2002 Hyundai Sonata Suspension Problems

The contact owns a 2002 Hyundai Sonata. The contact stated that while his girlfriend was driving at a slow speed, the sub frame snapped and fractured the axle. The vehicle was towed to an independent mechanic, and the contact was made aware of NHTSA Campaign Number: 09V124000 (Suspension). The vehicle was towed to the local dealer, who confirmed that the part had been discontinued. The vehicle was not diagnosed or repaired. The manufacturer was contacted and confirmed that the part had been discontinued. No additional assistance was provided. The failure mileage was approximately 86,000.

NHTSA ID

11681942

Incident

Aug 6, 2025

Mileage

86,000 mi

The contact owns a 2002 Hyundai Sonata. The contact stated while driving approximately 15 MPH and slowing for a right turn, the contact heard an abnormal popping sound coming from the front end of the vehicle. The contact was in the middle of the turn when the vehicle lost motive power. The contact stated that the engine was still running, but the vehicle was not responding as needed. The contact turned off the vehicle and observed that the passenger’s side control arm had detached and fallen onto the street. The contact had the vehicle towed to an independent mechanic. The vehicle was diagnosed, and it was determined that the entire front end was extremely corroded. The contact was informed that the vehicle was not drivable. The vehicle was not repaired. The manufacturer was not informed of the failure. The contact researched online and related the failure to NHTSA Campaign Number: 09V124000 (Suspension). The failure mileage was approximately 204,000.

NHTSA ID

11610010

Incident

Aug 5, 2024

Mileage

204,000 mi

The contact owns a 2002 Hyundai Sonata. The contact stated while driving at an undisclosed speed, the vehicle was shaking and made abnormal sounds. The vehicle then lost motive power. The vehicle was towed to an independent mechanic who diagnosed that the failure was related to NHTSA Campaign Number: 09V124000 (Suspension) however, the VIN was not included in the recall. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 145,000.

NHTSA ID

11484038

Incident

Sep 11, 2022

Mileage

145,000 mi

REAR SUBFRAME RUSTED AWAY AND TRAILING ARMS BOTH FELL OFF. WAS TRAVELING AND WHEN I WAS MAKING A LEFT TURN THE RIGHT TRAILING ARM BROKE OFF AND INSTANTLY MADE THE CAR ALMOST SWERVE OFF THE ROAD. I CONTINUED HOME A BLOCK FURTHER AND LOOKED TO SEE THE DAMAGE. RIGHT SIDE TRAILING ARM COMPLETELY DETACHED AND THE LEFT SIDE BARELY HANGING ON. SENT TO HYUNDAI TO HAVE LOOKED AT AND GIVEN A QUOTE. NOTHING YET...

NHTSA ID

11365401

Incident

Aug 31, 2020

Mileage

179,000 mi

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. WHILE EXITING THE FREEWAY AT APPROXIMATELY 45 MPH, THE PASSENGER SIDE AXLE FAILED AND DAMAGED THE WHEEL WITHOUT WARNING. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FRONT SUSPENSION NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE VEHICLE WAS ALSO TOWED TO MALLOY HYUNDAI (1880 OPITZ BLVD, WOODBRIDGE, VA 22191, (703) 490-8170) FOR ANOTHER DIAGNOSTIC TEST, BUT THE RESULTS WERE NOT YET AVAILABLE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND DID NOT ASSIST. THE FAILURE MILEAGE WAS APPROXIMATELY 155,000.

NHTSA ID

11245544

Incident

Aug 20, 2019

Mileage

155,000 mi

I PURCHASED THIS 2002 HYUNDAI SONATA AND HAD IT INSPECTED IN PENNSYLVANIA, THE VEHICLE FAILS DUE TO ROTTED/RUSTED OUT FRONT SUBFRAME, THIS COMPONENT WAS SUPPOSED TO BE REPLACED UNDER RECALL NHTSA CAMPAIGN ID NUMBER : 09V124000, MANUFACTURER CAMPAIGN NUMBER: 089 HOWEVER HYUNDAI SAID IT WAS INSPECTED AND RECALL WAS CLOSED.

