Illustration18 MONTHS AFTER PURCHASING MY 2004 HYUNDAI SONATA BRAND NEW. THE REAR WHEEL BEARING SEIZED CAUSING MY TIRE TO DRAG WHILE DRIVING AND THE TIRE THEN POPPED. I WAS ABLE TO HAVE THE WHEEL BEARING REPLACED UNDER WARRANTY. HOWEVER, THEY WOULD NOT COVER THE TIRE. *JB
2004 Hyundai Sonata
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2004 Hyundai Sonata do not stand out strongly from the model-year median of 161.
About this comparison →How this year compares
Owner complaints by model year
Compare all Sonata years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
190–25K
1825–50K
2850–75K
2875–100K
45100–150K
17150K+
155 reports with mileage · 47 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 56 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Structure. Review the 47 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 46 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
22 crash reports2 fire reports23 injury reports
What owners actually said
202 reportsDT*: THE CONTACT STATED AFTER HAVING A FLAT TIRE DUE TO A ROAD HAZARD, THE DEALER PERFORMED AN INSPECTION AND IT WAS DETERMINED THE TREAD DEPTH WAS DEPLETED. THE TIRES WERE REPLACED. THE TIRES WERE MICHELIN MXD4 PLUS H 205/165/115. ADDITIONALLY, THE AUTOMATIC TRANSMISSION WAS SLIPPING INTO GEARS WITHOUT WARNING WHILE DRIVING…
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DT*: THE CONTACT STATED AFTER HAVING A FLAT TIRE DUE TO A ROAD HAZARD, THE DEALER PERFORMED AN INSPECTION AND IT WAS DETERMINED THE TREAD DEPTH WAS DEPLETED. THE TIRES WERE REPLACED. THE TIRES WERE MICHELIN MXD4 PLUS H 205/165/115. ADDITIONALLY, THE AUTOMATIC TRANSMISSION WAS SLIPPING INTO GEARS WITHOUT WARNING WHILE DRIVING VARIOUS SPEEDS. THE VEHICLE WAS INSPECTED BY THE DEALER WHO WAS UNABLE TO DUPLICATE THE PROBLEM. THE AUTOMATIC TRANSMISSION SEIZED AND WAS TOWED TO THE DEALER. THE VEHICLE IS CURRENTLY AWAITING REPLACEMENT OF THE AUTOMATIC TRANSMISSION.
I WAS GOING ABOUT 35 MILES PER HOUR AND REAR ENDED A ANOTHER VEHICLE AND MY DRIVERS AIR BAG DID NOT DEPLOY. I WAS NOT HURT, BUT MY DAUGHTER IN THE BACK SEAT WAS. *NM
I HAVE HAD SEVERAL VALVE STEM FAILURES AFTER THE REPLACEMENT OF TIRES ON MY 2004 HYUNDAI SONATA. THE WHEEL COVERS SHIFT AND CUT THE VALVE STEMS AND HAVE LEFT US WITH RAPID AIR LOSS. PLEASE REFER TO YOUR CASE NUMBER PE05-059. I HAVE EVEN HAD NEW WHEEL COVERS PLACED ON THE VEHICLE, BUT THEY HAVE ALSO SLIPPED OVER THE VALVE STEM…
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I HAVE HAD SEVERAL VALVE STEM FAILURES AFTER THE REPLACEMENT OF TIRES ON MY 2004 HYUNDAI SONATA. THE WHEEL COVERS SHIFT AND CUT THE VALVE STEMS AND HAVE LEFT US WITH RAPID AIR LOSS. PLEASE REFER TO YOUR CASE NUMBER PE05-059. I HAVE EVEN HAD NEW WHEEL COVERS PLACED ON THE VEHICLE, BUT THEY HAVE ALSO SLIPPED OVER THE VALVE STEMS. THIS IS A CONCERN BECAUSE AT HIGHWAY SPEEDS THIS COULD CAUSE A BLOW OUT AND AN ACCIDENT, LEADING TO INJURY OR DEATH. *JB
