Two problems related to power steering fluid 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.
On 11/3/08 I filed odi#10248441 regarding rotted right side sub-frame on my 2002 Hyundai Sonata which was repaired by dealer on 11/11/08 as a 1 time "goodwill" replacement. During replacement of sub-frame dealer damaged and replaced flexpipe and bolts. Car was returned and started leaking fluid which was found to be power steering fluid. We monitored and replaced fluid but steering was difficult and made noise mostly on start-up and turning corners. On 12/1/08 we had to have the car towed - we lost the power steering completely and it would no longer hold fluid. Dealer stated that power steering rack mount was completely cracked and had to be replace at a cost of over $1,000. We are refusing to pay for repair stating that cracked steering mount is related to rot problem and is the dealers responsibility. 12/3/08 we opened a case with Hyundai consumer complaints . Based on information researched on this site and other related sites the cracked power steering mount is common and related to rot problem. Currently waiting for a response from Hyundai. Car only has 41,400 miles and we have already had to replace brakes, tires, heat sensor, and sub-frame in addition to normal maintenance.
The insulated piece of tubing that covers a small portion of the power steering line should be replaced with a breathable type of product. My power steering fluid is leaking and it is not due to wear and tear on the vehicle. That portion of insulation on the power steering line retains moisture, therefore it causes that portion of the power steering line to rust and the fluid leaks out. This seems to be a manufacturing defect especially when the car has only 59,200 miles on it. Every two days I put in power steering fluid until I get an answer in reference to the warranty. This line has to be replaced.