Model year record

2004 Hyundai Sonata

1 recall campaign on file for this model year. 296 owner complaints on file.

Recalls

Recall campaignNHTSA 09V124000

Suspension

Component: Suspension
Manufacturer: Hyundai Motor Company
Vehicles affected: 188,282
Reported to NHTSA: 2009-04-16
Owners notified: 2009-07-17

Defect description

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.

Safety risk

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.

Manufacturer remedy

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

A complaint is one person's report to a federal agency. It is not a finding.

Component	Complaints	Median mileage
Suspension	56	105,000 mi
Air bags	43	84,209 mi
Structure: body	22	95,000 mi
Unknown or other	15	61,991 mi
Electrical system	14	99,549 mi
Steering	14	131,000 mi
Structure	13	101,650 mi
Latches/locks/linkages	11	60,000 mi
Wheels	11	131,000 mi
Service brakes	7	98,000 mi
Structure: frame and members: underbody shields	7	75,000 mi
Engine	5	130,000 mi
Engine and engine cooling	5	85,000 mi
Exterior lighting	5	57,446 mi
Service brakes, hydraulic	5	19,000 mi
Vehicle speed control	5	30,000 mi
Fuel system, gasoline	4	76,177 mi
Power train	4	127,949 mi
Power train: clutch assembly	4	40,000 mi
Fuel/propulsion system	3	129,000 mi
Seat belts	3	65,440 mi
Structure: body: door	3	51,900 mi
Structure: frame and members	3	90,000 mi
Tires	3	22,000 mi
Wheels: hub	3	50,515 mi
Air bags: frontal	2	15,420 mi
Latches/locks/linkages: doors: latch	2	34,000 mi
Power train: automatic transmission	2	22,000 mi
Service brakes, hydraulic: antilock/traction control/electronic limited slip	2	—
Air bags: side/window	1	—
Electrical system: horn	1	12,000 mi
Electrical system: wiring	1	53,700 mi
Electrical system: wiring: interior/under dash	1	98,000 mi
Equipment	1	110,865 mi
Equipment: appliance: air conditioner	1	39,000 mi
Fuel system, gasoline: delivery: hoses, lines/piping, and fittings	1	3,200 mi
Seat belts: front: buckle assembly	1	—
Seats	1	110,865 mi
Seats: mid/rear assembly	1	44,990 mi
Service brakes, air: supply: hoses, lines/piping, and fittings	1	122,000 mi
Service brakes, hydraulic: foundation components: disc: rotor	1	12,384 mi
Suspension: front	1	95 mi
Suspension: front: control arm	1	65,000 mi
Suspension: front: wheel bearing	1	—
Visibility: defroster/defogger/hvac system	1	70,000 mi
Visibility: rearview mirrors/devices: exterior	1	—
Visibility: sun/moon roof assembly	1	130,000 mi
Visibility: windshield	1	115,000 mi
Wheels: rim	1	—

The 2003 model has roughly the same number of complaints as this one. The 2005 model has about 1.5 times as many complaints as this one. These figures reflect raw complaint counts, not failure rates. Higher-selling model years naturally receive more complaints.

Safety recall repairs are provided free of charge by franchised dealers, regardless of vehicle age or mileage. This page displays aggregated data for the model year. To check recall status for a specific vehicle, search its VIN at nhtsa.gov.