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.
CERTAIN PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 301, "FUEL SYSTEM INTEGRITY" A VALVE ON THE FUEL TANK ASSEMBLY MAY NOT CLOSE PROPERLY. IF A VEHICLE ROLLS OVER AND THE FUEL TANK ASSEMBLY VALVE IS NOT PROPERLY CLOSED, FUEL SPILLAGE MAY OCCUR.
Safety risk
FUEL SPILLAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
Manufacturer remedy
DEALERS WILL INSTALL AN ADDITIONAL FUEL TANK ASSEMBLY VALVE. THE RECALL BEGAN ON OCTOBER 5, 2004. OWNERS SHOULD CONTACT HYUNDAI DE PUERTO RICO AT 1-800-981-0188.
SOME PASSENGER VEHICLES CONTAIN A FUEL TANK ASSEMBLY VALVE THAT MAY NOT CLOSE PROPERLY. IF A VEHICLE WITH A FUEL TANK ASSEMBLY VALVE THAT IS NOT PROPERLY CLOSED WERE TO ROLL OVER, FUEL SPILLAGE MAY OCCUR.
Safety risk
FUEL SPILLAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
Manufacturer remedy
DEALERS WILL INSTALL AN ADDITIONAL FUEL TANK ASSEMBLY VALVE. OWNER NOTIFICATION BEGAN ON JUNE 30, 2004. OWNERS SHOULD CONTACT HYUNDAI 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
Air bags
9
77,652 mi
Suspension
6
64,784 mi
Vehicle speed control
6
46,000 mi
Engine and engine cooling: engine
5
71,000 mi
Fuel system, gasoline
4
74,000 mi
Air bags: side/window
3
67,563 mi
Engine
3
106,600 mi
Engine and engine cooling
3
40,000 mi
Power train: automatic transmission
3
—
Air bags: frontal
2
67,563 mi
Air bags: frontal: sensor/control module
2
40,000 mi
Electrical system
2
106,600 mi
Fuel/propulsion system
2
122,554 mi
Power train
2
20,000 mi
Service brakes, hydraulic
2
38,000 mi
Structure: frame and members: underbody shields
2
—
Suspension: rear
2
—
Back over prevention: warnings: external/pedestrian alert
1
—
Electrical system: instrument cluster/panel
1
55,000 mi
Electrical system: 12V/24V/48V battery
1
82,000 mi
Electrical system: alternator/generator/regulator
1
82,000 mi
Electrical system: wiring
1
38,000 mi
Equipment: appliance: air conditioner
1
—
Exterior lighting: headlights
1
77,652 mi
Fuel system, gasoline: storage
1
—
Fuel system, other: storage: tank assembly: pressure relief devices
1
55,386 mi
Power train: axle assembly
1
30,250 mi
Seat belts: rear/other
1
57,000 mi
Service brakes
1
—
Service brakes, hydraulic: antilock/traction control/electronic limited slip
1
—
Service brakes, hydraulic: foundation components: disc: rotor
1
17,000 mi
Steering
1
30,000 mi
Structure
1
64,784 mi
Structure: frame and members
1
—
Suspension: front
1
245 mi
Suspension: front: control arm: lower ball joint
1
68,000 mi
Suspension: rear: shock absorber
1
50,000 mi
Tires
1
—
Unknown or other
1
—
Visibility: rearview mirrors/devices: interior
1
77,652 mi
Visibility: sun/moon roof assembly
1
—
The 2001 model has 27 times as many complaints as this one. The 2003 model has 3 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.