AFTER BUYING NEW TIRES FOR MY 2004 HYUNDAI SONATA, I STARTED EXPERIENCING FLAT TIRES ON MY FRONT TIRES. ALL FLATS INVOLVED PROBLEMS WITH VALVE STEMS. IT SEEMS THAT THE WHEEL COVERS ON THIS CAR ARE NOT MEANT FOR SOME BRANDS OF REPLACEMENT TIRES. THE TORQUE OF THE FRONT WHEEL SEEMS TO CAUSE THE WHEEL COVERS TO ROTATE THEREBY CU…
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AFTER BUYING NEW TIRES FOR MY 2004 HYUNDAI SONATA, I STARTED EXPERIENCING FLAT TIRES ON MY FRONT TIRES. ALL FLATS INVOLVED PROBLEMS WITH VALVE STEMS. IT SEEMS THAT THE WHEEL COVERS ON THIS CAR ARE NOT MEANT FOR SOME BRANDS OF REPLACEMENT TIRES. THE TORQUE OF THE FRONT WHEEL SEEMS TO CAUSE THE WHEEL COVERS TO ROTATE THEREBY CUTTING INTO THE VALVE STEMS. THE DEALERSHIP I WENT TO WOULD NOT WARRANT THE PROBLEM, BUT HE WAS AWARE OF SEEING MANY OTHER SONATAS WITH THE SAME PROBLEM. I WAS NOT WARNED WHEN I BOUGHT THE CAR THAT I HAD TO PAY CLOSE ATTENTION TO WHAT BRAND OF TIRES I USED AS REPLACEMENTS. ONE OF MY FLATS OCCURRED WHEN I WAS TRAVELING AT 60 MPH AND NEARLY CAUSED ME TO LOSE CONTROL OF THE CAR. *JB
DT*: THE CONTACT STATED WHILE DRIVING 35 MPH, THE VEHICLE WAS INVOLVED IN A CRASH AND THE AIR BAGS DID NOT DEPLOY. THE VEHICLE WAS STRUCK BROAD SIDED ON THE PASSENGER SIDE BETWEEN BOTH DOORS. BOTH PASSENGERS OF THE VEHICLE WERE WEARING SEAT BELTS AND RECEIVED ONLY MINOR INJURIES. THE VEHICLE WAS ABLE TO BE DRIVEN AWAY FROM T…
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DT*: THE CONTACT STATED WHILE DRIVING 35 MPH, THE VEHICLE WAS INVOLVED IN A CRASH AND THE AIR BAGS DID NOT DEPLOY. THE VEHICLE WAS STRUCK BROAD SIDED ON THE PASSENGER SIDE BETWEEN BOTH DOORS. BOTH PASSENGERS OF THE VEHICLE WERE WEARING SEAT BELTS AND RECEIVED ONLY MINOR INJURIES. THE VEHICLE WAS ABLE TO BE DRIVEN AWAY FROM THE SCENE. THE POLICE WERE AT THE SCENE OF THE ACCIDENT AND PROVIDED A WRITTEN REPORT; HOWEVER, THE VEHICLE HAS NOT BEEN INSPECTED BY THE INSURANCE COMPANY. UPDATED 5/2/2006- *NM
MY 2004 HYUNDAI SONATA HAS BEEN HAVING CLUTCH AND FLYWHEEL PROBLEMS STARTING AT LESS THAN 10,000 MILES. IT IS NOW AT 40,000 MILES AND IT'S GETTING WORSE. I'VE HAD MECHANICS (NOT BIASED HYUNDAI PERSONAL) TELL ME THAT THE FLY WHEEL IS MOST LIKELY WARPED, CAUSING THE CLUTCH TO SHIMMY AND SLIP UNDER LOAD (UP HILLS WITH PASSENGERS,…
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MY 2004 HYUNDAI SONATA HAS BEEN HAVING CLUTCH AND FLYWHEEL PROBLEMS STARTING AT LESS THAN 10,000 MILES. IT IS NOW AT 40,000 MILES AND IT'S GETTING WORSE. I'VE HAD MECHANICS (NOT BIASED HYUNDAI PERSONAL) TELL ME THAT THE FLY WHEEL IS MOST LIKELY WARPED, CAUSING THE CLUTCH TO SHIMMY AND SLIP UNDER LOAD (UP HILLS WITH PASSENGERS, ETC). I HAD THE DEALER LOOK AT IT AND THEY SAID IT WAS "FINE". I'M THINKING ABOUT TAKING IT TO ANOTHER DEALERSHIP. *JB
DT*: THE CONTACT STATED WHILE DRIVING A POPPING NOISE CAN BE HEARD WHILE APPLYING THE BRAKES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT REPAIR SHOP AND IT WAS FOUND THAT ALL FOUR ROTORS NEEDED TO BE REPLACED. THE MANUFACTURER HAS BEEN ALERTED.
