Which parts fail
Components named in complaints (service brakes, ABS, rotors and pads, parking brake).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Hyundai Sonata owners, lightly cleaned up (personal details are redacted by NHTSA).
I have a Hyundai Sonata. Its 2002 with 50,000 miles on it. The first time it gave me trouble, it was making a grinding sound while driving to work. The mechanic changed my caliber on one side of the car and replaced my hoses. Next month same sound started again. My mechanic changed the other caliber. Six months later. I started hearing that same sound and the brakes started locking. The mechanic didn't see anything wrong. Two weeks later, I lost my brakes while driving on interstate 10. I was able to coast to a stop without any incidents. I had my car towed to my mechanic.I was told I damaged the master cylinder. He put all new parts in my car (brake shoes,pads, calibers, master cylinder, etc.) and tested it. The next day while driving on I-10, it started locking up again. It has baffled my mechanic. My car is still in the shop. …
Dt: the contact owns a 2002 Hyundai Sonata lx. The brake line was attached to where it was suppose to be attached and it rubbed against the cv boot, causing the brake line and the cv boot to fail. The contact brought car last October to dealer because the cv boot failed and it was replaced under warranty. Currently, the brake line and the cv boot failed, causing vehicle to hit a garage. The dealership said it looked as if the brake line came loose from where it was suppose to be, and it was not covered under warranty. The consumer had to replaced the brake line with a temporary one in order to take the vehicle to the dealer for repair. The delaer claimed that whoeverr replaced it installed in improperly. The contact felt that this happened because of the brake line was rubbing against the cv boot. She replaced the brake line out of pocket. …
On cold mornings where the temperature would drop below 30, I was experiencing a loss of brake ability. This would only happen the first time I drove the car in the morning and always on the second or third tap of the brake pedal. I went to my dealership in November/December 2002 and they drained the brake line and told me it was fixed. It was not and I had to go back. This last time I could not stop in traffic and had to roll thru a busy intersection. The brake pedal would actually freeze up or lock in the "up" position in the car, therefore not allowing me to press down to stop. The emergency brake would work. My dealer had the car for more than a week before he was able to find the problem and fix it this second time. I believe he said it was a defect in a specific part. He told me "booster vacuum line check valve frozen shut" and he replaced the booster hose. …
We had our vehicle warrantied for the rotten frame on our vehicle last year. At that point you would think Hyundai would have warned us that our brake lines were swiss cheese just like our frame, these cars rot out, the entire vehicle is a death trap. The brake lines broke 3 times in the past 6 months after sections were already replaced. These vehicles need all the brake and fuel lines replaced immediately!!! This is not routine maintenance and should be recalled immediately!! The power steering line rotted out 5 years ago, this car was made out of really crappy metal. Dangerous vehicle. Everything on this vehicle is rotted out beyond what is normal, the wheels, the brake drums, everything on these vehicles rot to the point of swiss cheese. After 10 years these vehicles are very unsafe. Our vehicle only has 50,000 miles on it.
I was driving my vehicle under normal conditions on a major highway. Upon approaching an exit I applied the brakes to reduce my speed. The brake pedal went all the way to the floor and consequently I engaged my emergency brake to stop the vehicle. The brake warning light did not come on until I brought the vehicle to a complete stop. No accident ensured as a result. I had my vehicle towed to a repair facility where repairs were made. Repairs consisted of a complete replacement of all brakes lines since they were all rusted and corroded. Old parts are not available. A few months prior to this incident all the power steering lines required replacement due to rust and corrosion. The complete exhaust system currently requires replacement due to rust and corrosion (system is leaking).
Problems with brake equipment on Hyundai Sonata. While braking the consumer heard a noise front he rear of the vehicle. Over time the noise progressed into a grinding noise. The vehicle was taken to the dealer at 19400 miles and the consumer was informed that the rear brake pads needed to be replaced. The technician showed the consumer the corroded and dirty surfaces that the brake pad holder rested on. This surface is horizontal and does not allow the surface to drain or clean itself. The brake rotors were replaced by the dealer but the consumer was charged $160. For the labors and brake pads. The consumer believes that having the brake replaced at 19000 miles is unreasonable and request reimbursement.
The brake lines from engine to the back of the car need to be replaced because one of the attachments (holding the brake lines in place underneath the car) got rusted and corrosion. Then it caused the brake line to get rusted and brake fluid started to leak pretty bad. Is it normal for the brake lines to get rusted?? Should I report to Hyundai? The brake fluid reservoir went empty so quickly and I found the leaking spot. It squirts pretty bad when I apply the brake pedal. The leaking spot is underneath the car where the back seats are located. I need some advise before I start doing something. Thank you.
Dt: caller got into car, pulled it out of garage and got out of it. When she got back into vehicle and put it in gear it made a screaming noise and accelerated. She hit the brakes, but they did not work. She tried to stop the car by going up a hill instead vehicle hit a house three doors away. Upon impact, air bags did not deploy. Insurance claimed that dealer said there nothing was wrong with car. Manufacturer has not been contacted yet.
Front disc brake rotors we have two 2002 Hyundai sonatas, model gls 6 cylinder. Both cars have had ongoing problems with front rotors warping and having difficulty braking to an emergency stop. The dealer has replaced rotors on each vehicle once, and within an 18 month period, the problem re-occurs.
Dt: rotors have gone bad. The brakes pump back when brakes are depressed. The dealer turned the rotors at 13624 miles and within 1000 miles the rotors warped again. The dealer was unable to find the cause of the problem. Another service center indicated that eh rotors needed to be replaced.
Brake complaints in other Sonata years
Frequently asked questions
How common are brake problems on the 2002 Hyundai Sonata?
NHTSA has 26 complaints about the brakes of the 2002 Hyundai Sonata, 8% of the model year's 320 complaints. The component named most often is foundation components › disc › rotor (5 mentions).
Is there a recall for 2002 Hyundai Sonata brake problems?
No. NHTSA lists no brakes recall for the 2002 Hyundai Sonata, though it has 7 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 2002 Hyundai Sonata brake problems start?
Half of the complaints with a recorded mileage happened before about 40,000 miles, and 50% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 1 fire and 1 injury to brakes 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.