2003 Hyundai Sonata Body & Structure Problems

While making a right turn at about 25 mph, your car made a loud noise and shook violently. When inspected, the sub frame (a structural support underneath your vehicle) was found to be cracked due to rust and corrosion. This type of failure can affect your car's stability and handling. Fixing this would require replacing or welding the sub frame.

Your front sub-frame (a structural support component under the front of your car) is corroded due to a safety recall. The dealer inspected it and said the corrosion is too severe to repair, but they're refusing to replace the part as required by the recall. This leaves your vehicle's structural integrity compromised.

You noticed heavy rust on your car's subframe during a self-inspection at around 69,425 miles. The subframe is a critical structural component that supports your vehicle's suspension and engine, and severe rust can weaken its integrity over time. You haven't had a mechanic officially diagnose this, and the dealership hasn't offered any assistance. Addressing this would likely involve having a mechanic evaluate the rust damage and potentially treating it with rust prevention or replacing affected sections if the damage is severe.

Your car's right front sub-frame is experiencing internal rust and corrosion that has caused the steel to thin and develop holes. You may notice unusual noises, tire misalignment, and steering pulling to one side — signs that the lower control arm mounting point is weakening and potentially detaching from the sub-frame. The vehicle was purchased new in Nebraska and has been exposed to road salt its entire life, similar to other salt-heavy states. Fixing this issue will likely require inspection and replacement of the corroded sub-frame and associated suspension components.

REPEATED USE OF THE INTERIOR DOOR HANDLE MAY CAUSE WEAR OF THE CHROME PLATE. IF THE TOP EDGE OF THE HANDLE HAS VERY THIN CHROME PLATING, THAT PORTION OF THE PLATING MAY WEAR AWAY MORE EASILY THAN MORE THICKLY PLATED AREAS AS THE DOOR HANDLE IS USED. THE WORN CHROME PLATING ON THE UPPER EDGE OF THE HANDLE MAY RESULT IN A CRACK OR SEPARATION BETWEEN THE CHROME PLATING ON THE INBOARD AND OUTBOARD SURFACES OF THE HANDLE, WHICH MAY FORM A SHARP EDGE. CONSEQUENCE: THIS MAY INFLICT LACERATION INJURIES TO ANYONE USING THE DOOR HANDLE. BASICALLY WHEN YOU GO TO USE THE INSIDE DOOR HANDLES THE PEELING CHROME IS SHARP AND CUTS YOUR FINGERS. HYUNDAI RECALL #93 ENDED IN MARCH 2003, MY CAR WAS MANUFACTURED IN MAY 2003. THE PROBLEM IS IDENTICAL TO THE MODELS IN RECALL #93.

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. WHEN THE VEHICLE WAS TAKEN TO BE INSPECTED, THE INSPECTOR OBSERVED 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 UNKNOWN.

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT THE FOUR INTERIOR DOOR CHROME HANDLES EXHIBITED EXTREMELY SHARP EDGES. THE CONTACT SUFFERED FROM A TWO INCH LACERATION TO BOTH FINGERS ON THE LEFT HAND. THE FRONT DRIVER AND PASSENGER UPPER DOOR HANDLES CAUSED THE INJURIES. THE CONTACT APPLIED TAPE TO THE FOUR DOOR HANDLES TO AVOID ADDITIONAL INJURIES. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V171000 (LATCHES/LOCKS/LINKAGES). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 95,000.

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING AT 50 MPH, THE VEHICLE VEERED TO THE LEFT AND RIGHT INDEPENDENTLY. THE FAILURE OCCURRED INTERMITTENTLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE SUBFRAME NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 80,000.