DT*: THE CONTACT STATED WHEN THE ROAD SLANTED TO THE RIGHT, THE VEHICLE PULLED TO THE RIGHT. THE DEALERSHIP WHERE THE VEHICLE WAS PURCHASED, AS WELL AS ANOTHER DEALERSHIP, ALIGNED THE VEHICLE. THIS HAS NOT REPAIRED THE PROBLEM. UPDATED 03/15/06
DT: THE CONTACT'S VEHICLE WAS INVOLVED IN A CRASH. UPON IMPACT, FRONT AND SIDE AIR BAGS DID NOT DEPLOY. ALSO, THE SEAT BELTS DID NOT RESTRAIN THE CONTACT AND HER PASSENGER IN THE SEATS. THE CONTACT WAS THROWN INTO THE STEERING WHEEL, AND THE PASSENGER HIT THE WINDSHIELD. BOTH SUSTAINED SERIOUS INJURIES AND BROKEN BONES.…
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DT: THE CONTACT'S VEHICLE WAS INVOLVED IN A CRASH. UPON IMPACT, FRONT AND SIDE AIR BAGS DID NOT DEPLOY. ALSO, THE SEAT BELTS DID NOT RESTRAIN THE CONTACT AND HER PASSENGER IN THE SEATS. THE CONTACT WAS THROWN INTO THE STEERING WHEEL, AND THE PASSENGER HIT THE WINDSHIELD. BOTH SUSTAINED SERIOUS INJURIES AND BROKEN BONES. A POLICE REPORT WAS TAKEN, AND AN INSURANCE REPORT WAS FILED. PICTURES ARE AVAILABLE FOR REVIEW. THE VEHICLE WAS REPAIRED.*AK UPDATED 2/21/2006 - *NM
Official recalls
109V124000 · Suspension
Apr 16, 2009
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.
Consequence & remedy
Consequence: 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.
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.
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
1EA08016 · Front SUB-FRAME Corrosion
Opened Aug 21, 2008 · Closed Apr 20, 2009
Status: closed (inferred from source dates) · Structure; Structure:frame And Members; Suspension; Suspension:front; Suspension:front:control Arm
IN A LETTER DATED APRIL 14, 2009, HYUNDAI-KIA AMERICA TECHNICAL CENTER, INC (HYUNDAI) NOTIFIED NHTSA THAT HYUNDAIIS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 1999 THROUGH 2004 HYUNDAI SONATA VEHICLES MANUFACTURED PRIOR TO NOVEMBER 20, 2003 THAT ARE REGISTERED AND OPERATED IN THE FOLLOWING 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.HYUNDAI IS RECALLING THE VEHICLES TO REMEDY A CONDITION WHERE INTERNAL CORROSION OF THE FRONT SUBFRAME MAY LEAD TO SEPARATION OF THE LOWER CONTROL ARM AT THE FORWARD MOUNTING POINT AND/OR SEPARATION OF THE AXLE FROM THE TRANSAXLE.THIS COULD RESULT IN A LOSS OF VEHICLE CONTROL AND/OR VEHICLE DISABLEMENT. THE SUBFRAMES WILL BE INSPECTED IN THE RECALLED VEHICLES USING A PROCEDURE DEVELOPED BY HYUNDAI TO MEASURE METAL THICKNESS.PARTS WITH PERFORATIONS FROM CORROSION OR WITH METAL BELOW THE SPECIFIED THICKNESS WILL BE REPLACED WITH REDESIGNED SUBFRAMES.IF THE MINIMUM METAL THICKNESS IS MET, DRAINAGE HOLES AND RUST PROOFING MATERIAL WILL BE ADDED TO THE EXISTING SUBFRAME. ODI'S ANALYSIS OF COMPLAINT DATA REVEALED THAT 98% OF THE CONSUMER COMPLAINTS WERE FROM VEHICLES