2004 Hyundai Sonata Body & Structure Problems

Your front subframe has developed a hole due to rust. You've discovered that Hyundai previously issued recalls for this exact problem on your model, but when you check for open recalls using your VIN, none appear. Multiple dealerships confirmed Hyundai had addressed this issue before, which is concerning since you're still experiencing it. Fixing this will likely require subframe inspection and rust repair or replacement.

During routine maintenance at a Hyundai dealer, severe rust and corrosion were discovered on your car's K-frame (a critical structural component that supports the suspension and steering). The dealer didn't repair it and the cause wasn't identified. Fixing this will likely require professional removal of the rusted K-frame and either restoration or replacement with a new one.

WORN REAR TIRES PROMPTED PURCHASE OF NEW TIRES. TIRE TECHNICIANS NOTED THAT THE FRAME WAS CRACKED AND THAT THE VEHICE IS UNSAFE TO DRIVE. BOTH REAR TIRES ARE IN JEOPARDY BUT THE REAR PASSENGER SIDE IS BY FAR THE WORSE. VEHICLE HAD BEEN MAKING ODD NOISES ESPECIALLY WHEN TURNING AND SOME VIBRATION AT SPWEDS OVER 40MPH. FORTUNATELY THE THE TIRES DIDN'T FALL OFF WHILE IN MOTION.

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE THE VEHICLE WAS UNDERGOING ROUTINE SERVICE, THE TECHNICIAN NOTICED THAT UNDERNEATH THE FRONT OF THE VEHICLE WAS SEVERE CORROSION AND PERFORATION THAT NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 143,000.

FRONT LOWER CONTROL ARM BROKE DUE TO RUST WHILE BEING DRIVEN. PULLED OFF THE ROAD AND CALLED TOW TRUCK. OPERATOR TOLD ME TO LOOK UP SONATA RECALLS BECAUSE IT LOOKED LIKE ONE. IT WAS RECALL # 09V124000. CALLED LOCAL DEALERSHIP 6 TIMES IN TWO DAYS ALWAYS GOING TO ANSWERING MACHINE. THIRD DAY DROVE TO DEALERSHIP. THEY TOLD ME TO BRING IT IN AND THEY WOULD LOOK AT IT. TOW GUY SAID EVERY TIME IT IT WAS MOVED MORE DAMAGE WOULD BE DONE. HE DIDN'T WANT THE RESPONSIBILITY. DEALERSHIP WOULDN'T PICK IT UP. TOW GUY CALLED ANOTHER DEALERSHIP AND HE BROUGHT IT THERE (8/20/16) FIVE DAYS AFTER THE BREAKDOWN. AFTER 5 DAYS SECOND DEALERSHIP SAID IT WAS A RECALL ITEM AND SAID TO CALL HYUNDAI AMERICA. BEGAN DISCUSSIONS WITH HYUNDAI AMERICA- MANY CALLS- AND AFTER OVER 60 DAYS THEY DECIDED IT WAS BETWEEN THE DEALERSHIP AND SOME OTHER DEPARTMENT OF HYUNDAI AMERICA AND THEY COULDN'T DO ANYTHING. DEALERSHIP GAVE ME ANOTHER # TO CALL BUT THAT # HAD NO KNOWLEDGE OF MY CASE. THE EXPENSE OF BEING WITHOUT THE CAR HAS BEEN QUITE DRAINING. CASE # WITH HYUNDAI AMERICA IS 9566309. I WOULD LIKE THE CAR COMPLETELY REPAIRED BUT CAN'T GET ANYONE TO DO ANYTHING. THANKS

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. UPON TAKING THE VEHICLE TO A MECHANIC FOR INSPECTION, IT WAS DIAGNOSED THAT THERE WAS INTERNAL CORROSION ON THE FRONT SUBFRAME AND THE SEAL WAS DETERIORATING. THE DEALER AND THE MANUFACTURER STATED THAT THERE WAS NO RECALL TO ADDRESS THE REPAIR. THE MANUFACTURER PROVIDED NO REPAIR SOLUTION. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 104,000.

