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 2005 Hyundai Sonata owners, lightly cleaned up (personal details are redacted by NHTSA).
I took my car to the mechanic for a "once over" before driving from New Jersey to North Carolina. This car has only 41,000 original miles on it as we bought it new in 2005. Upon inspection, the mechanic came back with certain repairs that are needed due to age; but he was extremely concerned about a severe safety issue that the subframe had rotted out and needed to be replaced. This is a known corrosion issue with other years of manufacture for this model. There was a class action suit for this specific issue for 1999 to 2004 Sonatas. The subframe threatens to collapse from rust at any time and is an extreme hazard to the driver, passengers, and others on the road. There was absolutely no warning of this issue prior to this inspection, making it even more dangerous as it affects many drivers who are unaware of the issue.
Upon inspecting the undercarriage of my vehicle found the right side of Front Subframe Cradle Suspension rotted almost completely through. When researching for issues pertaining to this model found a TSA was issued , after a lawsuit in California, for the years prior and after my vehicle. The damage is concurrent with the TSA bulletin but excluded. How does a manufacturer whom obviously is aware of an ongoing issue allow so many people, families and children, drive and risk their lives on our public roadways. Is their a subclass recall that will aid those like myself take corrective action.
Severely rusted out and corroded front subframe, only noticed it on accident very recently, and my car is the last year of a generation that was recalled for this very issue within the Salt Belt- I live right at the bottom outskirts of the Salt Belt in NKY, and my car is the only year not recalled for subframe corrosion. It's bad and I'm freaked out and can't afford it unless I figure out how to do it myself without prematurely dying due to a dropped engine or something similar (premature because if I don't get it fixed soon I reckon that fate isn't too far off)
My wife had an accident on new jersey parkway south, the air bag on both the driver side and passengers side refuse to deploy, these has cause my wife broken ribbs and some bodily injuries according to doctors report....updated 07/13/16
I had come to a complete stop attempting to merge into traffic, as I pressed on accelerator, I felt it go down under my foot, thus hiting the right rear bumper of the car in front of me.this was the first time. The second time happened in January. 2012. I was turning into my parking spot, and I had softly braked. And as I pressed on the acceleator, and like the first time, I felt the accelerator go down beneath my foot, without pressing too hard. I ran into my apartment, and caused a good deal of damage to it.as well as my car. I have not had an incident since, but I remain scared that it will happen again. I took vehicle to oxmoor Hyundai, in louisville, and could not find find anything wrong, and I had to pay just under $100.00 to tell me this. And my auto insurance went up drastically.
Tl* the contact owns a 2005 Hyundai Sonata. The contact stated that there was an abnormal noise progressing from the vehicle. The vehicle was inspected and diagnosed by an independent mechanic who stated that the entire subframe was prematurely rusted and needed to be replaced. The manufacturer was notified of the failure and a service campaign, which excluded the vehicle although the symptoms were the same. The manufacturer was notified of the failure, but provided no remedy to prevent the failure other than taking the vehicle to a dealer for diagnostic testing and repair. The approximate failure mileage was 144,000.
Was trying to get ac compressor replaced by a local repairman, while performing the task, he found the subframe severely corroded, advised not to drive due to safety. Contacted Hyundai customer service, they advised to take car to Hyundai dealer for inspection of the car. The dealer said they would inspect and take pictures and contact the corporate office with info. Hyundai corporate advised that the warranty was up, would not be responsible for the repair. However, the 2001 thru 2004 Sonata models were recalled (09v12400, 04/16/2009, suspension) for the same problem, front subframe corrosion.
While changing my oil on the weekend, I noticed severe corrosion failures with the front subframe on the right side of my car. (see attached photos). One area was in front of the lower control arm and another area is behind the control arm. It looks like the subframe will fail at any moment and the control arm would be free to move anywhere. This would significantly affect control of the vehicle and be a serious safety concern. I see this part has already had a recall for 2001 to 2004 Hyundai sonatas which is the same body and frame style as the 2005 vehicle. Recall #09V124000.
Failed inspection in part due to front subframe rust through. Called Hyundai and spoke to a claims rep. By the name of nathan & tier2 rep tim. Both told me there were recalls on sonatas up to 2004 for this problem, but not 2005. The 2005 model is the same model as 2004. The model year didn't change till 2006 so why was 2005 excluded from the recall? My car has 120K miles on it. Both told me it wasn't under recall or warranty, and that Hyundai would not be able to do anything for me, . How is it the a car 11 years old has a bad frame? Hope you will be able to help us.
Tl* the contact owns a 2005 Hyundai Sonata. While operating the vehicle, a squealing type noise was heard from the front end of the vehicle. While making a turn, the front passenger side tire became worn. After replacing the front tire, the failure recurred. The vehicle was taken to an independent mechanic who looked under the vehicle and discovered that the entire subframe had sustained severe rusting and corrosion and would need to be replaced. The manufacturer was not notified of the failures. The failure mileage was 117,000.
Body complaints in other Sonata years
Frequently asked questions
How common are body problems on the 2005 Hyundai Sonata?
NHTSA has 30 complaints about the body & structure of the 2005 Hyundai Sonata, 18% of the model year's 165 complaints. The component named most often is body (22 mentions).
Is there a recall for 2005 Hyundai Sonata body problems?
No. NHTSA lists no body & structure recall for the 2005 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 2005 Hyundai Sonata body problems start?
Half of the complaints with a recorded mileage happened before about 105,000 miles, and 4% before 25,000 miles.
Is it dangerous?
Owners linked 4 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.