EITHER ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES. SIMILARLY 99.7% OF THE WARRANTY CLAIMS WERE FROM VEHICLES ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES.ODI IDENTIFIED 105 REPORTS OF LOWER CONTROL ARM DETACHMENT AND/OR AXLE SEPARATION FROM THE TRANSAXLE THROUGH ANALYSIS OF WARRANTY AND COMPLAINT INFORMATION AND CONSUMER INTERVIEWS.ONE HUNDRED THREE (103) OF THE 105 INCIDENTS INVOLVED VEHICLES IN STATES COVERED BY THE RECALL.IN ADDITION TO THE SUBJECT VEHICLES, HYUNDAI ALSO NOTED IN THE APRIL 14, 2009 LETTER THAT MY 2001 THROUGH 2004 XG300 AND XG350 WERE ALSO BEING RECALLED AS THEY WERE MANUFACTURED WITH SUBFRAMES SIMILAR IN DESIGN THE SUBJECT VEHICLES.BASED ON HYUNDAI'S DECISION TO CONDUCT A SAFETY RECALL THIS ENGINEERING ANALYSIS IS CLOSED.
Additional source detail variants (5)
Structure:frame And Members
IN A LETTER DATED APRIL 14, 2009, HYUNDAI-KIA AMERICA TECHNICAL CENTER, INC (HYUNDAI) NOTIFIED NHTSA THAT HYUNDAIIS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 1999 THROUGH 2004 HYUNDAI SONATA VEHICLES MANUFACTURED PRIOR TO NOVEMBER 20, 2003 THAT ARE REGISTERED AND OPERATED IN THE FOLLOWING 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.HYUNDAI IS RECALLING THE VEHICLES TO REMEDY A CONDITION WHERE INTERNAL CORROSION OF THE FRONT SUBFRAME MAY LEAD TO SEPARATION OF THE LOWER CONTROL ARM AT THE FORWARD MOUNTING POINT AND/OR SEPARATION OF THE AXLE FROM THE TRANSAXLE.THIS COULD RESULT IN A LOSS OF VEHICLE CONTROL AND/OR VEHICLE DISABLEMENT. THE SUBFRAMES WILL BE INSPECTED IN THE RECALLED VEHICLES USING A PROCEDURE DEVELOPED BY HYUNDAI TO MEASURE METAL THICKNESS.PARTS WITH PERFORATIONS FROM CORROSION OR WITH METAL BELOW THE SPECIFIED THICKNESS WILL BE REPLACED WITH REDESIGNED SUBFRAMES.IF THE MINIMUM METAL THICKNESS IS MET, DRAINAGE HOLES AND RUST PROOFING MATERIAL WILL BE ADDED TO THE EXISTING SUBFRAME. ODI'S ANALYSIS OF COMPLAINT DATA REVEALED THAT 98% OF THE CONSUMER COMPLAINTS WERE FROM VEHICLES EITHER ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES. SIMILARLY 99.7% OF THE WARRANTY CLAIMS WERE FROM VEHICLES ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES.ODI IDENTIFIED 105 REPORTS OF LOWER CONTROL ARM DETACHMENT AND/OR AXLE SEPARATION FROM THE TRANSAXLE THROUGH ANALYSIS OF WARRANTY AND COMPLAINT INFORMATION AND CONSUMER INTERVIEWS.ONE HUNDRED THREE (103) OF THE 105 INCIDENTS INVOLVED VEHICLES IN STATES COVERED BY THE RECALL.IN ADDITION TO THE SUBJECT VEHICLES, HYUNDAI ALSO NOTED IN THE APRIL 14, 2009 LETTER THAT MY 2001 THROUGH 2004 XG300 AND XG350 WERE ALSO BEING RECALLED AS THEY WERE MANUFACTURED WITH SUBFRAMES SIMILAR IN DESIGN THE SUBJECT VEHICLES.BASED ON HYUNDAI'S DECISION TO CONDUCT A SAFETY RECALL THIS ENGINEERING ANALYSIS IS CLOSED.
