAGE WAS 110,978.

PURCHASED CAR JUNE 4, 2018. TOLD BY MECHANIC FRAME IS RUSTED OUT AND UNSAFE TO DRIVE. WILL NOT PASS STATE INSPECTION.

WAS TRYING TO GET AC COMPRESSOR REPLACED BY A LOCAL REPAIRMAN, WHILE PERFORMING THE TASK, HE FOUND THE SUBFRAME SEVERELY CORRODED, ADVISED NOT TO DRIVE DUE TO SAFETY. CONTACTED HYUNDAI CUSTOMER SERVICE, THEY ADVISED TO TAKE CAR TO HYUNDAI DEALER FOR INSPECTION OF THE CAR. THE DEALER SAID THEY WOULD INSPECT AND TAKE PICTURES AND CONTACT THE CORPORATE OFFICE WITH INFO. HYUNDAI CORPORATE ADVISED THAT THE WARRANTY WAS UP, WOULD NOT BE RESPONSIBLE FOR THE REPAIR. HOWEVER, THE 2001 THRU 2004 SONATA MODELS WERE RECALLED (09V12400, 04/16/2009, SUSPENSION) FOR THE SAME PROBLEM, FRONT SUBFRAME CORROSION.

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. WHILE THE VEHICLE WAS BEING REPAIRED BY AN INDEPENDENT MECHANIC, THE TECHNICIAN NOTICED THAT THE SUBFRAME WAS RUSTED. THE CONTACT CALLED LESTER GLENN HYUNDAI AT 732-451-3016 AND WAS INFORMED OF THE COST FOR A DIAGNOSTIC TEST. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INFORMED THE CONTACT ABOUT A RECALL, BUT IT WAS NOT ON HIS SPECIFIC YEAR. THE APPROXIMATE FAILURE MILEAGE WAS 85,000. *TT UPDATED 8/22/18*JB

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. WHILE OPERATING THE VEHICLE, A SQUEALING TYPE NOISE WAS HEARD FROM THE FRONT END OF THE VEHICLE. WHILE MAKING A TURN, THE FRONT PASSENGER SIDE TIRE BECAME WORN. AFTER REPLACING THE FRONT TIRE, THE FAILURE RECURRED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO LOOKED UNDER THE VEHICLE AND DISCOVERED THAT THE ENTIRE SUBFRAME HAD SUSTAINED SEVERE RUSTING AND CORROSION AND WOULD NEED TO BE REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURES. THE FAILURE MILEAGE WAS 117,000.

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. THE CONTACT STATED THAT THERE WAS AN ABNORMAL NOISE PROGRESSING FROM THE VEHICLE. THE VEHICLE WAS INSPECTED AND DIAGNOSED BY AN INDEPENDENT MECHANIC WHO STATED THAT THE ENTIRE SUBFRAME WAS PREMATURELY RUSTED AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND A SERVICE CAMPAIGN, WHICH EXCLUDED THE VEHICLE ALTHOUGH THE SYMPTOMS WERE THE SAME. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE, BUT PROVIDED NO REMEDY TO PREVENT THE FAILURE OTHER THAN TAKING THE VEHICLE TO A DEALER FOR DIAGNOSTIC TESTING AND REPAIR. THE APPROXIMATE FAILURE MILEAGE WAS 144,000.

THE SUB FRAME IN THE FRONT RUSTED OUT JUST LIKE THE SALT BELT 1999-2004 THE CAR HAS ONLY TWO SPOTS OF RUST AT THE BACK FENDER. NO OTHER RUST I TOOK IT TO A SERVICE STATION BECAUSE IT WAS PULLING TO THE RIGHT HE LIFTED THE CAR AND THE SUB FRAME IS ROTTED OUT JUST LIKE THEY DID ON THE 1999-2004 BUT HYUNDAI WILL NOT FIX BECAUSE ITS A 2005 I THINK THE PART IS THE SAME AS THE 2004 AND THEY CANT TELL ME THAT AND WONT HELP ME.

I HAVE A HYUNDAI SONATA 2005 AND THE MECHANIC FROM HYUNDAI DEALERSHIP NOTIFIED ME THE SUBFRAME CORROSION ISSUE. THE SYMPTOM OF MY CAR EXACTLY SAME AS THE CASE FROM NICHOLAS CIRULLI AND ROBERT D'ELIA V. HYUNDAI MOTOR COMPANY AND HYUNDAI MOTOR AMERICA, WHICH EVENTUALLY RECALLED 2000 - 2004 HYUNDAI SONATA DUE TO THE SUBFRAME CORROSION ISSUE. I AM WONDERING WHETHER 2005 HYUNDAI SONATA OWNERS EXPERIENCE A SIMILAR ISSUE AND THIS VEHICLE SHOULD BE INCLUDED ON THE RECALL AS WELL. I WOULD APPRECIATE IF NHTSA WOULD REVIEW THIS CASE. THANKS.

FAILED INSPECTION IN PART DUE TO FRONT SUBFRAME RUST THROUGH. CALLED HYUNDAI AND SPOKE TO A CLAIMS REP. BY THE NAME OF NATHAN & TIER2 REP TIM. BOTH TOLD ME THERE WERE RECALLS ON SONATAS UP TO 2004 FOR THIS PROBLEM, BUT NOT 2005. THE 2005 MODEL IS THE SAME MODEL AS 2004. THE MODEL YEAR DIDN'T CHANGE TILL 2006 SO WHY WAS 2005 EXCLUDED FROM THE RECALL? MY CAR HAS 120K MILES ON IT. BOTH TOLD ME IT WASN'T UNDER RECALL OR WARRANTY, AND THAT HYUNDAI WOULD NOT BE ABLE TO DO ANYTHING FOR ME, . HOW IS IT THE A CAR 11 YEARS OLD HAS A BAD FRAME? HOPE YOU WILL BE ABLE TO HELP US.

THE EXTERIOR PAINT ON THE DOOR HANDLES CAME OFF BOTH THE DRIVERS SIDE AND THE PASSENGER SIDE..THE METAL WRAPPING OF THE INTERIOR DOOR HANDLES BECAME DANGEROUSLY SHARP, AND CUT ME ON MY FINGER. THIS ALL HAPPENED AROUND 2009.SINCE THEN THE INTERIOR CLOTH HEADER HAS COME LOOSE FROM THE ROOF, AND IS NOW HANGING. *TR

CHROME INTERIOR DOOR HANDLE. THE CHROME ON THE HANDLE IS CRACKING AT THE CHROME EDGE. IT HAS A SHARP EDGE AND CUT MY PASSENGERS HAND. I HAD THIS HANDLE REPLACED UNDER WARRANTY ONCE BEFORE FOR THIS ISSUE AND NOW IT IS HAVING THE SAME ISSUE AS BEFORE. THEY HAVE A RECALL ON THE 2002 - 2003 SONATAS PERSONALLY I DON'T THINK THEY FIXED ANYTHING AND THIS SHOULD BE INCLUDED FOR THE RECALL AS WELL. *TR

ABOUT TWO YEARS AGO THE CHROME PLATING ON THE INTERIOR DOOR HANDLES STARTED TO PEEL OFF, RESULTING IN HAZARDOUS SHARP EDGES BEING FORMED. SINCE THEN IT HAS ONLY GOTTEN WORSE AND EVERYONE IN MY FAMILY HAS RECEIVED AT LEAST ONE CUT OR LACERATION FROM THESE SHARP EDGES. YESTERDAY (03/02/2014) AS I WAS GETTING OUT OF MY VEHICLE I RECEIVED A CUT ON MY HAND ABOUT AN INCH LONG AND A QUARTER INCH DEEP. IT REQUIRED STITCHES TO CLOSE THE OPEN WOUND.I KNOW THAT HYUNDAI HAS ISSUED RECALLS FOR THIS SAME EXACT PROBLEM ON THEIR 2003-2004 MODELS. CLEARLY MY 2005 NEEDS TO BE INCLUDED IN THIS RECALL. *TR

