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2004 Hyundai Santa Fe

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2004 Hyundai Santa Fe do not stand out strongly from the model-year median of 212.5.

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When problems were reported

Mileage at the reported incident

250 reports with mileage · 53 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Suspension. Review the 69 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Air Bags. Review the 43 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Vehicle Speed Control. Review the 39 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

32 crash reports7 fire reports27 injury reports

Fuel/propulsion System complaints

25 reports
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115,000 miles · Mar 8, 2016
Fuel/propulsion System

A STRONG ODOR OF GASOLINE WAS NOTICEABLE UPON ENTERING MY GARAGE. FURTHER INSPECTION REVEALED GAS LEAKING FROM MY '04 HYUNDAI SANTA FE. THE SERVICE STATION DETERMINED THAT A FUEL TANK AND CENTER HEAT SHIELDING REPLACEMENT WAS NECESSARY AS BOTH WERE DEFECTIVE, LEAKING FUEL, AND POSED A VERY HIGH RISK OF DANGER. NEEDLESS TO SAY…

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A STRONG ODOR OF GASOLINE WAS NOTICEABLE UPON ENTERING MY GARAGE. FURTHER INSPECTION REVEALED GAS LEAKING FROM MY '04 HYUNDAI SANTA FE. THE SERVICE STATION DETERMINED THAT A FUEL TANK AND CENTER HEAT SHIELDING REPLACEMENT WAS NECESSARY AS BOTH WERE DEFECTIVE, LEAKING FUEL, AND POSED A VERY HIGH RISK OF DANGER. NEEDLESS TO SAY, I WAS STUCK PAYING A VERY HEFTY BILL TO THE REPAIR CENTER RATHER THAN WORRYING ABOUT BLOWING UP MYSELF, MY PASSENGERS, OR MY HOUSE. I SEE THAT THERE HAVE BEEN OTHER COMPLAINTS ABOUT THE SAME PROBLEM WITH THIS MAKE AND MODEL OF HYUNDAI.

NHTSA ODI #10845592

102,000 miles · Feb 12, 2016
Electrical SystemEngineFuel/propulsion System

CAR STALLS WITHOUT WARNING WHILE DRIVING. FIRST OCCURRENCE WAS OVER A YEAR AGO. I WAS DRIVING DOWN I5 GOING 70 MPH WHEN THE CAR SUDDENLY DIED. I LOST MY POWER STEERING AND BRAKES. I MANAGED TO COAST TO THE NEXT EXIT. IT STARTED AFTER SITTING A FEW MINUTES. AND I WAS ABLE TO MAKE IT HOME. I'VE RECEIVED CODES FOR CAMSHAFT SENSOR, …

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CAR STALLS WITHOUT WARNING WHILE DRIVING. FIRST OCCURRENCE WAS OVER A YEAR AGO. I WAS DRIVING DOWN I5 GOING 70 MPH WHEN THE CAR SUDDENLY DIED. I LOST MY POWER STEERING AND BRAKES. I MANAGED TO COAST TO THE NEXT EXIT. IT STARTED AFTER SITTING A FEW MINUTES. AND I WAS ABLE TO MAKE IT HOME. I'VE RECEIVED CODES FOR CAMSHAFT SENSOR, MISFIRES, LOW CATALYST. I'VE CHANGED THE CAM AND CRANK SENSORS, COILS, SPARK PLUGS, TIMING BELT AND ASSEMBLY, FUEL PRESSURE REGULATOR AND FUEL PUMP OVER THE PAST YEAR. STILL HAVING THE ISSUE. CAR DRIVES FANTASTIC FOR ABOUT 10 MILES AND STALLS OUT. AFTER WAITING ABOUT 5 MIN. IT CAN BE DRIVEN FOR ANOTHER FEW MILES BEFORE STALLING OUT AGAIN. CHECK ENGINE LIGHT DOES NOT TURN ON WHEN IT STALLS NOW. VERY DANGEROUS WHEN TRYING TO DRIVE IN TOWN OR ATTEMPTING TO MERGE INTO TRAFFIC. YOU NEVER KNOW WHEN IT WILL STALL OUT.

NHTSA ODI #10825883

180,000 miles · Feb 10, 2016
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 HYUNDAI SANTE FE. AFTER THE VEHICLE WAS REFUELED, THE CONTACT NOTICED FUEL LEAKING FROM THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 180,000.