Structure
IN A LETTER DATED APRIL 14, 2009, HYUNDAI-KIA AMERICA TECHNICAL CENTER, INC (HYUNDAI) NOTIFIED NHTSA THAT HYUNDAIIS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 1999 THROUGH 2004 HYUNDAI SONATA VEHICLES MANUFACTURED PRIOR TO NOVEMBER 20, 2003 THAT ARE REGISTERED AND OPERATED IN THE FOLLOWING 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.HYUNDAI IS RECALLING THE VEHICLES TO REMEDY A CONDITION WHERE INTERNAL CORROSION OF THE FRONT SUBFRAME MAY LEAD TO SEPARATION OF THE LOWER CONTROL ARM AT THE FORWARD MOUNTING POINT AND/OR SEPARATION OF THE AXLE FROM THE TRANSAXLE.THIS COULD RESULT IN A LOSS OF VEHICLE CONTROL AND/OR VEHICLE DISABLEMENT. THE SUBFRAMES WILL BE INSPECTED IN THE RECALLED VEHICLES USING A PROCEDURE DEVELOPED BY HYUNDAI TO MEASURE METAL THICKNESS.PARTS WITH PERFORATIONS FROM CORROSION OR WITH METAL BELOW THE SPECIFIED THICKNESS WILL BE REPLACED WITH REDESIGNED SUBFRAMES.IF THE MINIMUM METAL THICKNESS IS MET, DRAINAGE HOLES AND RUST PROOFING MATERIAL WILL BE ADDED TO THE EXISTING SUBFRAME. ODI'S ANALYSIS OF COMPLAINT DATA REVEALED THAT 98% OF THE CONSUMER COMPLAINTS WERE FROM VEHICLES EITHER ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES. SIMILARLY 99.7% OF THE WARRANTY CLAIMS WERE FROM VEHICLES ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES.ODI IDENTIFIED 105 REPORTS OF LOWER CONTROL ARM DETACHMENT AND/OR AXLE SEPARATION FROM THE TRANSAXLE THROUGH ANALYSIS OF WARRANTY AND COMPLAINT INFORMATION AND CONSUMER INTERVIEWS.ONE HUNDRED THREE (103) OF THE 105 INCIDENTS INVOLVED VEHICLES IN STATES COVERED BY THE RECALL.IN ADDITION TO THE SUBJECT VEHICLES, HYUNDAI ALSO NOTED IN THE APRIL 14, 2009 LETTER THAT MY 2001 THROUGH 2004 XG300 AND XG350 WERE ALSO BEING RECALLED AS THEY WERE MANUFACTURED WITH SUBFRAMES SIMILAR IN DESIGN THE SUBJECT VEHICLES.BASED ON HYUNDAI'S DECISION TO CONDUCT A SAFETY RECALL THIS ENGINEERING ANALYSIS IS CLOSED.
