2004 Hyundai Santa FE Problems

What owners report

Owners of the 2004 Santa Fe most often report broken front coil springs, fuel tanks rusting through and leaking, and brakes that fail to stop the vehicle at low speed. Complaints describe these problems appearing from very low mileage up to well over 150,000 miles, with spring and fuel tank failures clustering on higher-mileage vehicles. Many reports involve a dealer visit where the fault was confirmed but not covered or not repaired.

1. 1
   Suspension

   Front coil spring breaks and can puncture the tire

   • 58 complaints (19%)
   • median 91,315 mi at 9.3 yrs old (51 state mileage)
   • owner-quoted repair $1,102 (median of 8 quotes)
   • filed 2007–2020

   Owners describe a loud popping or clunking noise from the front end, often while backing out of a driveway, followed by the vehicle leaning to one side. In many reports a piece of the spring is found on the ground, and in some cases the broken spring rubs against or punctures the front tire. Complaints describe dealers replacing the spring, and several mention a recall for rusted springs where owners say brackets were installed but the spring itself was not replaced. Mostly reported between roughly 55,000 and 150,000 miles, often in vehicles driven in road-salt areas.

   Recall 14V4350003 related service bulletins

   What to check: Ask whether recall 14V435000 was performed and whether the front coil springs were inspected or replaced; have a mechanic look for cracks at the base of each front spring and for rust staining on the strut area.

   2 excerpts from owner complaints in NHTSA records

   “On 12/31/2012, the coil spring on my 2004 Hyundai Santa Fe fractured and punctured the right front tire of the vehicle. I paid upwards of $2000 on 1/7/2013 to have this repaired. I have since traded in the vehicle and no longer own it. I recently received a recall notice from Hyundai USA describing the same coil spring fracture that I experienced a couple of years earlier. This recall is called 'campaign124' by Hyundai. …”

   NHTSA complaint #10652463, filed 2014-11, 160,000 miles

   “While backing out of my driveway, I heard a clunk sound in the front of my vehicle. Upon inspection, I found a c shaped piece of metal on the driveway. I immediately drove to my mechanic's shop, where he told me that the coil spring on my Santa Fe had broken on the passenger's side. The coil spring on the driver's side was also cracked. He had to replace both coil springs. He later told me that it was unusual to have these springs break for no apparent reason. …”

   NHTSA complaint #10524851, filed 2013-07, 97,000 miles
2. 2
   Fuel system

   Fuel tank rusts through and leaks

   • 33 complaints (11%)
   • median 97,000 mi at 11.0 yrs old (27 state mileage)
   • filed 2009–2021

   Owners report a strong gasoline smell around the rear of the vehicle and visible fuel dripping under the tank, sometimes a puddle on the garage floor after the car sits. Several complaints say a shop or dealer found the tank rusted through and recommended replacement; some owners note the plastic shield over the tank traps moisture and salt. Several mention being told the repair was outside warranty coverage, including owners above a mileage limit on an extended corrosion warranty. Typically reported between about 90,000 and 180,000 miles, on older vehicles in areas where roads are salted.

   What to check: Inspect the tank and its plastic cover from underneath for rust, dampness or fuel staining, and check for a fuel smell after the car has been parked; ask whether the tank has already been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Came home from vacation a found the contents of my fuel tank on the garage floor. Lucky there was no fire or explosion. I took it to the service garage and they informed me that the gas tank rusted through and along with the protective plates, all had to be replaced. Contacted Hyundai but they were not helpful.”

   NHTSA complaint #10544270, filed 2013-09, 100,100 miles

   “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. …”

   NHTSA complaint #10779206, filed 2015-10, 148,750 miles
3. 3
   Brakes

   Brakes fail to stop the vehicle at low speed

   • 86 complaints (28%)
   • median 55,400 mi at 6.4 yrs old (71 state mileage)
   • 23 mention a crash, fire or injury
   • owner-quoted repair $1,350 (median of 8 quotes)
   • filed 2004–2023

   Complaints describe the pedal going down without the vehicle slowing or stopping, usually at walking pace, when parking, reversing or approaching a light, and in some reports the vehicle struck another car or a building. Some owners describe a vibrating pedal with the ABS light on between about 3 and 12 mph, sometimes after the brakes got wet. Dealers are described as unable to duplicate the problem, and some owners were told their vehicle was not covered by the ABS-related recall. Reported across a wide mileage range, from near-new vehicles to about 100,000 miles.

   Recall 04V1310004 related service bulletins

   What to check: Ask whether recall 04V131000 applied and was completed, test the brakes at very low speed on a wet surface, and have the ABS system scanned for stored codes and sensor faults.

