Body problems of the 2004 Hyundai Sonata

18 problems related to body have been reported for the 2004 Hyundai Sonata. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Hyundai Sonata based on all problems reported for the 2004 Sonata.

1 Body problem

Failure Date: 06/10/2022

The front subframe has a hole in it it rusted for some reason and upon research there was a recall on this particular issue but now there isn’t one. I went to two dealerships and they informed me that Hyundai had recalls on this issue that’s why I’m confused on why when I search by my VIN there isn’t any open recalls. Just because they isn’t any open recalls on this doesn’t mean that people aren’t still experiencing this issue.

2 Body problem

Failure Date: 01/19/2022

I own a 2004 Hyundai Sonata. On 1/19/22, while driving the car, the brakes started failing. I was able to drive the car to my independent mechanic's shop and they repaired the brake issue with a fabrication and installation of the brake line. As my inspection was due, I made an appt with them to bring it back for inspection before the month was over. When I did bring it back however, another mechanic (who apparently had seen underneath the car when they did the brake work) stated that it would never pass inspection as the corrosion was severe. I then made an appt on 2/9 with the dealer who sold me the vehicle. The dealer however stated that the VIN was not included in the NHTSA campaign 09v124000 (suspension). I believe it should have been included in that recall and that I am entitled to the "remedy" outlined in the NHTSA recall.

3 Body problem

Failure Date: 04/01/2021

The contact owns a 2004 Hyundai Sonata. The contact stated that while at the local dealer faulkner Hyundai (11500 roosevelt blvd, philadelphia) for routine maintenance, it was discovered that the k-frame had sustained severe rusting and corrosion. The cause of the failure was not determined and the vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 73,000. ## #vpic# 3 - VIN corrected, error in one position (assuming check digit is correct); 14 - unable to provide information for all the characters in the VIN. #vpic#.

4 Body problem

Failure Date: 08/24/2018

Tl- the contact owns a 2004 Hyundai Sonata. The contact stated that when the vehicle was inspected for routine maintenance, it was diagnosed by the independent mechanic that there had been extensive rust and corrosion concerning the front frame, the rear frame, near the front passenger side tire and near the front rear tire tie rods pertaining to the sub-frame. The independent mechanic referred the contact to call the manufacturer for a recommendation. The manufacturer had a dealer key Hyundai of salem, 470 s broadway, salem, nh 03079, (603) 841-3099 schedule an appointment 08/28/18 to diagnose and repair the vehicle. The contact was not included in NHTSA action number: ea08016 (suspension, structure) and NHTSA campaign number: 09v124000 (suspension). The manufacturer provided no remedy, stated the vehicle was excluded from the recall campaign and to have the dealer repair the vehicle. The approximate failure mileage was not available. Dyd.

5 Body problem

Failure Date: 09/15/2017

Worn rear tires prompted purchase of new tires. Tire technicians noted that the frame was cracked and that the vehice is unsafe to drive. Both rear tires are in jeopardy but the rear passenger side is by far the worse. Vehicle had been making odd noises especially when turning and some vibration at spweds over 40mph. Fortunately the the tires didn't fall off while in motion.

6 Body problem

Failure Date: 05/03/2017

Tl-the contact owns a 2004 Hyundai Sonata. The contact stated while driving at unknown speeds the steering was unstable and the vehicle was shaking. The check engine was illuminated the vehicle was taken to a independent mechanic where it was diagnosed that the cradle had a large rust spot. The vehicle was not repaired. The manufacturer was not made aware of the failure. The vehicle mileage was 188,000. Ap.

7 Body problem

Failure Date: 08/15/2016

Front lower control arm broke due to rust while being driven. Pulled off the road and called tow truck. Operator told me to look up Sonata recalls because it looked like one. It was recall # 09v124000. Called local dealership 6 times in two days always going to answering machine. Third day drove to dealership. They told me to bring it in and they would look at it. Tow guy said every time it it was moved more damage would be done. He didn't want the responsibility. Dealership wouldn't pick it up. Tow guy called another dealership and he brought it there (8/20/16) five days after the breakdown. After 5 days second dealership said it was a recall item and said to call Hyundai America. Began discussions with Hyundai America- many calls- and after over 60 days they decided it was between the dealership and some other department of Hyundai America and they couldn't do anything. Dealership gave me another # to call but that # had no knowledge of my case. The expense of being without the car has been quite draining. Case # with Hyundai America is 9566309. I would like the car completely repaired but can't get anyone to do anything. Thanks.

