2004 Hyundai Sonata Body and structure Problems
- Complaints
- 47about this part
- Share
- 23%of 202 total for the year
- Median mileage
- 98,000miles
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
NHTSA recorded 47 complaints about the body and structure of the 2004 Hyundai Sonata, 23% of the 202 complaints for this model year. Where a mileage was given, the median is 98,000 miles. 2 of these say a crash was involved, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“Recall on 2004 Hyundai. I called 5 dealers to have them inspect my car, due to the recall I received about possible frame rusting. The wait is any where from 10 days to a month, just to have them look at the frame. I explained that my car is showing the signs of damaged rusted frame. I requested that they either. Pay for my room or pay for my car rental.”
NHTSA complaint #10291650, filed 2009-11, 138,000 miles“Inside door handles thin covering (appears to be aluminum) is peeling apart and I have cut my hand on the sharp edge which came apart. Dealer will not replace the handle because Hyundai has not recalled the 2004 models which has the ***same problem**as the 2003 model.”
NHTSA complaint #10350643, filed 2010-08, 93,000 miles“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.”
NHTSA complaint #10679022, filed 2015-01, 140,000 miles“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. …”
NHTSA complaint #10918912, filed 2016-10, 95,000 miles“When having my car aligned, a technician showed me that the right front subframe is rusted through. Supposedly Hyundai fixed this 5 years ago, with one of two fixes: either replacement or drilling drainage holes and apply a rust protector. One can see a hole drilled on the left subframe but not the right side. Besides my car, one has to ask: did Hyundai really do anything to fix this situation or did they act like they did? A car rusting through the frame in five years is unheard of, and I fear others might have this same problem. Hyundai does not want to talk to me.”
NHTSA complaint #10615189, filed 2014-07, 175,000 milesRelated service bulletins
- 10235566Apr 24, 2023Hyundai applies a Paint Protection Film (PPF) on new vehicles before delivery to dealerships. It provides a barrier between the paint and contaminants, such as rail dust, acid…
Body and structure: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2024 | 5 | 11% |
| 2023 | 4 | 5% |
| 2022 | 3 | 3% |
| 2021 | 4 | 3% |
| 2020 | 17 | 9% |
| 2019 | 7 | 4% |
| 2018 | 17 | 5% |
| 2017 | 37 | 5% |
| 2016 | 31 | 4% |
| 2015 | 52 | 5% |
| 2014 | 17 | 2% |
| 2013 | 50 | 3% |
| 2012 | 39 | 3% |
| 2011 | 73 | 2% |
| 2010 | 164 | 48% |
| 2009 | 40 | 9% |
| 2008 | 15 | 4% |
| 2007 | 21 | 3% |
| 2006 | 44 | 4% |
| 2005 | 30 | 18% |
| 2004 | 47 | 23% |
| 2003 | 38 | 19% |
| 2002 | 88 | 28% |
| 2001 | 69 | 34% |
| 2000 | 109 | 39% |
| 1999 | 36 | 29% |
| 1998 | 2 | 4% |
| 1996 | 2 | 9% |
| 1995 | 5 | 8% |
| 1992 | 2 | 9% |
| 1990 | 1 | 6% |
| 1989 | 1 | 9% |
Other parts of the 2004 Hyundai Sonata
56 complaintsAir bags
46 complaintsElectrical system
17 complaintsBrakes
16 complaintsSteering
13 complaintsWheels
13 complaintsLatches, locks and linkages
12 complaintsOther or unknown
12 complaintsTransmission and drivetrain
10 complaintsFuel system
8 complaintsEngine
5 complaintsEngine cooling
5 complaints
← All problems reported for the 2004 Hyundai Sonata
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology