2005 Hyundai Sonata Suspension Problems

Your car's front subframe has severe rust and corrosion that you recently discovered. Your 2005 model year is the only year in your generation that wasn't recalled for this exact problem, despite living in a salt-prone region. If left unrepaired, the corroded subframe could fail and cause the engine to drop or other serious structural damage. Fixing this will likely require replacing the entire front subframe, which is a major repair.

Your car's subframe has severe rust that has eaten through most of the metal, creating a serious safety hazard. If the subframe breaks while you're driving, you could lose control of the vehicle. Your mechanic recommends immediate inspection and likely replacement of the rusted subframe components.

Your front sub-frame has rusted through and broke while driving, creating a serious safety hazard. Similar defects in earlier model years (1999-2004) were addressed in a class action lawsuit, but your 2005 model was excluded. Hyundai has offered only a one-time extended warranty repair, and you've been asked to pay approximately $2,000 for the fix. The repair will likely involve replacing the rusted sub-frame component that supports your vehicle's front suspension.

While performing routine maintenance, you discovered severe rust and corrosion on the front subframe on the right side of your vehicle, with damage both in front of and behind the lower control arm. The corrosion appears extensive enough that the subframe could fail, potentially allowing the control arm to move freely and causing you to lose control of the car. This is a serious safety issue, especially since older Sonata model years (2001-2004) had a recall for the same subframe corrosion problem. Addressing this will likely require professional inspection and replacement of the corroded subframe sections.

Your car's engine subframe has rusted through, and you've had difficulty getting a replacement part that fits correctly. You've already paid a mechanic $600 for a replacement part, but multiple OEM parts ordered have been too large or otherwise incompatible with your vehicle. A properly fitted subframe is important for vehicle safety and structural integrity.

Your car's subframe (the metal frame that supports the suspension) cracked after hitting a pothole at 45 mph. Multiple mechanics confirmed the crack was caused by severe salt corrosion eating away at the metal. Even though 2003 and 2004 models with the same part have been recalled for this exact rust problem, your 2005 Sonata has not been recalled despite having the same component and vulnerability.

You discovered that the front subframe cradle on the right side of your vehicle has rusted through almost completely. Hyundai issued a technical service advisory (TSA) for this same issue on model years before and after yours, but your vehicle was excluded from that advisory. This corrosion could compromise your vehicle's structural integrity and suspension support. Addressing this will likely require replacement of the corroded subframe cradle and any related suspension components.

Your Sonata's sub-frame (the structural component that supports the suspension) is severely rusted, which was discovered during a state inspection. You contacted Hyundai about a potential suspension recall, but the manufacturer determined your vehicle's VIN wasn't covered by that recall. This rust could eventually compromise the structural integrity and safety of your suspension system, potentially requiring sub-frame repair or replacement.

During a tire alignment service, your mechanic discovered that the front subframe has internal rust. While there were no visible warning signs before this discovery, this type of rust could potentially compromise the structural integrity of the suspension, which might affect your ability to control the vehicle safely.

Your car's front and rear subframes (the metal frames that support the suspension) have developed rust holes, which is causing damage to connected parts like ball joints and tie rod ends. This can affect your car's handling and steering stability. Fixing this will likely require replacing the rusted subframe sections and any damaged suspension components.

Your engine cradle or subframe has developed rust holes, which is unusual for a well-maintained car with only 39,900 miles. The dealer refused to cover repairs under warranty and said you'd need to pay for the work yourself. The repair will likely involve replacing or welding the damaged subframe component.

Your car's front subframe has developed severe rust throughout. This is the structural component that supports your front suspension and engine. While no crash or fire has occurred, severe rust can compromise the structural integrity of this critical component. Addressing this will likely require professional inspection and possible subframe replacement or rust repair treatment.

THE ENGINE CRADLE AND BOTH REAR UPPER STRUT MOUNTS ARE CORRODED TO THE POINT THAT THE CAR IS UNSAFE TO DRIVE AND PRESENTS A SAFETY HAZARD TO ITS DRIVER, OCCUPANTS, AND OTHERS ON THE ROAD. IT WILL NOT PASS THE ANNUAL PENNSYLVANIA SAFETY INSPECTION. THE MECHANIC SHOWED ME (THE OWNER) AT LEAST ONE LARGE HOLE IN THE CRADLE (SILVER-DOLLAR SIZED) AS WELL AS LONG THREE-FINGER WIDE HOLES IN THE UPPER REAR STRUT MOUNTS. (THIS IS SIMILAR TO A PROBLEM THAT I ENCOUNTERED IN 2010 IN MY HYUNDAI ELANTRA (REAR SUSPENSION ONLY IN THAT CAR), REPORTED TO THE NTHSB AND SUBSEQUENTLY RECTIFIED BY HYUNDAI USA.) MOREOVER, THIS IS SIMILAR TO PROBLEMS CITED IN ROBERT D'ELIA V. HYUNDAI MOTOR COMPANY AND HYUNDAI MOTOR AMERICA AND RECTIFIED IN A SUBSEQUENT SETTLEMENT AND RECALL. THIS CONCERNS A CAR WITH 100XXX MILES ON THE ODOMETER. CAR WAS UNDERCOATED BY DEALERSHIP AT POS. DRIVEN EXCLUSIVELY IN A SALT-BELT STATE. N.B. - THE 2004 HYUNDAI SONATA SUB-FRAME IS IDENTICAL TO THE 2002 - 2004 SUBFRAMES.

I TOOK MY CAR TO MY MECHANIC TO CHANGE OIL ON 1/9/2018 AND HE DISCOVERED A BIG HOLE (BIGGER THAN THE FIST-SIZE) ON THE RIGHT FRONT OF THE SUBFRAME UNDERNEATH THE CAR DUE TO RUSTING AND SEVERE CORROSION (PLEASE SEE THE ATTACHED PICTURE FOR MORE DETAILS). THE MECHANIC TOLD ME THAT THIS IS A SERIOUS SAFETY ISSUE, WHICH IS NOT SUPPOSED TO HAPPEN. HE STRONGLY RECOMMENDED ME TO GO TO THE DEALER AND HAVE THIS FIXED AS SOON AS POSSIBLE. RIGHT AFTER THAT, I CALLED HYUNDAI CUSTOMER SERVICE AND THEY TOLD ME THAT MY CAR DOESN'T HAVE A WARRANTY AND IT IS NOT UNDER RECALL BASED ON THE VIN, SO THEY WILL NOT DO ANYTHING ABOUT IT. I GOT THE SAME ANSWER FROM THE DEALER AT HYUNDAI DAVIS IN NJ. I SEARCHED ONLINE AND FOUND 2 RECALLS ISSUED BY HYUNDAI FOR THE SAME PROBLEM. ONE STARTED IN 2009 WITH THE NHTSA RECALL ID # 09V124000 (INCLUDING 1999-2004 HYUNDAI SONATA) AND ANOTHER ONE IN 2013 WITH NHTSA CAMPAIGN # 13V354000 (INCLUDING 2006-2010 SONATA). HOWEVER, HYUNDAI CUSTOMER SERVICES CAN'T PROVIDE ANY EXPLANATIONS WHY 2005 SONATA IS NOT INCLUDED IN THE TWO RECALLS. ACCORDING TO THE NEWS ONLINE, 'THE RECALL, LIMITED TO AMERICA'S SO-CALLED "SALT BELT" STATES, IS CENTERED AROUND POTENTIALLY EXCESSIVE CORROSION OF THE FRONT SUB-FRAME DUE TO WINTER ROAD SALT APPLICATIONS. IF UNNOTICED, THE LOWER CONTROL ARM MAY SEPARATE FROM ITS MOUNT.' 'ROAD SALT AND WATER CAN ENTER PORTIONS OF THE REAR CROSSMEMBER, LEADING TO CORROSION OF THE CROSSMEMBER STEEL. THIS MAY LEAD TO DETACHMENT OF ONE OF THE REAR CONTROL ARMS. CONTROL ARM SEPARATION MAY SUDDENLY CHANGE THE REAR WHEEL ALIGNMENT, AFFECTING THE HANDLING OF THE VEHICLE, INCREASING THE RISK OF A CRASH.' IT IS NOT SAFE FOR ME TO DRIVE THE CAR, HOWEVER, CURRENTLY, I STILL HAVE TO DRIVE THE CAR ON HIGHWAY TO WORK ON A DAILY BASIS SINCE THIS IS THE ONLY CAR I HAVE.

TAKATA RECALL SUBFRAME IS ROTTED. MECHANIC ADVISED NOT TO DRIVE IT AS IT IS VERY UNSAFE. CAR HAS LESS THAN 60,000 MILES ON IT

FRONT CRADLE RUST OUT UNSAFE WILL NOT PASS INSPECTION. THE 2004S WERE RECALLED BUT NOT THE 2005S.

DIRECT REPLY - LETTER FROM SENATOR BROWN INQUIRY ON BEHALF OF CONSTITUENT REGARDING HYUNDAI RECALL. *SMD 2005 HYUNDAI SONATA. THE CONSUMER STATED DURING A MAINTENANCE CHECK, THE MECHANIC FOUND THE SUB-FRAME UNDER THE FRONT END OF THE VEHICLE KNOWN AS THE ENGINE CRADLE WAS BADLY CORRODED TO THE EXTENT THAT SIGNIFICANT METAL IN THE SUB-FRAME WAS GONE; PERHAPS MORE THAN 50% GONE AT ON E LOCATION. APPARENTLY, THERE WAS NO RECALL FOR THE CONSUMERS MODEL YEAR. HOWEVER, A RECALL WAS ISSUED FOR OTHER YEARS. THE CONSUMER REFERENCED RECALL # 09V124000. *JB

LETTER FROM SENATOR PORTMAN ON BEHALF OF CONSTITUENT RE 2005 HYUNDAI SONATA SAFETY RECALL. *LD THE CONSUMER STATED FOR SEVERAL WEEKS, HIS DAUGHTER NOTICED SOME UNUSUAL VIBRATIONS AND NOISE WHILE DRIVING. AN INSPECTION REVEALED THE SUB-FRAME UNDER THE FRONT END ALSO CALLED THE CRADLE, WAS BADLY CORRODED TO THE EXTENT THAT SIGNIFICANT METAL IN THE SUB-FRAME WAS GONE;PERHAPS MORE THAN 50% GONE AT ONE LOCATION. THE CONSUMER WAS INFORMED A RECALL HAD BEEN ISSUED FOR THE VERY PROBLEM. HOWEVER, IT DIDN'T APPLY TO THE 2005 MODEL. HYUNDAI REFUSED TO COVER THE REPAIR, STATING THE MODEL WAS NOT COVERED. THE CONSUMER REFERENCED RECALL # 09V124000. *JB

BROUGHT TO GET OIL CHANGED, MECHANIC SHOWED ME THE ENGINE CARRIER WAS ABOUT TO FAIL. IT IS ALMOST RUSTED THRU 2004 HA RECALL BUT NOT 2005 ALSO WHEN IN PARK CAR ROLLS

I OWN A 2005 HYUNDAI SONATA GLS. WHILE DRIVING DOWN THE FREEWAY AT 70 MPH THE CAR SUDDENLY BECAME HARD TO CONTROL, AS IN IT STARTED PULLING EXTREMELY HARD TO THE RIGHT. I HAD TO DRIVE HOME WITH THE STEERING WHEEL COCKED TO THE LEFT IN ORDER TO GO STRAIGHT. I BROUGHT IT INTO THE SHOP THINKING IT NEEDED AN ALIGNMENT - BOTH FRONT TIRES WERE TILTED IN AT THE TOP - WHAT I FOUND OUT WAS THAT THE SUBFRAME WAS RUSTED IN HALF. IT SEEMS VERY SHADY TO ME THAT THERE IS A RECALL FOR THIS EXACT PROBLEM FOR PRETTY MUCH EVERY YEAR EXCEPT 2005. THIS IS THE SAME MODEL AS THE 2004 AND IT WAS MANUFACTURED THAT YEAR AS WELL. *ALSO, THE TRIM ON THE CAR, WHICH IS WHAT MAKES IT MORE EXPENSIVE, IS CONSTANTLY COMING OFF WHILE I'M DRIVING. THE SILVER TRIM AROUND THE PASSENGER WINDOW FLEW OFF ON THE TOLLWAY. THE DRIVER'S WINDOW TRIM CAME OFF DUE TO ICE - IT WAS REPLACED BY A BODY SHOP, BUT LATER FLEW OFF ON THE TOLLWAY AS WELL. THE TRIM ON ALL FOUR DOORS IS NOW BOLTED ON AS THAT KEPT FALLING OFF TOO. *ALSO, THERE IS SIGNIFICANT RUST RIGHT ABOVE THE TOP OF THE WINDSHIELD TO THE POINT THAT IT WILL SOON BE RAINING IN MY CAR.

FAILED INSPECTION IN PART DUE TO FRONT SUBFRAME RUST THROUGH. CALLED HYUNDAI AND SPOKE TO A CLAIMS REP. BY THE NAME OF MIKE EXT.631677. MIKE 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 115K MILES ON IT AND THE UNDERBODY IS ALWAYS WASHED DURING WINTER SEASONS. MIKE TOLD ME IT WASN'T UNDER WARRANTY, AND THAT HYUNDAI WOULD NOT BE ABLE TO DO ANYTHING FOR ME, TO CONTACT MY DEALERSHIP, MAYBE THEY WOULD DO SOMETHING. I HAVE A 1969 CAMARO AND THE SUBFRAME IS FINE. HOW IS IT THE A CAR 10 YEARS OLD HAS A BAD FRAME? HOPE YOU WILL BE ABLE TO HELP US.

I NOTICE THAT THERE IS A RECALL ON HYUNDAI SONATA'S FROM 2006 -2010 IN REGARDS TO RUST CONCERNS WITH REAR SUSPENSION. THIS WAS JUST DETECTED BY MY MECHANIC THAT THE ATTACHING POINT FOR THE CONTROL ARM HAS RUSTED AND BECAME SEPARATED FROM THE CROSSMEMBER. THE RESULT AND MY IMMEDIATE CONCERN WAS THE SUDDEN CHANGE IN VEHICLE HANDLING, A LOUD NOISE COMING FROM THE REAR TIRE WHEN I HIT A SMALL BUMP. I WAS WONDERING WHY THE 2005 SONATA ISN'T COVERED IN THIS RECALL?

ACCORDING TO MECHANIC THE UPPER CONTROL ARM REAR PASSENGER SIDE IS RUSTED AND DETACHED.

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING 10 MPH, THE FRONT DRIVER'S SIDE WHEEL PARTIALLY SEPARATED FROM THE SUSPENSION SYSTEM. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS WHERE IT WAS ADVISED THAT THE SUB FRAME WAS RUSTED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED AND MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 135,000. *TR