PAINT IS FALLING OFF AROUND THE EXTERIOR DOOR HANDLES. PASSENGER SIDE DOOR IS RARELY USED AND THIS IS THE WORST SIDE OF IT. VEHICLES ARE SUPPOSED TO RECEIVE MULTIPLE COATS OF PAINT AT TIME OF MANUFACTURE IT APPEARS THAT THIS IS NOT THE CASE WITH MANY OF THE 2004 SONATA MODELS, I HAVE NOTICED MANY OF THE SAME MODEL CARS AROUND TOWN WITH PEELING PAINT AROUND THE DOOR HANDLES. THIS VEHICLE HAS BARELY OVER 100K MILES.

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE A FUEL LINE WAS BEING REPLACED ON THE VEHICLE, THE TECHNICIAN NOTICED A HOLE ON THE FRONT PASSENGER SIDE SUBFRAME. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE FAILURE MILEAGE WAS 112,000.

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THERE WAS PREMATURE RUSTING ON THE UNDERCARRIAGE AND SUBFRAME OF THE VEHICLE, WHICH PROGRESSED OVER TIME IN THE FRONT AND THE REAR. THE VEHICLE FAILED INSPECTION. THE MECHANIC FOUND HOLES, EXTENSIVE RUST, AND CORROSION TO THE POINT THAT THE FRAME COULD FRACTURE. THE FRAME NEEDED TO BE REPLACED DUE TO THE FAILURE. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS NOT AVAILABLE.

THE CHROME PLATING ON THE INTERIOR DOOR LATCHES IS PEELING OFF CAUSING PASSENGERS TO CUT THEIR HANDS/FINGERS WHEN OPENING THE DOOR. *JS

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE FRAME OF THE VEHICLE WAS CORRODED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE FRAME NEEDED TO BE REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 90,000.

WHEN HAVING MY CAR ALIGNED, A TECHNICIAN SHOWED ME THAT THE RIGHT FRONT SUBFRAME IS RUSTED THROUGH. SUPPOSEDLY HYUNDAI FIXED THIS 5 YEARS AGO, WITH ONE OF TWO FIXES: EITHER REPLACEMENT OR DRILLING DRAINAGE HOLES AND APPLY A RUST PROTECTOR. ONE CAN SEE A HOLE DRILLED ON THE LEFT SUBFRAME BUT NOT THE RIGHT SIDE. BESIDES MY CAR, ONE HAS TO ASK: DID HYUNDAI REALLY DO ANYTHING TO FIX THIS SITUATION OR DID THEY ACT LIKE THEY DID? A CAR RUSTING THROUGH THE FRAME IN FIVE YEARS IS UNHEARD OF, AND I FEAR OTHERS MIGHT HAVE THIS SAME PROBLEM. HYUNDAI DOES NOT WANT TO TALK TO ME. *TR

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE SUB FRAME WAS RUSTED ON THE PASSENGER'S SIDE. THE VEHICLE WAS TAKEN TO THE DEALER BUT WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 118,000. *TR

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT THE FRONT PASSENGER'S SIDE EXTERIOR DOOR HANDLE BECAME FRACTURED WHILE THE CONTACT ATTEMPTED TO ACCESS THE DOOR. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 83,954.

THIN COATING OF CHROME PEELED/BROKE OFF CAUSING RAZOR SHARP EDGE. MY HAND WAS LACERATED ON THIS HANDLE. *TR

TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT HE DISCOVERED INTERNAL CORROSION OF THE FRONT SUB-FRAME ON THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS BUT THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED BUT OFFERED NO ASSISTANCE. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 124,000.

