Model year record

2004 Hyundai Sonata recalls & problems

The 2004 Hyundai Sonata has 1 safety recall and 202 owner complaints on file with NHTSA. The most-reported problem area is suspension (56 complaints).

Recalls1safety recalls

Complaints202filed by owners

Crashes · fires22 · 2reported in complaints

Injuries · deaths32 · 0reported in complaints

2004 Hyundai Sonata in an NHTSA crash test — NHTSA crash test

Safety recalls

SuspensionApr 16, 2009

Suspension

Recall 09V124000188,282 vehiclesopened after NHTSA action (ODI)

Problem: 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.
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.
Fix: 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.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Crash test ratings

2004 Hyundai Sonata 4-DR w/SAB

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

2004 Hyundai Sonata NHTSA side crash test — NHTSA side barrier crash test

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

Fuel economy

Sonata

23mpg combined

City / highway	20 / 28 mpg
Fuel	Regular Gasoline

2.4 L · 4 cyl · Manual 5-spd · Front-Wheel Drive · about $2,900/year to fuel

Sonata

22mpg combined

City / highway	19 / 28 mpg
Fuel	Regular Gasoline

2.4 L · 4 cyl · Automatic 4-spd · Front-Wheel Drive · about $3,050/year to fuel

Sonata

20mpg combined

City / highway	17 / 25 mpg
Fuel	Regular Gasoline

2.7 L · 6 cyl · Automatic 4-spd · Front-Wheel Drive · about $3,350/year to fuel

Sonata

20mpg combined

City / highway	18 / 25 mpg
Fuel	Regular Gasoline

2.7 L · 6 cyl · Manual 5-spd · Front-Wheel Drive · about $3,350/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
SuspensionFront; Front › Wheel bearing	56	1	0	0	105,000 mi
StructureBody; Frame and members › Underbody shields	48	2	0	11	96,500 mi
Air bagsFrontal; Side/window	46	15	1	15	74,000 mi
Electrical systemWiring › Interior/under dash; Wiring	17	1	1	0	98,000 mi
WheelsHub; Rim	14	1	0	0	128,500 mi
Latches/locks/linkagesDoors › Latch	13	0	0	7	60,000 mi
Steering	13	0	0	0	132,160 mi
Unknown or other	12	1	0	2	85,495 mi
Power trainClutch assembly; Automatic transmission	10	2	0	0	43,750 mi
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Foundation components › Disc › Rotor	8	3	0	2	15,692 mi
Service brakes	7	3	0	2	98,000 mi
Fuel system, gasolineDelivery › Hoses, lines/piping, and fittings	5	0	0	0	61,588 mi

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Steering
2004 Hyundai Sonata GLS front sub frame (K Frame) has rusted out but I guess for certain VIN numbers there was a recall. Mine has the same issue and has caused suspension issues with the control arms and axles, subframe has snapped due to rusting in Michigan.
Apr 28, 2026
Suspension
On February, 16th 2026, I took my vehicle into the Automotive shop for an oil change. They inspected the car as well and they found that the front passenger side of the vehicle subframe has a substantial amount of the metal rusted through. The file attached was a photo of the repair invoice from Lukeâs Auto in Upper Arlington, OH. I see that there is an open safety recall for this exact issue on the 2004 Hyundai Sonata. Although this recall was sent out in 2009, am I able to take this to a local Hyundai dealership to have this fixed?
Feb 16, 2026
Suspension
I got this car a Hyundai sonata 2004 about 2 to 3 years ago. At first I didn't notice the problem until a couple months into me having the car I was on the freeway and it suddenly felt like I was out of control of my car and the back end was like swerving like I was pulling a trailer. And ever since then it's gotten worse now my front right tire goes flat randomly. A friend mechanic of mine looked at it and said that it is a suspension He just doesn't know what part of the suspension. This is dangerous because I could lose control of my car I have at any time. That could be detrimental and there is a recall in it seems like almost every other state but Utah. For the exact issue that I'm…
Aug 14, 2025
Unknown or other
My 2004 sonata which was manufactured 05/07/04. has front frame corrosion exactly like the 089 safety recall that hyundia issued already for 1998-2003. My car was manufactured a few months later and they are denying the repair because it doesnât fall in their production dates.
Mar 7, 2025
Suspension
I currently own a 2004 Hyundai Sonata with a severe sub-fame deterioration, Unfortunately it does not fall under the so called salt belt states, That being said I don't know how Kansas does not fit that especially north east Kansas. Wondering if there's some way that they could reconsider on this matter and maybe get some help. I know the cars almost 20 yrs but it's in good shape with only 108000 miles on it. Thanks for any help with this matter. I was just informed by Hyundai that they would not do anything with it so I guess my only option is to drive it at my own risk and hope for the best. Regardless I'm very upset with there decision and that there okay with a persons life knowing this…
Apr 15, 2009
Air bagsCrash2 injuries
The contact owns a 2004 Hyundai Sonata. The contact stated her fiance was driving 20-25 MPH on a steep hill with her in the front passenger's side seat. The contact stated that her fiance depressed the brake pedal to come to a complete stop at the stop sign, but the brake pedal went down to the floorboard, and the vehicle failed to respond. The contact's fiance veered to the left and intentionally hit a telephone pole to avoid crashing into a parked vehicle, and to prevent a more severe accident from occurring as the road was significantly steep. The brake warning light was illuminated. The air bags failed to deploy. The contact sustained a seatbelt mark. The contact's fiance was not…
Nov 6, 2023 · 185,000 miles
Engine
UNKNOWN, I recently purchased it from a dealership in Lemon Grove Cailfornia. Ever since I bought it,it has never had a catalytic converter and only one muffler. It is a 2.7L motor DOHC and requires 2 catalytic converters and dual exhaust due to the double overhead cam. It has cause motor oil into my engine block and has coughed my heater core. Also blown head gasket. I have hired certified ASE mechanics to replace parts and then I run into another problem.
Aug 25, 2023
Suspension
The contact owns a 2004 Hyundai Sonata. The contact stated while driving approximately 30 MPH, the accelerator pedal was depressed, and the vehicle started shuddering. The contact stated she heard abnormal creaking and cracking sounds. The contact stated no warning light was illuminated. The contact stated that the failure had become more frequent. The contact had taken the vehicle to an independent where it was diagnosed and determined that the front subframe, lower panels, and control arms needed to be replaced. The vehicle had not been repaired. The manufacturer had been informed of the failure. The contact researched online and related the failure to NHTSA Campaign Number: 09V124000…
Mar 3, 2023 · 147,000 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

FRONT SUB-FRAME CORROSIONClosedLed to recall 09V124000
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…
EA08016 · opened Aug 21, 2008 · closed Apr 20, 2009