   2 excerpts from owner complaints in NHTSA records

   “The night I took delivery of the vehical I had electrical problems this was to be fix by dealership, well now 8/15/2004 there are more elec. Problems the fuses are blowing and the brakes are not stopping as should be.also the trasmission when appling the gas pulls to the right, and between 40/60 MPH jecksing sensation to the vehicle.”

   NHTSA complaint #10086919, filed 2004-08, 5,000 miles

   “I purchased my new car on 02/09/04 at bronx Hyundai. It is a 4-wheel drive 3.5 ltr engine Hyundai Santa Fe. Upon driving I felt a hard knocking-vibrating sound when I drive on local (dry) streets and then a feeling that the car jumps (lunge forwards)after I stop. On several occasions I thought someone hit me from behind. This continues to happen only when I drive locally. The car has never done this on the highway, which is part of my daily commute. …”

   NHTSA complaint #10074599, filed 2004-06, 100 miles
4. 4
   Vehicle speed control

   Unexpected acceleration or engine surging

   • 62 complaints (20%)
   • median 37,115 mi at 6.6 yrs old (50 state mileage)
   • 7 mention a crash, fire or injury
   • owner-quoted repair $1,000 (median of 5 quotes)
   • filed 2004–2023

   Owners describe the vehicle lunging forward when the accelerator is lightly pressed, revving on its own, or accelerating while the brake is held, including in reverse and once through a garage door. Complaints mention throttle position sensor replacement, PCM reprogramming and electronic throttle work by the dealer, with several saying the problem returned or could not be duplicated. One owner links it to a throttle/accelerator position code and a transmission ratio code at highway speed. Reported from very low mileage up to about 70,000 miles, with several reports on nearly new vehicles.

   1 related service bulletin

   What to check: Ask for any service history on throttle body, accelerator pedal sensor or PCM reprogramming; on a test drive, check for a steady idle and for any surge when moving off from a stop or shifting into gear.

   2 excerpts from owner complaints in NHTSA records

   “Few weeks after the purchase of my Santa Fe, the car began to shudder during acceleration. I have been to the dealership twice for this problem. The first time they could not duplicate the problem. The second time they duplicated but they could not figure out what was wrong before the three day rental car rule. So they gave it back to me sayings it still is bad. We are currently waiting for the service sheet from that time.”

   NHTSA complaint #10113869, filed 2005-03, 100 miles

   “Car shuts off while driving, losing power steering and brakes, while traveling at highway speed or braking down a windy canyon road. Problem includes intermittent jerking, jumping, hiccupping - whatever you want to call it, it's not safe to drive. First month, after brand-new ny dealership purchase, I replaced my throttle position sensor 3 times. Trouble with my current problem began at 4 years, well under 30,000 miles. For a year I had to fear for my life every time I drove, never knowing if this trip would kill me or other motorists. …”

   NHTSA complaint #10731794, filed 2015-07, 28,000 miles
5. 5
   Engine cooling

   Stalling or shutting off while driving

   Mentioned in 7 of 60 sampled complaints

   Owners report the engine quitting without warning at speed or after refueling, sometimes with loss of power steering and power assist for the brakes. Several say the car restarted after a pause and that shops could not reproduce the fault; some describe replacing cam and crank sensors, coils, plugs, fuel pump and regulator without a lasting fix. Some complaints tie stalling after refueling to a failed purge valve and a tank needing replacement. Reported from about 20,000 miles upward, with several reports in the 90,000 to 150,000 mile range.

   What to check: Ask whether the purge valve, fuel pump and sensors have been replaced, look for stored codes, and note whether the engine idles steadily or stumbles shortly after a fill-up during a test drive.

   2 excerpts from owner complaints in NHTSA records

   “A 2004 Hyundai Santa Fe has developed a potential fire/explosion hazard which Hyundai has ignored after I pointed it out. Hyundai also refused to release to me the Santa Fe's off road capabilities. This car was purchased new. Can you help me please?”

   NHTSA complaint #10139144, filed 2005-10, 11,588 miles

   “After starting vehicle and while driving, engine shuts down immediately and without warning. Was able to steer to the side of the street it as it was still rolling. No indications came on as to what the issue may point to. I shut the engine off and waited for a tow to my home which I total took about 45 minutes. Once at home the vehicle started with no issues. For the next two days my vehicle was at my mechanics and he could not reproduce the problem. I went ahead and had the transmission. …”

   NHTSA complaint #10548940, filed 2013-10, 70,863 miles

Buying note. On a 2004 Santa Fe, prioritize a mechanic's inspection of the front coil springs and the fuel tank for rust, and confirm whether the front spring and ABS recalls were completed for the vehicle. A service history covering throttle, sensor and brake work helps show how the specific vehicle has behaved.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.