Suspension:front:control Arm
IN A LETTER DATED APRIL 14, 2009, HYUNDAI-KIA AMERICA TECHNICAL CENTER, INC (HYUNDAI) NOTIFIED NHTSA THAT HYUNDAIIS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 1999 THROUGH 2004 HYUNDAI SONATA VEHICLES MANUFACTURED PRIOR TO NOVEMBER 20, 2003 THAT ARE REGISTERED AND OPERATED IN THE FOLLOWING 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.HYUNDAI IS RECALLING THE VEHICLES TO REMEDY A CONDITION WHERE INTERNAL CORROSION OF THE FRONT SUBFRAME MAY LEAD TO SEPARATION OF THE LOWER CONTROL ARM AT THE FORWARD MOUNTING POINT AND/OR SEPARATION OF THE AXLE FROM THE TRANSAXLE.THIS COULD RESULT IN A LOSS OF VEHICLE CONTROL AND/OR VEHICLE DISABLEMENT. THE SUBFRAMES WILL BE INSPECTED IN THE RECALLED VEHICLES USING A PROCEDURE DEVELOPED BY HYUNDAI TO MEASURE METAL THICKNESS.PARTS WITH PERFORATIONS FROM CORROSION OR WITH METAL BELOW THE SPECIFIED THICKNESS WILL BE REPLACED WITH REDESIGNED SUBFRAMES.IF THE MINIMUM METAL THICKNESS IS MET, DRAINAGE HOLES AND RUST PROOFING MATERIAL WILL BE ADDED TO THE EXISTING SUBFRAME. ODI'S ANALYSIS OF COMPLAINT DATA REVEALED THAT 98% OF THE CONSUMER COMPLAINTS WERE FROM VEHICLES EITHER ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES. SIMILARLY 99.7% OF THE WARRANTY CLAIMS WERE FROM VEHICLES ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES.ODI IDENTIFIED 105 REPORTS OF LOWER CONTROL ARM DETACHMENT AND/OR AXLE SEPARATION FROM THE TRANSAXLE THROUGH ANALYSIS OF WARRANTY AND COMPLAINT INFORMATION AND CONSUMER INTERVIEWS.ONE HUNDRED THREE (103) OF THE 105 INCIDENTS INVOLVED VEHICLES IN STATES COVERED BY THE RECALL.IN ADDITION TO THE SUBJECT VEHICLES, HYUNDAI ALSO NOTED IN THE APRIL 14, 2009 LETTER THAT MY 2001 THROUGH 2004 XG300 AND XG350 WERE ALSO BEING RECALLED AS THEY WERE MANUFACTURED WITH SUBFRAMES SIMILAR IN DESIGN THE SUBJECT VEHICLES.BASED ON HYUNDAI'S DECISION TO CONDUCT A SAFETY RECALL THIS ENGINEERING ANALYSIS IS CLOSED.
Suspension:front
IN A LETTER DATED APRIL 14, 2009, HYUNDAI-KIA AMERICA TECHNICAL CENTER, INC (HYUNDAI) NOTIFIED NHTSA THAT HYUNDAIIS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 1999 THROUGH 2004 HYUNDAI SONATA VEHICLES MANUFACTURED PRIOR TO NOVEMBER 20, 2003 THAT ARE REGISTERED AND OPERATED IN THE FOLLOWING 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.HYUNDAI IS RECALLING THE VEHICLES TO REMEDY A CONDITION WHERE INTERNAL CORROSION OF THE FRONT SUBFRAME MAY LEAD TO SEPARATION OF THE LOWER CONTROL ARM AT THE FORWARD MOUNTING POINT AND/OR SEPARATION OF THE AXLE FROM THE TRANSAXLE.THIS COULD RESULT IN A LOSS OF VEHICLE CONTROL AND/OR VEHICLE DISABLEMENT. THE SUBFRAMES WILL BE INSPECTED IN THE RECALLED VEHICLES USING A PROCEDURE DEVELOPED BY HYUNDAI TO MEASURE METAL THICKNESS.PARTS WITH PERFORATIONS FROM CORROSION OR WITH METAL BELOW THE SPECIFIED THICKNESS WILL BE REPLACED WITH REDESIGNED SUBFRAMES.IF THE MINIMUM METAL THICKNESS IS MET, DRAINAGE HOLES AND RUST PROOFING MATERIAL WILL BE ADDED TO THE EXISTING SUBFRAME. ODI'S ANALYSIS OF COMPLAINT DATA REVEALED THAT 98% OF THE CONSUMER COMPLAINTS WERE FROM VEHICLES EITHER ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES. SIMILARLY 99.7% OF THE WARRANTY CLAIMS WERE FROM VEHICLES ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES.ODI IDENTIFIED 105 REPORTS OF LOWER CONTROL ARM DETACHMENT AND/OR AXLE SEPARATION FROM THE TRANSAXLE THROUGH ANALYSIS OF WARRANTY AND COMPLAINT INFORMATION AND CONSUMER INTERVIEWS.ONE HUNDRED THREE (103) OF THE 105 INCIDENTS INVOLVED VEHICLES IN STATES COVERED BY THE RECALL.IN ADDITION TO THE SUBJECT VEHICLES, HYUNDAI ALSO NOTED IN THE APRIL 14, 2009 LETTER THAT MY 2001 THROUGH 2004 XG300 AND XG350 WERE ALSO BEING RECALLED AS THEY WERE MANUFACTURED WITH SUBFRAMES SIMILAR IN DESIGN THE SUBJECT VEHICLES.BASED ON HYUNDAI'S DECISION TO CONDUCT A SAFETY RECALL THIS ENGINEERING ANALYSIS IS CLOSED.