NHTSA ODI #10825326

150,000 miles · Nov 28, 2015
Fuel/propulsion SystemVehicle Speed Control

WHEN I PUT GAS IN MY CAR IT WILL NOT START AFTERWARD. FIRST IT STARTED ONLY WHEN MY CAR WAS TURNED OFF. WHEN I LEFT MY CAR RUNNING IT WAS OK. NOW IT TURNS OFF WHEN MY CAR IS RUNNING ALSO. THE MECHANIC SAID, IT MAY BE A BAD FUEL PUMP, COST $350 TO REPLACE, BUT CAN'T GUARANTEE THIS WILL FIX THE ISSUE. I SEE I AM NOT THE ONLY ONE W…

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WHEN I PUT GAS IN MY CAR IT WILL NOT START AFTERWARD. FIRST IT STARTED ONLY WHEN MY CAR WAS TURNED OFF. WHEN I LEFT MY CAR RUNNING IT WAS OK. NOW IT TURNS OFF WHEN MY CAR IS RUNNING ALSO. THE MECHANIC SAID, IT MAY BE A BAD FUEL PUMP, COST $350 TO REPLACE, BUT CAN'T GUARANTEE THIS WILL FIX THE ISSUE. I SEE I AM NOT THE ONLY ONE WITH THIS ISSUE. WHY IS THIS NOT A RECALL?? I GOOGLE IT AND THERE ARE SO MANY PEOPLE WITH SAME PROBLEM. ALSO WITH THE CAR ACCELERATING BY ITSELF. I THOUGHT I WAS CRAZY. I SEE NOW THAT OTHERS ARE HAVING THIS PROBLEM AS WELL. EVERYONE SAID I IMAGINED IT. WHY IS THIS NOT A RECALL?

NHTSA ODI #10807296

92,000 miles · Oct 29, 2015
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 HYUNDAI SANTA FE. IMMEDIATELY AFTER REFUELING THE VEHICLE, IT WOULD SUDDENLY STALL. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE PURGE VALVE FAILED AND THE FUEL TANK WOULD NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WA…

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TL* THE CONTACT OWNS A 2004 HYUNDAI SANTA FE. IMMEDIATELY AFTER REFUELING THE VEHICLE, IT WOULD SUDDENLY STALL. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE PURGE VALVE FAILED AND THE FUEL TANK WOULD NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 92,000.

NHTSA ODI #10786932

92,000 miles · Oct 28, 2015
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 HYUNDAI SANTA FE. THE CONTACT STATED THAT IMMEDIATELY AFTER REFUELING THE VEHICLE, IT WOULD SUDDENLY STALL. THE VEHICLE WAS TAKEN TO THE DEALER WHO DIAGNOSED THAT THE PURGE VALVE AND THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE F…

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TL* THE CONTACT OWNS A 2004 HYUNDAI SANTA FE. THE CONTACT STATED THAT IMMEDIATELY AFTER REFUELING THE VEHICLE, IT WOULD SUDDENLY STALL. THE VEHICLE WAS TAKEN TO THE DEALER WHO DIAGNOSED THAT THE PURGE VALVE AND THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 92,000.

NHTSA ODI #10786610

148,750 miles · Oct 2, 2015
Fuel/propulsion System

I SMELLED GAS RECENTLY WHEN OPENING AND GETTING INTO MY 2004 SANTA FE. I TOOK IT TO A CAR REPAIR SHOP. THEY INSPECTED IT AND FOUND RUST HOLES IN THE GAS TANK WHICH GAS WAS LEAKING OUT OF! I CAN'T IMAGINE THE HOW TERRIBLE AN EVENT COULD HAVE OCCURRED IF THE LEAKING GAS HAD EXPLODED WHEN I STARTED THE CAR OR BEEN CLOSE TO AN O…

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I SMELLED GAS RECENTLY WHEN OPENING AND GETTING INTO MY 2004 SANTA FE. I TOOK IT TO A CAR REPAIR SHOP. THEY INSPECTED IT AND FOUND RUST HOLES IN THE GAS TANK WHICH GAS WAS LEAKING OUT OF! I CAN'T IMAGINE THE HOW TERRIBLE AN EVENT COULD HAVE OCCURRED IF THE LEAKING GAS HAD EXPLODED WHEN I STARTED THE CAR OR BEEN CLOSE TO AN OPEN FLAME WITH THE CAR WHEN IT WAS LEAKING. I HAVE OWNED MANY CARS IN MY LIFE AND HAVE NEVER HAD A FUEL TANK RUST OUT. I THINK THE NHTSA NEEDS TO TAKE A VERY CLOSE LOOK AT THIS PROBLEM AND POSSIBLY ISSUE A RECALL ON THE GAS TANKS OF SANTA FES AND OTHER VEHICLES THEY MANUFACTURE THAT USE THE SAME GAS TANK.