NHTSA ID

11130762

Incident

Sep 17, 2018

Mileage

111,000 mi

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. THE CONTACT STATED THAT PREMATURE RUST AND CORROSION OCCURRED ON THE FRONT SUBFRAME. THE RUST WENT THROUGH THE FRONT SUBFRAME, CAUSING IT TO FRACTURE. THE VEHICLE WAS SERVICED BY CHECKERED FLAG HYUNDAI (3033 VIRGINIA BEACH BLVD, VIRGINIA BEACH, VA 23452, (757) 687-3462) FOR NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE DEALER HAD TO DISASSEMBLE THE VEHICLE. OTHER PARTS WERE DAMAGED. THE DEALER REFUSED TO REPLACE THE DAMAGED PARTS AND STATED THAT THEY WOULD ONLY SERVICE THE RECALL, WHICH WAS COMPLETED. ALSO, THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V317000 (LATCHES/LOCKS/LINKAGES). THE CONTACT WAS NOT NOTIFIED BY THE MANUFACTURER OF THE TWO RECALLS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE PARTS WERE DAMAGED FROM THE COMPLETION OF THE RECALL REPAIR. THE MANUFACTURER REFUSED TO PROVIDE COVERAGE FOR THE REPLACEMENT OF THE DAMAGED PARTS, STATING THAT THE DEALER PROVIDED THE REMEDY FOR THE RECALL REPAIR. THE DEALER AND THE MANUFACTURER EXPECTED THE CONTACT TO REPLACE THE PARTS THAT WERE DAMAGED. THE APPROXIMATE FAILURE MILEAGE WAS 94,724.

NHTSA ID

11061504

Incident

Nov 1, 2017

Mileage

94,724 mi

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. WHILE DRIVING 65 MPH, THE REAR PASSENGER SIDE TIRE BUCKLED AND ENDED UP UNDER THE VEHICLE. THE UPPER CONTROL ARM RUSTED IN HALF, WHICH CAUSED THE VEHICLE TO SPIN OUT OF CONTROL. THERE WAS NO CRASH. THE VEHICLE WAS TOWED, BUT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 260,000.

NHTSA ID

10950378

Incident

Feb 7, 2017

Mileage

260,000 mi

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. WHILE DRIVING 40 MPH, THE FRONT DRIVER SIDE LOWER CONTROL ARM FRACTURED AND DAMAGED THE FRONT AXLE, STRUT, FRONT FENDER, AND FRONT TIRE. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC. THE CONTACT SUSTAINED INJURIES TO THE NECK AND LOWER BACK, BUT DID NOT REQUIRE MEDICAL ATTENTION. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V125000 (SUSPENSION). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 86,000.

NHTSA ID

10882009

Incident

Jun 30, 2016

Mileage

86,000 mi

THE VEHICLE STARTED MAKING A NOISE AND DRIVING WEIRD. IT LOOKED LIKE ONE TIRE WAS POINTED STRAIGHT AND THE OTHER TIRE TURNED SLIGHTLY. I STOPPED AT A GAS STATION TO SEE WHAT WAS WRONG AND THEY SAID THE A FRAME WAS ALMOST RUSTED INTO. I HAD ALREADY HAD THE METAL IN THE REAR OF THE CAR REPLACED FROM BEING RUSTED OUT NEAR WERE THE SHOCK ATTACHES. I HAVE RESEARCHED AND SEEN WHERE SEVERAL SONATAS HAVE BEEN RECALLED DUE TO SEVERE RUST ISSUES. THE BODY EVEN HAS BEEN RUSTING BADLY. THE BIGGER CONCERN IS THE FRAME. I AM AFRAID TO DRIVE IT NOW. DO NOT KNOW WHAT RECOURSE I HAVE. THIS HAPPENED WHILE DRIVING. THE CAR IS NOW PARKED AND AM AFRAID TO MOVE IT, EVEN TO A GARAGE.

NHTSA ID

10871455

Incident

May 25, 2016

Mileage

151,946 mi

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. WHILE THE VEHICLE WAS BEING SERVICED AT AN INDEPENDENT MECHANIC'S WORKSHOP, IT WAS OBSERVED THAT THE FRONT LOWER CONTROL ARMS WERE PERFORATED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V125000 (SUSPENSION). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 82,000.

NHTSA ID

10851447

Incident

Mar 16, 2016

Mileage

82,000 mi

SERVER SUBFRAME RUST RIGHT SIDE ABOUT TO BREAK AND NOT TAKING GAS IN FUEL TANK

NHTSA ID

10823377

Incident

Oct 21, 2014

REAR UPPER CONTROL ARMS (PASSENGER AND DRIVER) HAD BROKEN DURING NORMAL DRIVING CONDITIONS. THE BREAK IS WHERE THE EXTENSIONS CONNECT TO THE BUSHINGS. CORROSION SEEMS TO BE THE CULPRIT BECAUSE THE METAL HAD ROTTED VERY THIN AND BECAME PERFORATED.

NHTSA ID

10819222

Incident

Nov 12, 2015

Mileage

136,000 mi

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. WHILE DRIVING APPROXIMATELY 33 MPH, THE CONTACT'S VEHICLE STRUCK A POTHOLE. AS A RESULT, THE CONTACT VEERED TO THE RIGHT AND CRASHED INTO ANOTHER VEHICLE. THE AIR BAGS DEPLOYED. THE CONTACT SUSTAINED A NECK INJURY THAT REQUIRED MEDICAL ATTENTION. A POLICE REPORT WAS FILED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE SUBFRAME WAS RUSTED AND FAILED TO SUPPORT THE CONTROL ARM. THE TECHNICIAN INFORMED THAT THE SUBFRAME NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND STATED THAT THE VIN WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE FAILURE MILEAGE WAS 105,000.

NHTSA ID

10724319

Incident

Mar 15, 2014

Mileage

105,000 mi

I BACKED OUT OF THE DRIVEWAY AND THE SUBFRAME ON THE PASSENGER SIDE COLLAPSED AND THE TIE ROD AND CV JOINT CAME LOOSE. THE STEERING WENT OUT. A CERTIFIED FRAME MECHANIC SAID THE SUB FRAME RUSTED OUT.

NHTSA ID

10723711

Incident

May 30, 2015

Mileage

81,000 mi

NOTICED PULLING TO RIGHT AS DRIVING, ALONG WITH RATTLING IN FRONT END. FOUND THAT DRIVER FRONT SUBFRAME NEAR LOWER SUSPENSION MOUNT IS COMPLETELY RUSTED THROUGH. DISCOVERED THAT THIS IS A NOTED ISSUE WITH THESE MODEL VEHICLES AND THAT A RECALL HAS BEEN ISSUED BY THE MANUFACTURER. DUE TO OBVIOUS SAFETY CONCERNS I WOULD LIKE TO KNOW HOW TO PROCEED WITH THIS CONCERN. *TR

NHTSA ID

10667814

Incident

Dec 22, 2014

ALOT OF PROBLEMS WITH THIS CAR. *TR

NHTSA ID

10663027

Incident

Dec 9, 2014

Mileage

156,000 mi

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. WHILE DRIVING APPROXIMATELY 35 MPH, THE CONTACT HEARD A LOUD BANGING NOISE NEAR THE FRONT END OF THE VEHICLE. THE CONTACT DISCOVERED THAT THE LOWER CONTROL ARM ON THE PASSENGER SIDE HAD SEPARATED BECAUSE THE SUBFRAME WAS RUSTED. AN INDEPENDENT MECHANIC DIAGNOSED THE VEHICLE AND CONFIRMED THE CAUSE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 206,341.

NHTSA ID

10621313

Incident

Aug 9, 2014

Mileage

206,341 mi

WAS DRIVING DOWN THE WHEN I HEARD A POP SOUND THAT HAD CAME FROM THE CURBSIDE OF THE VEHICLE THEN THE CAR STARTED PULLING TO THE RIGHT SIDE OF THE ROAD AND DID NOT REALLY THINK TO MUCH ABOUT BECAUSE THOUGHT NEEDED TO JUST HAVE ALIGNMENT DONE TO THE VEHICLE THEN NEXT FRIDAY I HAD TAKE THE CAR TO HAVE THE ALIGNMENT DONE ON THE VEHICLE THEY CALLED ME AND SAID THAT THE SUB-FRAME OF THE VEHICLE WAS RUSTED IN HALF AND THAT IT WAS UNSAFE TO DRIVE. I LOOKED UP THE RECALLS ON THE VEHICLE AND SEEN WHERE IT HAD A RECALL FOR THE SUB-FRAME RUSTING AND SET UP A APT . TO HAVE IT TAKEN CARE OF BUT THEY ARE SAYING THAT SINCE MY CAR IS NOT REGISTERED IN ONE OF THE SALT-BELT STATES THAT THEY ARE NOT GOING TO HONOR THE RECALL EVEN THOUGH THE RUST IS THERE AND THE SUB-FRAME IS RUSTED IN HALF AND THE LOWER CONTROL ARM IS RUSTED OFF. REF #[XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10595756

