16 problems related to frame rust have been reported for the 2002 Hyundai Sonata. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2002 Hyundai Sonata based on all problems reported for the 2002 Sonata.
The contact owns a 2002 Hyundai Sonata. The contact stated that the heat shield fell off the vehicle. The vehicle was taken to an independent mechanic who diagnosed that the subframe was severely rusted and corroded. The contact stated that the vehicle was taken to another independent mechanic who diagnosed that the undercarriage had severe rust and corrosion, and was unsafe to drive. The vehicle was then taken to grossinger Hyundai of palatine (221 e lake cook rd, palatine, IL 60074 (847) 348-6700) where it was diagnosed that the rear subframe was severely rusted, needed replacement, and was unsafe to drive. The vehicle was not repaired. The manufacturer was notified and did not assist. The failure mileage was approximately 165,000.
The vehicle started making a noise and driving weird. It looked like one tire was pointed straight and the other tire turned slightly. I stopped at a gas station to see what was wrong and they said the a frame was almost rusted into. I had already had the metal in the rear of the car replaced from being rusted out near were the shock attaches. I have researched and seen where several Sonatas have been recalled due to severe rust issues. The body even has been rusting badly. The bigger concern is the frame. I am afraid to drive it now. Do not know what recourse I have. This happened while driving. The car is now parked and am afraid to move it, even to a garage.
The contact owns a 2002 Hyundai Sonata. While driving approximately 35 mph, the contact heard a loud banging noise near the front end of the vehicle. The contact discovered that the lower control arm on the passenger side had separated because the subframe was rusted. An independent mechanic diagnosed the vehicle and confirmed the cause of the failure. The vehicle was not repaired and the manufacturer was notified. The failure mileage was 206,341.
The contact owns a 2002 Hyundai Sonata. While driving approximately 33 mph, the contact's vehicle struck a pothole. As a result, the contact veered to the right and crashed into another vehicle. The air bags deployed. The contact sustained a neck injury that required medical attention. A police report was filed. The vehicle was taken to an independent mechanic where it was diagnosed that the subframe was rusted and failed to support the control arm. The technician informed that the subframe needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and stated that the VIN was included in NHTSA campaign number: 09v124000 (suspension). The failure mileage was 105,000.
The contact owns a 2002 Hyundai Sonata. While driving approximately 5 mph, the contact heard a loud crunching noise and the vehicle stopped moving. The contact noticed that the front passenger side wheel was pointing outward. The vehicle was towed to an authorized dealer who stated that the subframe had rusted. The vehicle had not been repaired. The current and failure mileages were 122,050.
Excessive sub frame rust caused it to brake, and as a result practically disabled driving and almost led to an accident on highway. Control of the vehicle is very dangerous, as the wheels are angled differently because of the sub frame bent.
Front subframe rusting out.
The contact owns a 2002 Hyundai Sonata. The contact stated that entire rear subframe had rusted. The contact called the dealership and was advised to take the vehicle in for diagnosis. The vehicle had not been repaired for the problem at the time the complaint was filed. Also, while driving at 40 mph, the vehicle would drop from fourth gear to first gear suddenly. The vehicle was taken to the dealership and repairs were performed on the censors; however, the problem was not fixed. The failure mileage was approximately 95,000. The current mileage was approximately 112,000.
My frame on my car rusted through leaving my car sitting on my tires literally! while driving through town. I have called the Hyundai manufacturer and they took down information, I am now waiting on the decision if it will cost me anything or not.
Subframe rusted completely through. Luckily this was discovered during a repair of a power steering failure. This is a common complaint regarding the 1999-2004 Sonata in high salt areas and Hyundai is apparently replacing the frame out of warrant (mine was under an extended warranty anyway). I believe this should be a full recall to protect those who are otherwise unaware of this defect which has caused, in some cases, wheel separations. Dealer told me that the part had a large hole completely through the frame.
Took my 2002 Hyundai Sonata to our local repair shop for state inspection and he told my husband that my subframe was completely rusted out. . . He could stick his fingers all the way through the frame. He said it was very dangerous and to call our local Hyundai dealer. I did and the service guy there said to bring it in for inspection. That they have identified the rusting out of Sonata subframes as a problem and under "goodwill". . . . They will fix it for free, unless the car has been wrecked. Told him my car was not wrecked. . . . In for state inspection only. I have just recently noticed when driving my Sonata the steering wheel shaking very bad. . . . Especially when breaking on a hill. I thought maybe my brakes were going bad. No!!! it was my rusted out subframe. I believe there should be a class-action lawsuit filed. I have to take my Sonata to the dealership in 5 days so they can order a new subframe. Thankfully, none of my family has been injured because of this. What I want to know is. . . . . Why hasn't their been a recall on this for Sonatas???? is Hyundai going to wait for fatalities before they take action??? our mechanic told us the engine could fall off and/or our tires could break off while driving. And we don't do alot of city driving. . . . Mainly highway driving and my 17-year old son has been driving this Sonata. I thank god nothing happened while he was driving the Sonata. Please respond to me ASAP. There needs to be a recall now!! I am contacting other Sonata owners who've had the same problem and we are getting a class-action lawsuit together.
Took my car to shop today because the power steering was leaking, hard to turn on corners - this first appeared yesterday. I was hearing odd noises from under the car on the way to the shop. Mechanic put car on lift and showed me how the engine cradle/frame is rusted through. They suspect the problem started above and worked through as I have been a fanatic about regular maintenance on this car - always with the same shop so they know me and the vehicle. Now I'm waiting to see if Hyundai will cover this.
The contact owns a 2002 Hyundai Sonata. Upon taking the vehicle in for inspection, the mechanic discovered that the subframe was rusted in several places. The contact was advised not to drive the vehicle. There were no recalls for this failure. The current and failure mileages were 85,000.
The contact owns a 2002 Hyundai Sonata. The contact stated that there was rust under the frame of his vehicle. The dealer stated that they have never seen any other vehicles with rust under the frame. The contact welded the rusted frame onto to the vehicle over a year ago. The contact received a recall notice; however, the dealer informed him that since he did such a good job welding the frame back together they didn't have to work on it. They also informed him that they are not going to replace the frame. The contact asked the dealer for a guarantee in writing that the frame would not break again. He also asked the dealer to replace the frame with a new frame. The VIN is not available. The failure mileage was 63,000.
I have an 2002 Hyundai Sonata. My complete subframe rusted out a few years ago. The car was only 3 or 4 years old at the time. The complete subframe was replaced on a hush hush bases. I have the pics to prove it. Never will I buy another Hyundai or kia never. My god my family could have been killed. But what do they care it's not their family.
I own a 2002 Hyundai Sonata with the engine cradle frame completely rusting out. Vehicle failed nh state inspection and is considered unsafe to drive at this point. Mileage: 123,000.