NHTSA ODI #10779206

Mileage unknown · Oct 2, 2014
Fuel/propulsion System

I BROUGHT THE VEHICLE IN FOR AN OIL CHANGE. THE GENTLEMAN SAID THAT THE FUEL TANK HAS A RUST HOLE IN IT AND IS LEAKING FUEL. THIS IS CAUSED BY A PLASTIC COVER THAT RETAINS SALT AND MOISTURE AND CAUSES THE TANK TO RUST. *TR

NHTSA ODI #10640779

107,000 miles · Sep 15, 2014
Fuel/propulsion System

THE VEHICLE HAD A STRONG SENT OF GASOLINE WHEN PARKED. THE VEHICLE WAS TAKEN TO THE MECHANIC, I WAS INFORMED THAT IT WAS A GAS LEAK AND THE GAS TANK HAD TO BE REPLACED. AFTER THE GAS TANK WAS REPLACED, THE MECHANIC INFORMED ME THAT THE TANK HAD RUSTED AND THAT WAS THE REASON FOR THE LEAK. HE SHOWED ME THE GAS TANK AND THERE W…

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THE VEHICLE HAD A STRONG SENT OF GASOLINE WHEN PARKED. THE VEHICLE WAS TAKEN TO THE MECHANIC, I WAS INFORMED THAT IT WAS A GAS LEAK AND THE GAS TANK HAD TO BE REPLACED. AFTER THE GAS TANK WAS REPLACED, THE MECHANIC INFORMED ME THAT THE TANK HAD RUSTED AND THAT WAS THE REASON FOR THE LEAK. HE SHOWED ME THE GAS TANK AND THERE WAS EXTENSIVE RUST ON IT. THERE WAS A PLASTIC PART UNDER THE TANK THAT RETAINED WATER AND ROAD SALT AND CAUSED THE TANK TO PREMATURELY RUST. THERE IS NO REASON FOR A VEHICLE THAT IS GARAGED AND WASHED REGULARLY TO HAVE A RUSTED OUT GAS TANK. CLEARLY, THERE IS A DESIGN FLAW THAT ALLOWED THE PLASTIC PART UNDER THE TANK TO COLLECT WATER AND RUST. *TR

NHTSA ODI #10633155

115,000 miles · Jul 1, 2014
Fuel/propulsion System

THERE IS A STRONG SMELL OF GASOLINE COMING FROM MY VEHICLE - IT CONSUMES BOTH THE INTERIOR AND THE AROUND THE ENTIRE EXTERIOR OF THE VEHICLE. LOOKING AT ALL OF THE COMPLAINTS, THIS IS NOT THE FIRST TIME THIS HAS HAPPENED. WHY ISN'T THERE A RECALL?? HYUNDAI - ARE YOU DOING ANYTHING TO HELP YOUR CUSTOMERS????? *TR

NHTSA ODI #10607248

Official recalls

3

14V435000 · Suspension:front:springs:coil Springs

Jul 18, 2014

Hyundai Motor Company (Hyundai) is recalling certain model Year 2001-2006 Santa Fe vehicles manufactured from March 31, 2000, through February 15, 2006, that are registered and operated, or which were originally sold and registered, in the following 20 “salt belt" states and the District of Columbia: Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin. The affected vehicles may experience front coil spring corrosion from road salt, causing the coil spring to fracture and make contact with the tire.

Consequence & remedy

Consequence: If the front coil spring fractures due to corrosion it could cause the coil spring to make contact with the tire, possibly puncturing the tire and increasing the risk of a vehicle crash.

Remedy: Hyundai will notify owners, and dealers will inspect and if necessary replace the coil spring, free of charge. The recall began on October 24, 2014. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 124.

04V131000 · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

Mar 16, 2004

ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH 3.5 LITER V-6 ENGINES, 4-WHEEL DRIVE AND ANTILOCK BRAKING SYSTEMS (ABS), IF THE BRAKE PEDAL IS DEPRESSED AT SPEEDS BETWEEN 3 AND 12 MPH WHEN THE BRAKE PAD FRICTION SURFACES ARE WET, A VIBRATION MAY OCCUR BETWEEN THE BRAKE DISCS AND PADS CAUSING ABS SENSOR ELECTRONIC SIGNAL NOISE TO DEVELOP. AT SPEEDS BELOW 5 MPH, THE ABS SENSOR SIGNAL NOISE MAY CAUSE THE ABS ELECTRONIC CONTROL UNIT (ECU) TO ACTIVATE THE ABS, EXTENDING THE STOPPING DISTANCE.

Consequence & remedy

Consequence: IF AN EXTENDED STOPPING DISTANCE OCCURS, IT COULD RESULT IN A CRASH.

Remedy: DEALERS WILL REPROGRAM THE ABS ECU. OWNER NOTIFICATION BEGAN ON MARCH 24, 2004. OWNERS SHOULD CONTACT HYUNDAI AT 1-800-633-5151.

03V520000 · Equipment:other:labels

Dec 18, 2003

CERTAIN SPORT UTILITY VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."

Consequence & remedy

Consequence: THE TIRE PRESSURE LABELS DO NOT CONTAIN THE INFORMATION REQUIRED BY THE STANDARD.

Remedy: OWNERS WILL BE PROVIDED WITH A CORRECT LABEL AND INSTALLATION INSTRUCTIONS. OWNER NOTIFICATION BEGAN ON OCTOBER 29, 2003. OWNERS SHOULD CONTACT HYUNDAI AT 1-800-633-5151.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

0

No exact-year investigations in this snapshot.