Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Hyundai Santa Fe owners, lightly cleaned up (personal details are redacted by NHTSA).
This was a recall for hundai santa fe vehicles from 2001-2006. For unknown reasons I was not aware of recall. It was for 15 years or 150 miles. It is a danger as my car leaks gas. I am at 135,000 miles. But my car is a 2004. I purchased the vehicle in the last 2 years. I believe the recall should extend till the repair is complete for the reasons as follows. 1. it can explode. 2. it is a polluter 3. Hyundai acknowledges it as faulty equipment. 4. Corporations must be resonsible or they are irresponsible. 5. Cars are expensive they must maintain as least minimum safety requirements.
When car parked smell of gasoline, looked under car on drive side of tank has tiny drop off fuel come from plastic cover of tank and a drop on ground looks it was spread by continuous slow weeping when parked, draw for a while came back parked went back and check under same spot tiny drop on ground coming from plastic cover drain hole, did not seem loose much gas, park over weekend found drip smell and the dry spot seemed about one foot in diameter and strong odor when go near back of car, noticed this at parked vehicle, over night parked the spot is about 6 inches dried wet about 1 inch every day last few weeks. …
Car stalls without warning while driving. First occurrence was over a year ago. I was driving down i5 going 70 MPH when the car suddenly died. I lost my power steering and brakes. I managed to coast to the next exit. It started after sitting a few minutes. And I was able to make it home. I've received codes for camshaft sensor, misfires, low catalyst. I've changed the cam and crank sensors, coils, spark plugs, timing belt and assembly, fuel pressure regulator and fuel pump over the past year. Still having the issue. Car drives fantastic for about 10 miles and stalls out. After waiting about 5 min. It can be driven for another few miles before stalling out again. Check engine light does not turn on when it stalls now. Very dangerous when trying to drive in town or attempting to merge into traffic. You never know when it will stall out.
I smelled gas recently when opening and getting into my 2004 Santa Fe. I took it to a car repair shop. They inspected it and found rust holes in the gas tank which gas was leaking out of! I can't imagine the how terrible an event could have occurred if the leaking gas had exploded when I started the car or been close to an open flame with the car when it was leaking. I have owned many cars in my life and have never had a fuel tank rust out. I think the NHTSA needs to take a very close look at this problem and possibly issue a recall on the gas tanks of Santa fes and other vehicles they manufacture that use the same gas tank.
Tl* the contact owns a 2004 Hyundai Santa Fe. While the vehicle was parked, there was an abnormal odor of fuel inside and outside the vehicle. The contact noticed fuel leaking and that the check engine indicator was illuminated. The vehicle was taken to a local dealer (columbia Hyundai, 10981 montgomery rd, cincinnati, oh 45249, [phone]) where it was diagnosed that the coil spring and fuel tank needed to be replaced. The contact was informed that the vehicle was 15 years old and exceeded the mileage to be included in a recall. The manufacturer was not notified. The failure mileage was 198,000.
When I put gas in my car it will not start afterward. First it started only when my car was turned off. When I left my car running it was OK. Now it turns off when my car is running also. The mechanic said, it May be a bad fuel pump, cost $350 to replace, but can't guarantee this will fix the issue. I see I am not the only one with this issue. Why is this not a recall?? I google it and there are so many people with same problem. Also with the car accelerating by itself. I thought I was crazy. I see now that others are having this problem as well. Everyone said I imagined it. Why is this not a recall?
My Santa Fe stay over nite, inside my garage and I notice very strong odor of gasoline every time I open my garage and after I look under, I spot a drop of gasoline on the passenger side between a plastic cover and the fuel tank, while is park over nite, while I am driving I am afraid that something happen, like people throwing cigarette but and cut my car on flame. After I read other people recent complaints I decide to stop using my Santa Fe, I think this is a defect from Hyundai to create a fuel tank that holds water and salt between the tank and the cover.
A strong odor of gasoline was noticeable upon entering my garage. Further inspection revealed gas leaking from my '04 Hyundai Santa Fe. The service station determined that a fuel tank and center heat shielding replacement was necessary as both were defective, leaking fuel, and posed a very high risk of danger. Needless to say, I was stuck paying a very hefty bill to the repair center rather than worrying about blowing up myself, my passengers, or my house. I see that there have been other complaints about the same problem with this make and model of Hyundai.
Tl* the contact owns a 2004 Hyundai Santa Fe. While the vehicle was parked or being driven, there was a strong fuel odor coming from the vehicle. In addition, there was fuel leaking from the rear of the vehicle. An independent mechanic stated that fuel was leaking from the seam of the fuel tank and the fuel tank needed replacement. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 138,900.
Bought an used 2004 Santa Fe in August from a dealer. Two weeks ago I started noticing a strong smell of gas around my vehicle and last week I began seeing a small discolored area on the cement in the garage. Mom checked my vehicle and found that the my fuel tank is leaking. The discoloration of the cement under my vehicle is in fact leaking gas. Tank is corroded and I will need a new tank installed.
Fuel System complaints in other Santa Fe years
Frequently asked questions
How common are fuel system problems on the 2004 Hyundai Santa Fe?
NHTSA has 40 complaints about the fuel & propulsion system of the 2004 Hyundai Santa Fe, 13% of the model year's 303 complaints. The component named most often is delivery › fuel pump (1 mentions).
Is there a recall for 2004 Hyundai Santa Fe fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 Hyundai Santa Fe, though it has 3 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Hyundai Santa Fe fuel system problems start?
Half of the complaints with a recorded mileage happened before about 100,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.