IN 2005, I PURCHASED A 2003 HYUNDAI SONATA. AFTER PURCHASING MY CAR, I FOUND OUT THAT IT HAD A RECALL ON THE FUEL VALVE THAT THE COMPANY HAD TO RE-INSTALL. THIS RECALL INFORMATION WAS NOT ON MY CARFAX REPORT. LATER, THE MANUFACTURER HAD A RECALL ON INTERIOR DOOR HANDLES THAT PEELED AND CUT HANDS. THEIR SOLUTION WAS TO WRAP MY HANDLES WITH ELECTRICAL TAPE; AFTER MY OBJECTION, THEY INSTALLED THE SAME RECALLED HANDLES. I'VE HAD MY INTERIOR HANDLES REPLACED THREE TIMES BECAUSE THE MANUFACTURER DIDN'T MAKE THE HANDLES OUT OF A DIFFERENT MATERIAL AND CHOOSES TO REINSTALL THE SAME RECALLED HANDLE. ON NOVEMBER 22ND, I WENT TO CAPITOL HYUNDAI TO HAVE THEM REPLACE THE RECALLED FUEL VALVE, AND INTERIOR DOOR HANDLES ON MY 2003 HYUNDAI SONATA. A SERVICE REP INFORMED ME THAT ONCE THE COMPANY REPLACES ANY RECALLED ITEMS THE FIRST TIME, IT IS THE CUSTOMER'S RESPONSIBILITY TO PAY FOR THEM IF THEY FAIL AGAIN. SURELY, THIS CANNOT BE CORRECT! RECALLS DO NOT EXPIRE AND AS LONG AS THE OWNER HAS THE VEHICLE, THE MANUFACTURER/DEALERSHIP SHOULD BE RESPONSIBLE IF THEIR MATERIALS ARE CONTINUOUSLY FAILING TO MEET SAFETY REQUIREMENTS. WHAT ARE FOLKS MAKING PAYMENTS OR CAN'T AFFORD ANOTHER VEHICLE NOW SUPPOSED TO DO? DRIVE AROUND IN A DANGEROUS VEHICLE? BE IT 1 TIME OR 1 MILLION TIMES, I WANT CAPITOL HYUNDAI TO INDEFINITELY HONOR THEIR RECALLS--AT THEIR EXPENSE. *TR

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT THE CHROME COVERING ON THE INTERIOR DOOR HANDLE WAS CORRODED AND CRACKED, WHICH CREATED SHARP EDGES ON THE HANDLE. WHEN USING THE DOOR HANDLE TO EXIT THE VEHICLE, THE CONTACT EXPERIENCED SCRATCHES AND SMALL LACERATIONS DUE TO THE SHARP EDGES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER STATED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V317000 (LATCHES/LOCKS/LINKAGES). THE FAILURE MILEAGE WAS 105,000.

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE INSPECTING THE VEHICLE, THE FRONT WHEELS APPEARED TO BE ANGLED INWARD. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DISCOVERED THAT THE FRONT PASSENGER SIDE OF THE ENGINE CRADLE WAS RUSTED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 131,000.

PASSENGER SIDE CRADLE RUSTED THROUGH. DRIVER SIDE IS FINE. RECALL # 089. *TR

CHROME ON INTERIOR DOOR HANDLES PEELS AND CREATES LACERATION HAZARD. THE MANUFACTURER ISSUED A RECALL TO REPLACE AFFECTED HANDLES BECAUSE OF A STATED LACERATION HAZARD. THE DEALER REPLACED HANDLES UNDER THE RECALL. HOWEVER, THE REPLACEMENT HANDLES ARE NOT AN IMPROVED PRODUCT AND THE CHROME PEELS LIKE THE ORIGINALS. THE DEALER ONLY ALLOWS ONE REPLACEMENT UNDER THE RECALL, WHICH CREATES A CONTINUING HAZARD TO THE OWNER AND PASSENGERS. *TR

BOUGHT CAR USED FROM LOT...CHROME PLATING ON HANDLES PEELING AND CUT YOU IF YOUR NOT CAREFUL. JUST FOUND OUT THERE WAS A RECALL FOR THIS BEFORE I PURCHASED THE CAR. IS THERE ANYTHING I CAN DO? *TR

THE INTERIOR DOOR HANDLES OF MY 2003 HYUNDAI SONATA WENT UNDER A RECALL IN JULY 2009 BECAUSE THE CHROME PLATING WAS SPLITTING OPEN AND CUTTING PEOPLE. THREE DOOR HANDLES WERE REPLACED AND ONE WAS REWRAPPED TO FIX THE PROBLEM. IN SEPTEMBER 2013 THE SAME ISSUE AROSE WHEN MY WIFE AND BROTHER-IN-LAW CUT THEIR HANDS ON THE DOOR HANDLES, WHOSE CHROME PLATING HAS AGAIN BEGUN TO SPLIT. HYUNDAI HAS SAID THAT NO REPAIRS WILL BE MADE, SINCE THE HANDLES WERE TREATED AND THE 2009 RECALL HAS FINISHED. *TR