THE CHROME ON THE INSIDE DOOR HANDLES ARE CRACKING & PEELING. I HAVE CUT MY FINGER TWICE NOW ON THE SHARP EDGES. ALSO, THE PAINT IS COMING OFF THE MOLDING AROUND THE OUTSIDE DOOR HANDLE ON THE REAR DRIVER SIDE. *TR *JS

+THE INTERIOR DOOR LEVERS CHROME IS PEELING OFF CAUSING THE LEVERS TO HAVE SHARP EDGES WHICH CUT YOUR FINGERS. *TR

THE INTERNAL FLOOR ON DRIVER SIDE SHOWS OBVIOUS EROSION FROM NORMAL SALT EXPOSURE IN THE WINTER. DEALER IGNORED MY COMPLAINT OF THE EROSION WHEN I WENT TO ADDRESS ANOTHER RECALL REGARDING SALT EROSION. ME AND A FAMILY MEMBER RECEIVED CUTS ON THE FINGER FROM PEELING COVERING ON INTERIOR DOOR HANDLE. PAINT NEAR EXTERIOR HANDLES SCRATCHES EASILY AND EVENTUALLY REVEALS THE COLOR OF THE SECOND LAYER OF PAINT WHICH IS A DRASTICALLY DIFFERENT COLOR FROM THE CAR'S EXTERIOR PAINT COLOR. *TR

INTERIOR CHROME DOOR HANDLE CRACK, CAUSING THE CHROME PLATING TO SEPARATE. AFTER SEPARATION THE HANDLE BECOMES EXTREMELY SHARP AND CUT MY HAND.

TL*THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE VEHICLE HAD WATER DAMAGED DUE TO A DEFECTIVE AIR CONDITIONING HOSE SEALANT THAT ALLOWED WATER TO PENETRATE WHICH CAUSED MILDEW TO FORM ON THE INTERIOR OF THE VEHICLE. THE DEALER STATED THAT THE INSTRUMENTAL PANEL WILL NEED TO BE REMOVED IN ORDER TO REPLACE THE DAMAGED WIRING AND SEALANT. THE CONTACT STATED THAT A YEAR AGO WATER PENETRATED THE INTERIOR OF THE VEHICLE DUE TO THE SEALANT AROUND THE BRAKE LIGHTS. THE VIN INFORMATION WASN'T AVAILABLE. THE MANUFACTURER WILL BE CONTACTED. THE FAILURE MILEAGE WAS 39,000 AND THE CURRENT MILEAGE WAS 69,000.

INTERIOR DOOR HANDLE CHROME PEELING OFF CAUSING SHARP METAL THAT CAN CUT FINGERS OR HANDS. *TR

INSIDE DOOR HANDLES THIN COVERING (APPEARS TO BE ALUMINUM) IS PEELING APART AND I HAVE CUT MY HAND ON THE SHARP EDGE WHICH CAME APART. DEALER WILL NOT REPLACE THE HANDLE BECAUSE HYUNDAI HAS NOT RECALLED THE 2004 MODELS WHICH HAS THE ***SAME PROBLEM**AS THE 2003 MODEL. *TR

CHROME IS PEELING OFF THE INTERIOR DOOR HANDLES CAUSING CUTS TO HANDS/FINGERS ON MY 2004 HYUNDAI SONATA. *TR

2004 HYUNDAI SONATA. BUILT IIN FEBRUARY 2004, THE CHROME PLATING OF THE INTERIOR DOOR HANDLE CAME LOOSE. OUR HANDS HAVE BEEN CUT SEVERAL TIMES BY THE SHARP EDGES OF THE CHROME THAT IS PEELING BACK. FINALLY HAD TO PEEL THE CHROME OFF AND SAND THE EDGES. *TR

RECALL ON 2004 HYUNDAI. I CALLED 5 DEALERS TO HAVE THEM INSPECT MY CAR, DUE TO THE RECALL I RECEIVED ABOUT POSSIBLE FRAME RUSTING. THE WAIT IS ANY WHERE FROM 10 DAYS TO A MONTH, JUST TO HAVE THEM LOOK AT THE FRAME. I EXPLAINED THAT MY CAR IS SHOWING THE SIGNS OF DAMAGED RUSTED FRAME. I REQUESTED THAT THEY EITHER. PAY FOR MY ROOM OR PAY FOR MY CAR RENTAL. *TR