TL*THE CONTACT OWNS A 2005 HYUNDAI SONATA. THE CONTACT STATED THAT THE CHROME TRIM ON THE INTERIOR DOOR HANDLES STARTED TO SEPARATE, LEAVING SHARP EDGES AND LACERATIONS TO WHOMEVER OPENED THE DOOR. THE CONTACT STATED THAT HE RECEIVED SMALL LACERATIONS TO HIS LEFT HAND AS A RESULT OF OPENING THE DOOR. THE VEHICLE WAS NOT INSPECTED BY A DEALER OR AN INDEPENDENT MECHANIC. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 140,000. THE CURRENT MILEAGE WAS APPROXIMATELY 155,000. THE VIN WAS UNAVAILABLE.

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 45 MPH, THE PASSENGER SIDE REAR MOLDING TO THE WINDOW FRACTURED AND DETACHED FROM THE VEHICLE. THE DEALER WAS CONTACTED AND THEY ADVISED HIM THAT THERE WAS ONLY A ONE YEAR WARRANTY ON THE MOLDING. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGES WERE APPROXIMATELY 36,500. ....UPDATED 12/03/12 *BF THE CONSUMER STATED THE CHROME ON TOP OF THE MOLDING, ABOVE THE RIGHT REAR DOOR, BECAME DETACHED AND FLEW OFF. UPDATED 01/10/12

THE DRIVERS DOOR HANDLE HAS A CHROME COVER ON IT, THAT AT ONE POINT WAS GLUED TIGHT TO THE HANDLE, BUT NOW DUE TO WEAR AND TEAR, THE EDGE OF THE PLASTIC CHROME PIECE IS EXPOSED AND IT YOUR NOT PAYING ATTENTION AND SLIDE YOUR HAND ACROSS IT WHEN OPENING THE DOOR, IT CAN RESULT IN A CUT.GASH IN SOMEONE'S HAND. (INJURY) I HAVE GOTTEN A FEW CUTS, NOTHING SERIOUS, BUT IF SOMEONE REALLY WAS IN A RUSH, IT COULD BE QUITE A DEEP CUT/GASH IN YOUR HAND. *TR

PAINT IS PEELING FROM EXTERIOR DOOR HANDLES OF MY 2005 HYUNDAI SONATA. *TR

I PURCHASED A 2005 HYUNDAI SONATA NEW ON 2/18/05 AND THE DEALER, PARR HYUNDAI IN BREMERTON INSTALLED A PLASTIC HOOD DEFLECTOR. IN THE SPRING OF 2007, I REPORTED THAT THE DEFLECTOR WAS VIBRATING AND THE DEALER CHECKED IT OUT. SAID NOTHING WAS WRONG. IN JULY 2007, WHILE DRIVING ON HIGHWAY I 5 FROM OLYMPIA TO TACOMA, WA., THE DEFLECTOR SUDDENLY FLEW OFF. I WAS GOING ABOUT 65 MILES PER HOUR. IT WAS DARK AND I DID NOT SEE WHERE IT WENT. LUCKILY, IT DID NOT HIT ANYONE. HAD THAT HAPPENED, IT WOULD HAVE CAUSED SERIOUS DAMAGE TO ANY VEHICLE FOLLOWING OR PERHAPS KILLED SOMEONE. I REPORTED IT TO THE DEALER, BUT THEY CLAIMED A ROCK HIT MY CAR. I DO NOT BELIEVE THIS IS TRUE. THE VIBRATIONS WERE GETTING WORSE AND I HAD DECIDED TO RETURN TO THE DEALER AND HAVE THE DEFLECTOR REMOVED. I WAITED TOO LONG, HOWEVER, AND THE DEFLECTOR FLEW OFF. THE DEFECTOR PART NUMBER IS 00239-F2000. MY CONCERN IS NOT FINANCIAL, SINCE MY LOSS WAS ONLY $66.13. WHAT DOES CONCERN ME IS THAT FUTURE FAILURES OF THE DEFLECTORS COULD CAUSE GREAT BODILY HARM AND PROPERTY DAMAGE. THE AUTO DEALER DOES NOT APPEAR TO BE CONCERNED. *TR