THE CHROME ON THE INTERIOR DOOR HANDLE OF DRIVER SIDE EXHIBITED A CRACK AND SEPARATED. MY WIFE CUT HER FINGER ON THE CRACKED CHROME PLATING. I CONTACTED HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151 AND WAS TOLD THAT MY VEHICLE WAS NOT INCLUDED IN THE DOOR HANDLE RECALL (I.E., NHTSA CAMPAIGN ID NUMBER: 09V171000). I DON'T UNDERSTAND HOW ONE VEHICLE CAN BE RECALLED WHILE OTHERS OF THE SAME YEAR AND MODEL ARE NOT. *TR

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 50 MPH, HE HEARD A LOUD, ABNORMAL NOISE. THE CONTACT PULLED OVER AND INSPECTED THE VEHICLE WHEN HE NOTICED THAT THE SUB FRAME WAS FRACTURED. THE VEHICLE WAS LATER TOWED TO AN INDEPENDENT MECHANIC WHERE THEY CONFIRMED THAT THE FRONT SUB FRAME WAS FRACTURED AND ALSO ADVISED THAT IT NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 160,000.

VEHICLE HAD BEEN RECALLED IN 2009 (PE08071) DUE TO DEFECTIVE CHROME ON DOOR HANDLES. THIS VEHICLE HAD BEEN TAKEN TO DEALERSHIP, CHROME WAS REPAIRED AS IT HAD CAUSED A SMALL LACERATION. CHROME IS AGAIN DEFECTIVE, CAUSED LACERATION ON HAND AGAIN TODAY WHEN ATTEMPTED TO OPEN DOOR. THIS OCCURRED ON THE PASSENGER SIDE DOOR WHICH IS VERY RARELY USED. CHROME IS ALSO PEELING OFF OF EMERGENCY BRAKE HANDLE, RISKING FURTHER LACERATION. CONTACTED DEALERSHIP (GO HYUNDAI - 104TH & FEDERAL, WESTMINSTER, CO), DEALERSHIP SAID THIS IS NO LONGER COVERED AS THEY DO NOT WARRANTY THE WORK DONE AS PART OF A RECALL. IN ADDITION, CAR IS TOO OLD FOR IT TO BE COVERED UNDER WARRANTY. CAR DOES CONTINUE TO BE COVERED UNDER WARRANTY FOR POWERTRAIN ONLY. I HAVE NEVER EXPERIENCED THIS TYPE OF PROBLEM ON ANY MODEL OF CAR REGARDLESS OF AGE. THIS APPEARS TO BE UNIQUE TO HYUNDAI. *JS

I TOOK MY CAR IN TO HAVE A FAULTY DOOR HANDLE REPLACED WHICH I CUT MY HAND ON. IT HAD ALREADY BEEN REPLACED ONCE DURING A RECALL. OBVIOUSLY THE SAME FAULTY PART WAS PUT ON AGAIN. I WAS ADVISED THAT I WOULD HAVE TO PAY $125.00 FOR A NEW HANDLE BECAUSE THEY ONLY PERFORM A RECALL ONCE. I THOUGHT THAT RECALL PARTS WERE REPLACED WITH DIFFERENT PARTS THAT ARE NOT FAULTY AND THE PARTS WERE GUARANTEED. I SHOULD NOT HAVE TO PAY FOR THIS SERVICE DUE TO ANOTHER FAULTY HANDLE THAT THEY REPLACED. I NEVER EXPECT TO OPEN MY CAR DOOR AND CUT MY HAND NOR SHOULD I HAVE TO WRAP MY DOOR HANDLE AS THEY SUGGESTED. I AM SO UPSET OVER THIS AND WILL NEVER PURCHASE ANOTHER HYUNDAI AND EVEN HAVE MY CAR SERVICED THERE AGAIN. ALL I AM ASKING IS FOR HYUNDAI TO TAKE RESPONSIBILITY AND REPLACE THIS HANDLE WITH ONE THAT WILL NOT CHIP. *JS