8 Body problem

Failure Date: 08/01/2016

The contact owns a 2004 Hyundai Sonata. Upon taking the vehicle to a mechanic for inspection, it was diagnosed that there was internal corrosion on the front subframe and the seal was deteriorating. The dealer and the manufacturer stated that there was no recall to address the repair. The manufacturer provided no repair solution. The VIN was not available. The approximate failure mileage was 104,000.

9 Body problem

Failure Date: 04/15/2016

The contact owns a 2004 Hyundai Sonata. While driving 10 mph, subframe fractured. The failure caused the front axle to fracture and separate from the vehicle. The front axle was cut away from the subframe to have the vehicle towed. The vehicle was towed to the dealer to be diagnosed, but was not repaired. The vehicle was included in NHTSA campaign number: 09v124000 (suspension). The manufacturer was not notified of the failure. The approximate failure mileage was 164,000.

10 Body problem

Failure Date: 03/19/2015

Severe rust affecting undercarriage. Vehicle was part of recall for sub frame assembly and had to have entire engine cradle replaced. Remaining sections of undercarriage not included in recall, fuel lines, brake lines, suspension are also severely corroded as well as large portions of the passenger rear side body panels. Brake lines in rear portion of vehicle corroded so badly they failed and had to be replaced. Top portion of fuel pump located in top of gas tank also severely corroded.

11 Body problem

Failure Date: 07/06/2014

My wife somehow got her foot caught in her sandal and trying to get it unstuck hit a concrete light pole. The airbag shot white powder out ,light went on to show air bag went off but it never deployed. Had it been a worse accident fatal injury could have occurred because of faulty airbag not deploying yet showing it did by all symptoms such as the light, white powder and the seat belt cannot be moved and will not operate. This is a safety issue no matter if under warranty or not.

12 Body problem

Failure Date: 04/29/2014

The car was parked in a residential parking area. It had been backed into the space. After starting the car and putting the transmission in drive, the car accelerated uncontrollably. This occurred so quickly the driver was unable to control the vehicle. Brakes did not stop the vehicle. It appeared that the accelerator was stuck. The vehicle hit a car in the next row of cars. Because of rain, the car then skidded 180 degrees and struck two cars in the same line of cars from which it had departed. Only at this time by turning getting the car out of gear and turning the key could the car be stopped. The driver believes this was the result of either a the accelerator sticking on its own or a thick rubber winter mat slid up and jammed the accelerator.

13 Body problem

Failure Date: 12/05/2013

The contact owns a 2004 Hyundai Sonata. The contact stated that the front passenger's side exterior door handle became fractured while the contact attempted to access the door. The vehicle was not repaired. The manufacturer was not notified of the problem. The approximate failure mileage was 83,954.

14 Body problem

Failure Date: 09/19/2012

Tl- the contact owns a 2004 Hyundai Sonata. The contact stated that he discovered internal corrosion of the front sub-frame on the vehicle. The vehicle was taken to an independent mechanic for diagnosis but the vehicle was not repaired. The manufacturer was notified but offered no assistance. The vehicle had not been repaired. The failure and current mileages were 124,000. Kmj.

15 Body problem

Failure Date: 09/13/2012

Driving on clear paved street @ approximately 20 mph when loud crackling noise of front right fell to pavement. No loss of control, merely steered vehicle off main lane of street. No structure or object found on paved street for approximately 50 yds to final point of exiting off of street. Witness in car with driver can attest to no pot holes or other noted objects anywhere in area of tire markings on paved street. Auto required full tow to closest dealership.

16 Body problem

Failure Date: 05/15/2012

The frame to the car has a hole rusted thru the lower control arm bolt and is no longer drivable. The car was stranded on the highway and someone could have been killed Hyundai says its not covered under the recall but its the exact same problem as all the rest.

17 Body problem

Failure Date: 10/02/2010

Interior chrome door handle crack, causing the chrome plating to separate. After separation the handle becomes extremely sharp and cut my hand.

18 Body problem

Failure Date: 07/14/2008

+the interior door levers chrome is peeling off causing the levers to have sharp edges which cut your fingers.


Other Structure related problems of the 2004 Hyundai Sonata


Safety Ratings of Sonata Cars
Fuel Economy of Sonata Vehicles
Sonata Service Bulletins
Sonata Safety Recalls
Sonata Defect Investigations