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 2004 Hyundai Sonata owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2004 Hyundai Sonata. The contact stated that while driving the vehicle, she noticed that her brakes were failing. The contact stated that she drove her vehicle to an independent mechanic who attempted to replace the brakes however, the mechanic informed her that her vehicle had a lot of corrosion on the brakes, and underneath the vehicle, which caused the brakes to fail. The contact stated that the mechanic did fabrication and installation of the brake line. The contact stated that she then took her vehicle to be inspected and was informed that the corrosion on the vehicle was too severe and the vehicle would not pass State Inspection. The vehicle was taken to the dealer and the contact was informed that the VIN was not included in NHTSA Campaign Number: 09V124000 (Suspension). The vehicle was not repaired. The manufacturer was not contacted. …
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.
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. …
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.
Tl* the contact owns a 2004 Hyundai Sonata. The contact noticed that the subframe was rusted, which caused the front driver and passenger tires to detach. The vehicle was taken to reliable Hyundai (438 s ingram mill rd, springfield, mo 65802) where they informed the contact the vehicle was too old and unable to be repaired. The front tires were replaced; however, the subframe remained rusted. The tires needed to be replaced four times. The manufacturer was notified of the failure and informed the contact that the VIN was not included in NHTSA campaign number: 09V124000 (suspension). The approximate failure mileage was 207,000.
Took car to mechanic for fuel pump work. He informed us that the engine cradle is rusted beyond repair and is un-safe to drive. I found the recall online and called Hyundai. They informed me that remediation had been done in 2009. (a new hole for drainage had been drilled in the engine cradle frame and a sealant applied). Evidently this did not stop the corrosion of the frame and caused a weakening of the frame and a crack in the structural area of the frame. Is Hyundai liable to repair this defect? I can supply pictures of the defect and crack in frame if necessary.
Tl* the contact owns a 2004 Hyundai Sonata. The contact stated that the vehicle had severe rust on the subframe. The VIN was not included in NHTSA campaign number: 09V124000 (suspension). After contacting the dealer and the manufacturer on multiple occasions, the contact was informed that the remedy needed to repair the vehicle had not yet been determined. The contact indicated that the manufacturer took too long to provide the remedy. The contact experienced the failure listed in the recall. The failure mileage was 75,000. Parts distribution disconnect.
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.
Tl* 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.
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.
NHTSA investigations
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 2004 Hyundai Sonata?
NHTSA has 47 complaints about the body & structure of the 2004 Hyundai Sonata, 23% of the model year's 202 complaints. The component named most often is body (22 mentions).
Is there a recall for 2004 Hyundai Sonata body problems?
No. NHTSA lists no body & structure recall for the 2004 Hyundai Sonata, though it has 1 recall 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 Sonata body problems start?
Half of the complaints with a recorded mileage happened before about 98,000 miles, and 3% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 0 fires and 11 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.