RE: HYUNDAI '04 SONATA - BOUGHT NEW AT KEY HYUNDAI BRANFORD CT RECEIVED RECALL NOTICE RE RUSTING SUBFRAMES. ISSUES I'VE HAD OVER LAST 12 MONTHS: STEERING WHEEL PULLING TO ONE SIDE - ALIGNMENT WAY OFF - FIXED, PROBLEM RECURRED. INTERMITTENT NOISES COMING FROM ?WHEELS STEERING COLUMN, ESP.WHEN TURNING CORNERS - SEEMS TO BE TWO SEPARATE DISTINCT NOISES. RECENTLY STEERING WH. WITH RHYTHMIC SHIMMY, INTERMITTENT. TOOK CAR INTO KEY H.FOR INSPECTION - TOLD IT NEEDS NEW SUBFRAME (6 HR.JOB) BUT NO ALIGNMENT WILL BE DONE, NO LOANER OR RENTAL WOULD BE GIVEN. CALLED HYUNDAI CUST. CENTER. TOLD THAT AN ALIGNMENT, RENTAL "..WASN'T PART OF THE DEAL" THEY PUT THE ONUS ON NHTSA - SAYS YOU DIDN'T TELL THEM THEY HAD TO DO ANY MORE THAN REPLACE THE S.F. MY REGULAR MECHANIC SAYS THAT IT IS WORRISOME THAT NO ALIGNMENT WILL BE DONE. "HOW CAN THEY DO ALL THAT FRONT END WORK AND NOT REALIGN THE WHEELS?" REGARDING A REPLACEMENT VEHICLE FOR THE DAY, CONSIDERING THE SUBFR. HAS TURNED OUT TO BE MAJOR 'LEMON', YOU'D THINK AS A GESTURE OF GOOD WILL, HYUNDAI WOULD PAY ANOTHER $25 - 30 FOR A RENTAL. THEIR CUST. ASSIS. CENTRE IS A JOKE. THE GIRL HANDLING CALLS KNOWS NOTHING ABOUT MECHANICS, HAS NO AUTHORITY AND JUST KEEPS SAYING SHE'S SORRY BUT THIS IS NHTSA'S DEAL, NOT HYUNDAI. ANOTHER ISSUE- WITH THE S.F. RECALL NOTICE, I RECEIVED A 2ND NOTICE RE: CHROME HANDLES PEELING ON INSIDE DOOR. MINE PEELED THE FIRST YEAR I HAD THE CAR - ABRASION TO MY FINGER. I TAPED THE HANDLE AND DIDN'T COMPLAIN. THE SERVICE MANAGER LAST WEEK TOLD ME RECALL GOES TO '03 MODELS (WHY DID I GET THE NOTICE?) AND SAYS I CAN PAY $90 FOR CHROME REPLACEMENT. AND BY THE WAY, ALSO HANDED ME $2500 WORTH OF OTHER WORK I NEED - I DON'T, ACCORDING TO MY MECHANIC. GUESS H. TRYING TO RECOUP MONEY SOME WAY, SINCE THEY HAVE TO REPLACE THE S.F.FREE. BOTTOM LINE: THIS IS MY 2ND H. AND MY LAST-LOST FAITH& WORRIED THAT THEY WILL NOT DO PROPER JOB ON RECALL WORK.WILL PAY FOR RENTAL AND ALIGNMENT MYSELF. ANY SUGGESTIONS? *TR

CHROME COVERING IS PEELING FROM HANDLES AND SHIFTER RESULTING IN PIECES BEING STUCK IN MY HAND AND CUTS. *TR

2004 HYUNDAI SONATA - INTERIOR DOOR HANDLE CAUSED HAND LACERATION BY PEELING CHROME PLATING /CRACK IN DOOR HANDLE ASSEMBLY. *TR

SEEMS TO BE A DEFECT IN THE DOOR HANDLES...WE HAVE FLAKING OF THE CHROME FINISH ON OUR 2004 SONATA AS WELL, PRIMARILY DRIVER'S DOOR. *TR

CHIPPING PAINT ON DOOR HANDLES ESPECIALLY ON THE ONES THAT ARE LESS USED. PAINT NOT MATCHING WHEN REPAIRS ARE DONE. *TR