NHTSA ACTION # EA08016 MY 2003 SONATA WHICH WAS PURCHASED IN NY OPERATED THERE UNTIL 06/2008 WAS NOT RECALLED UNDER THE ABOVE ACTION #. I FEEL THIS IS A MISTAKE AS THIS CAR IS SHOWING SYMPTOMS DESCRIBED IN THE RECALL # 09V124000. I CALLED HYUNDAI AMERICA WITH NEGATIVE RESULTS. *KB

CHROME ON INTERIOR - DRIVERS SIDE DOOR HANDLE HAS ERUPTED IN ONE SPOT PRODUCING A PIERCING SHARP NEEDLE-POINT WHICH CAN PIERCE THE FINGER OR HAND WHEN OPENING THE DOOR. CARE IS REQUIRED TO AVOID SKIN PIERCING INJURY. *KB

I HAVE A 2003 HYUNDAI SONATA. THE CHROME PLATES ON INTERIOR DOOR HANDLE OF DRIVER AND PASSENGER SIDE EXHIBITED A CRACK AND BEGAN TO SEPARATE. MY WIFE AND I HAVE BOTH CUT OUR FINGERS ON THE CRACKED CHROME PLATE. WHEN I BROUGHT MY VEHICLE TO THE DEALER, SERVICE MANAGER TOLD ME THAT MY VEHICLE WAS NOT INCLUDED IN THE DOOR HANDLE RECALL. HYUNDAI RECALL ONLY VEHICLE PRODUCE IN 2002- 2003 MARCH, BUT MY VEHICLE WAS PRODUCE IN 2003 APRIL. I DON'T UNDERSTAND HOW ONE VEHICLE WITH A PROBLEM CAN BE RECALLED, AND THE OTHER IN SAME YEAR AND MODEL WITH SAME PROBLEM IS NOT INCLUDED. *TR

MY WIFE AND I HAVE BOTH CUT OUR HANDS ON THE CHROME INSIDE DOOR HANDLES OF OUR 2003 HYUNDAI SONATA. WHEN I QUESTIONED THE DEALER , LAFONTAINE AUTOMOTIVE GROUP , IN DEARBORN,MI. I WAS TOLD THAT MY VEHICLE WAS NOT INCLUDED IN THE DOOR HANDLE RECALL. I DON'T UNDERSTAND HOW ONE VEHICLE WITH A PROBLEM CAN BE RECALLED, AND ANOTHER WITH OF THE SAME YEAR AND MODEL IS NOT INCLUDED. PLEASE EXPLAIN TO ME. I HAVE PICTURES THAT I WILL TRY TO SEND TO THE WEB SITE, IF I CAN'T I DO HAVE THEM FOR FUTURE REFERENCE. *TR

RUST AND BUBBLING PAINT AROUND FUEL DOOR, INSIDE FUEL DOOR AND BOTH REAR WHEEL WELLS ON A 2003 HYUNDAI SONATA WITH 88,483 MILES. *TR

PROBLEMS DUE TO RUST. SERVICE AT COLUMBIA HYUNDAI ON 8/4/08 TO REPLACE POWER STEERING LINE AFTER POWER STEERING FAILED DUE TO LINE RUSTING OUT. *TR

PROBLEMS DUE TO RUST. STATEMENT FROM KEY HYUNDAI SERVICE ON 12/11/06 INDICATES EXCESSIVE RUST CAUSED REAR BRAKE PADS TO STICK AND WEAR DOWN PREMATURELY. I HAD TO PAY TO HAVE THEM REPLACED. *TR

TWO OF THE INSIDE DOOR HANDLES HAVE A SILVER METALLIC FOIL THAT HAS SPLIT AND COME LOOSE. MY SON CUT HIS FINGER OPENING THE DOOR. NOW THE DRIVER DOOR INSIDE HANDLE ALSO HAS THE SILVER FOIL COMING LOOSE. WE HAVE HAD TO PUT TAPE ON IT TO PREVENT GETTING ANOTHER CUT FINGER. *TR

