Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2001 Hyundai Sonata owners, lightly cleaned up (personal details are redacted by NHTSA).
Upper rear control arm is connected to the subframe of the car and it's rotted/ rusted out where the bushing goes to hold the control arm in place. Where am I supposed to mount the bushing now since it's no longer there.
Noticed an issue in January 2010: took car to a auto-repair shop for repair; new tires and alignment service. On 03/22/2010 while leaving a shopping mall the vehicle lost control and veared a hard left into a cement light pole in the middle of the parking lot. (I was able to apply the brakes in time and turn the vehicle) only damage was to the front driver side bumper and quarter-panel, body damage only. I then tried to drive the vehicle which at that point operated in drivable condition. On my way to the auto-repair (less then 1 mile away) my vehicle completely broke down in the middle of an intersection in another shopping plaza. The car was then towed to the auto-repair shop, which then later called and explained that the frame of the car was cracked and the whieel was detatched. …
While rounding a gradual curve at approximately 50mph suddenly lost steering control and went off road. Examination of vehicle subsequent to the accident revealed loss of control caused by severely rusted right (passenger side) front subframe and approximately 8 inch hole and bending/cracking of such due to the rust, this on a vehicle which is otherwise pristine (there is absolutely no rust elsewhere on the vehicle). I urge NHTSA to require Hyundai to address what I have now learned is a very common problem with the model in question, especially before any other lives are put in jeopardy or lost due to what is clearly and obviously a gross manufacturing and/or design defect. …
Control arm completely separated/ broke from the subframe. Called Hyundai as mechanic said this should have been included under a recall that came out several years ago for "because of a potential corrosion risk involving the front sub-frame...corrosion May progress and the forward mounting of the lower control arm May detach from the sub-frame. If that happens, the vehicle May lose driver power to the wheels. The front wheel May make contact with the fender or wheel well." "separation of the forward mounting of the lower control arm May increase the risk of a crash" this is exactly what happened to my 17 year old daughter yesterday and fortunately she did not crash as she was not in a populated area, but it could have been much worse. Why is this particular 2001 Hyundai Sonata not covered under this recall. It needs to be covered and covered asap. Please assist. …
Tl* the contact owns a 2001 Hyundai Sonata. While making a right turn, there was an abnormal noise coming from the front passenger side tire. It was discovered that the control arm had fractured from the frame, which was crumbling due to rust and corrosion. The vehicle was towed to an independent mechanic for diagnostic testing and then towed to the contact's residence and to the dealer (Hyundai of chantilly, 14848 stonecroft center ct, chantilly, va 20151, [phone]). The contact was not sure if the vehicle was included or excluded from NHTSA campaign number: 09V124000 (suspension). The manufacturer was to provide a follow-up response to determine their solution for the dealer's repair. The vehicle was unable to be driven due to the failure. The approximate failure mileage was 133,000.
While driving my 2001 Hyundai Sonata, my right front lower control arm broke off, separating my wheel / it collapsed. The tow truck driver told me this and showed me how severe the sub frame was corroded. It broke off, he never saw anything like it. Please help. Is this a recall that I didn't get?
Tuesday, August 5, 2008, I brought in my 2001 gls v6 Hyundai Sonata to balise Hyundai of cape cod in hyannis, ma. My car had approximately 166,500 miles on it at this time. I was looking to get a throttle position sensor replaced. During their diagnostics, with the car on a lift, they noticed two things. One, a power steering leak was occurring most likely because of a corroded power steering line near the passenger side of the subframe. Two, in the immediate area of the suspected hose failure, the subframe had rusted through on two sides of the piece. The main hole in the subframe is fist-size or larger and the second is not good. I was informed that the subframe issue was a major safety hazard and warned me of what could happened should it fail. They also told me about the difficulties that replacing it could bring. …
2001 Hyundai Sonata v6, with under 120K miles. Tires replaced for wear and alignment performed on week of 12/08/2008. Mechanic pointed out alignment a moot point due to right sub frame, aka k-frame,aka engine frame, aka right wheel suspension mount was rusted through to point of being able to enter rust cavity with all fingers. This resulting to cracked subframe at wheel well side were suspension is mounted. Some complainants report leaking power steering line from overextended distance from frame stretch . This also is a problem in sante fe. I imagine the same k frame being used a cost saving measure. I'm now waiting for Hyundai America to respond to my case #3460531. Don't you believe anyone who discounts this as being out of warranty. …
Was informed approximately 2006-2007 by good samaritan, bill osterhage, that his daughter's 2002 Hyundai front tire rod axial broke d/t major corrosive issues with frame defects. He contacted an attorney for class action law suit to be started d/t safety issues to prevent death to others & repair frame to rob carey at rob.carey @att.net & [email]. From 2006- until 2009 during routine oil changes, I asked kerry Hyundai in alexandria, ky to check my frame d/t visual rust & about recall. Hyundai finally admitted after multiple complaints during routine maintenance in a letter to me on 6/24/09 that there was a recall on 4/16/09 and my frame to be replaced. 8/15/16 I lost control of my 2001 Sonata, Hyundai while driving on expressway during rush hour d/t major corrosive issues causing right rear tire rod to break. I did two 360 degree turns from fast lane to slow lane. …
2000 Hyundai Sonata with a defective sub frame. Consumer would like to be reimbursed for expenses on the repair of the sub-frame. He also believes that Hyundai needs to put out a recall on them and get them fixed due to concerns with the sub-frame. The consumer stated as he was driving, the lower control arm of the front passenger wheel disconnected from the vehicle which caused him to slide to an immediate halt. The cause of the failure was due to a poorly designed frame which rusted and rotted so badly that the control arm had fallen off the frame, the axle ripped from the transmission and the wheel had slammed into the wheel housing and quarter panel. The insurance company declared the vehicle a total loss due to the extent of the damage prior to the frame damage, the consumer experienced a flat tire which was due to excessive wear on the inside of tire.
NHTSA investigations
Front sub-frame corrosion
The office of defects investigation (odi) opened preliminary evaluation, pe08-029, on April 22, 2008, based on 40 consumer complaints alleging front sub-frame corrosion in model year (my) 1999 through 2002 Hyundai sonata vehicles.complaints describe severe corrosion of the vehicle sub-frame in the area where the right-front lower control arm is attached.in some vehicles, sub-frame corrosion has caused complete or…
Front sub-frame corrosion
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,…
Body complaints in other Sonata years
Frequently asked questions
How common are body problems on the 2001 Hyundai Sonata?
NHTSA has 69 complaints about the body & structure of the 2001 Hyundai Sonata, 34% of the model year's 205 complaints. The component named most often is frame and members (51 mentions).
Is there a recall for 2001 Hyundai Sonata body problems?
No. NHTSA lists no body & structure recall for the 2001 Hyundai Sonata, 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 2001 Hyundai Sonata body problems start?
Half of the complaints with a recorded mileage happened before about 114,000 miles, and 2% before 25,000 miles.
Is it dangerous?
Owners linked 3 crashes, 0 fires and 3 injuries to body & structure 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.