Suspension
IN A LETTER DATED APRIL 14, 2009, HYUNDAI-KIA AMERICA TECHNICAL CENTER, INC (HYUNDAI) NOTIFIED NHTSA THAT HYUNDAIIS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 1999 THROUGH 2004 HYUNDAI SONATA VEHICLES MANUFACTURED PRIOR TO NOVEMBER 20, 2003 THAT ARE REGISTERED AND OPERATED IN THE FOLLOWING 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.HYUNDAI IS RECALLING THE VEHICLES TO REMEDY A CONDITION WHERE INTERNAL CORROSION OF THE FRONT SUBFRAME MAY LEAD TO SEPARATION OF THE LOWER CONTROL ARM AT THE FORWARD MOUNTING POINT AND/OR SEPARATION OF THE AXLE FROM THE TRANSAXLE.THIS COULD RESULT IN A LOSS OF VEHICLE CONTROL AND/OR VEHICLE DISABLEMENT. THE SUBFRAMES WILL BE INSPECTED IN THE RECALLED VEHICLES USING A PROCEDURE DEVELOPED BY HYUNDAI TO MEASURE METAL THICKNESS.PARTS WITH PERFORATIONS FROM CORROSION OR WITH METAL BELOW THE SPECIFIED THICKNESS WILL BE REPLACED WITH REDESIGNED SUBFRAMES.IF THE MINIMUM METAL THICKNESS IS MET, DRAINAGE HOLES AND RUST PROOFING MATERIAL WILL BE ADDED TO THE EXISTING SUBFRAME. ODI'S ANALYSIS OF COMPLAINT DATA REVEALED THAT 98% OF THE CONSUMER COMPLAINTS WERE FROM VEHICLES EITHER ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES. SIMILARLY 99.7% OF THE WARRANTY CLAIMS WERE FROM VEHICLES ORIGINALLY SOLD OR OPERATED IN SALTBELT STATES.ODI IDENTIFIED 105 REPORTS OF LOWER CONTROL ARM DETACHMENT AND/OR AXLE SEPARATION FROM THE TRANSAXLE THROUGH ANALYSIS OF WARRANTY AND COMPLAINT INFORMATION AND CONSUMER INTERVIEWS.ONE HUNDRED THREE (103) OF THE 105 INCIDENTS INVOLVED VEHICLES IN STATES COVERED BY THE RECALL.IN ADDITION TO THE SUBJECT VEHICLES, HYUNDAI ALSO NOTED IN THE APRIL 14, 2009 LETTER THAT MY 2001 THROUGH 2004 XG300 AND XG350 WERE ALSO BEING RECALLED AS THEY WERE MANUFACTURED WITH SUBFRAMES SIMILAR IN DESIGN THE SUBJECT VEHICLES.BASED ON HYUNDAI'S DECISION TO CONDUCT A SAFETY RECALL THIS ENGINEERING ANALYSIS IS CLOSED.