I TOOK MY 2003 HYUNDAI SONATA IN FOR A ROUTINE INSPECTION AND FOUND OUT THAT THE ENGINE CRADLE HAD RUSTED THROUGH AND WAS NO LONGER DRIVABLE. THE ENGINE CRADLE HAD TO BE REPLACED, WHICH IS NO SMALL FEAT ON THIS VEHICLE. I HAVE READ SEVERAL OTHER COMPLAINTS OF THIS AND KNOW IT'S UNDER INVESTIGATION, BUT WANTED TO LOG MY COMPLAINT AS WELL. *TR

WITHIN ONE YEAR OF BUYING MY HYUNDAI 2003 SONNTA, I CUT MY FINGER ON THE SILVER COATED INSIDE DOOR HANDLE ON THE DRIVER SIDE. THE SILVER COATING OF THE DOOR HANDLE SOMEHOW SPLINTERED AND CUT MY FINGER LIKE A STRAIGHT RAZOR BLADE. THE CUT WAS VERY DEEP AND MY FINGER BLED PROFUSELY FOR ABOUT 10 OR 15 MINUTES. I CONTACTED THE DEALER AND THE HANDLE WAS REPLACED. A SHORT TIME AFTER, MY HUSBAND SLICED HIS FINGER ON THE PASSENGER SIDE INSIDE DOOR HANDLE. AGAIN THE CUT WAS VERY DEEP; IT WAS LIKE A STRAIGHT RAZOR CUT. HIS FINGER BLED PROFUSELY FOR 10 - 15 MINUTES. AGAIN THE DEALER REPLACED THE HANDLE. BACK IN NOVEMBER OF 2007, SOMEONE WAS GETTING OUT OF THE BACK SEAT, AND THEN THIS PERSON CUT HER FINGER ON THE SILVER COATED INSIDE DOOR HANDLE. THIS TIME I CONTACTED HYUNDAI HEADQUARTERS AND TOLD THEM ABOUT THE PROBLEM..THE REP. I SPOKE TO SAID SHE DID NOT HEAR OF ANY SIMILIAR PROBLEMS. THEY CONTACTED THE CAR DEALER AND THE HANDLE WAS REPLACED. NOW A COUPLE OF WEEKS AGO, I CUT MY HAND ON THE PASSENGER DOOR HANDLE (THIS WAS A HANDLE THAT HAD PREVIOUSLY BEEN REPLACED). I CONTACTED HYUNDAI AGAIN AND AM AWAITING DISPOSITION ON THIS. THERE IS SOMETHING VERY WRONG WITH THESE DOOR HANDLES. THE CUT IT CAUSES IS LIKE A STRAIGHT RAZOR CUT. IT SLICES DEEP AND IT BLEEDS VERY BADLY. I TOLD HYUNDAI THAT I AM SURE I AM NOT THE ONLY PERSON TO EXPERIENCE THIS SERIOUS PROBLEM. IN FACT, I SEARCHED THE INTERNET AND FOUND THERE ARE OTHER PEOPLE THAT HAVE THE SAME PROBLEM WITH THESE DOOR HANDLES. THIS IS A VERY SERIOUS PROBLEM THAT I THINK THE GOV. NEEDS TO GET INVOLVED WITH. THANK YOU MARIA FACCHIN THANK YOU MARIA FACCHIN *TR

CUT FINGERS ON SHARP CHROME LAMINATION ON DOOR HANDLES. *TR

DRIVER DOOR ALARM KEEPS ALARMING. I TOOK IT IN TO THE DEALER ONCE ALREADY TO BE REPAIRED. THE SERVICE MANAGER AT THIS TIME TOLD ME THAT ON THIS MODEL THE DOOR NEEDS TO BE TIGHTENED/ADJUSTED. NOW 2 MONTHS LATER THE SAME THING IS HAPPENING ONLY WORSE. NOW THE DOOR LIGHT IS COMING ON AND THE LIGHT ON THE DASH BOARD IS COMING ON. MAYBE THE DOOR IS DEFECTIVE AND GOING TO FALL OFF. *NM