Incident

May 22, 2014

Mileage

158,000 mi

MY SON WAS OPERATING THE VEHICLE AND WAS MAKING A LEFT TURN. DURING THE TURN, THE RIGHT FRONT WHEEL BUCKLED UNDER AND THE VEHICLE BECAME INOPERABLE. VEHICLE WAS TOWED TO A REPAIR FACILITY. THEY FOUND THAT THERE WAS SIGNIFICANT CORROSION IN THE SUB-FRAME WHICH CAUSED IT TO FAIL. I HAVE DONE SOME RESEARCH ON NHTSA SITE AND IT APPEARS THAT CAMPAIGN 09V124000 DESCRIBES THE ISSUE. I HAVE CONTACTED HYUNDAI. THEY HAVE INSTRUCTED ME TO HAVE TO VEHICLE DELIVERED TO LOCAL DEALER FOR INSPECTION TO DETERMINE IF IT IS COVERED UNDER A RECALL PROGRAM. THEIR FIRST RESPONSE WAS TO TELL ME THAT THE RECALL WAS ONLY COVERING CERTAIN STATES, KENTUCKY NOT BEING ONE OF THEM. WHEN I TOLD THEM I HAD PURCHASED THE CAR USED AND HAD NO WAY OF KNOWING WHAT OTHER STATES THE VEHICLE HAD BEEN IN, THEY AGREED TO EXAMINE THE VEHICLE. I BELIEVE THE VEHICLE REPAIR SHOULD BE COVERED SINCE THE DAMAGE IS AS DESCRIBED IN THE RECALL NOTICE. *TR

NHTSA ID

10587174

Incident

Apr 23, 2014

Mileage

156,000 mi

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE WOULD ABNORMALLY DRIFT TO THE RIGHT. THE CONTACT ALSO STATED THAT A LOUD NOISE WAS HEARD FROM THE VEHICLE WHENEVER DRIVING OVER AN UNEVEN ROAD SURFACE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC HOWEVER, NO REPAIRS WERE PERFORMED. THE MANUFACTURER WAS MADE AWARE OF THE DEFECT. THE FAILURE MILEAGE WAS 55,086.

NHTSA ID

10557903

Incident

Dec 19, 2013

Mileage

55,086 mi

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. THE CONTACT STATED THAT THE FRONT SUBFRAME MOTOR AND SUSPENSION WAS FOUND TO BE SEVERELY CORRODED. THE MANUFACTURER ADVISED THAT THE VIN WAS NOT INCLUDED NHTSA CAMPAIGN NUMBER 09V124000 (SUSPENSION) THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 202,000. *TR

NHTSA ID

10555421

Incident

Nov 13, 2013

Mileage

202,000 mi

AFTER HAVING INCREASED DIFFICULTY CONTROLLING THE CAR, I TOOK IT TO MY TIRE DEALER FOR AN ALIGNMENT AND WAS TOLD THAT THEY COULD NOT HELP ME BECAUSE THE FRAME WAS "BROKEN" AND WAS SHREDDING MY REAR TIRES. I CALLED HYUNDAI CORPORATE AND WAS TOLD THAT THERE WAS A RECALL ON THE SUBFRAME AND WAS ADVISED TO TAKE THE CAR TO MY LOCAL DEALER FOR INSPECTION. UPON INSPECTION, I WAS TOLD THAT IT WAS COVERED ON THE RECALL AND LEFT IT WITH THEM FOR TWO DAYS FOR REPAIR. WHEN I PICKED THE CAR UP, I WAS TOLD THAT THE FRONT WAS REPAIRED AT NO COST TO ME, HOWEVER, THE REAR (WHICH IS WHAT I WENT IN FOR) WAS IN VERY BAD SHAPE BUT IT WAS NOT COVERED AND WOULD COST ME $1,500 TO REPAIR IT. I CANNOT UNDERSTAND HOW THE FRONT OF A FRAME CAN BE PART OF A RECALL, BUT THE REAR IS NOT. ????? AND I CANNOT UNDERSTAND WHY THE LOCAL DEALER DIDN'T CALL TO TELL ME THIS BEFORE HE DID THE WORK ON THE FRONT. HAD I KNOWN HOW MUCH IT WAS GOING TO COST ME, I WOULD HAVE TOLD HIM NOT TO BOTHER. SHOULD I CHOOSE TO KEEP THE CAR, IN ADDITION TO $1,500 TO REPAIR THE REAR FRAME, I WILL ALSO NEED TO BUY TWO TIRES TO REPLACE THE TWO WHICH THIS REAR FRAME IS SHREDDING. UNBELIEVABLE. *TR

NHTSA ID

10546905

Incident

Sep 14, 2013

Mileage

129,000 mi

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING OVER A POT HOLE AT APPROXIMATELY 25 MPH, THE VEHICLE BEGAN TO PULL TO THE LEFT INDEPENDENTLY. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, WHO INFORMED THE CONTACT THAT THE FRONT END SUB FRAME CRADLE WAS COMPLETELY FRACTURED. THERE WAS A RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 09V124000 (SUSPENSION) HOWEVER, THE CONTACT'S VIN WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 89,727.

NHTSA ID

10537672

Incident

Aug 21, 2013

Mileage

89,727 mi

MY CAR HAD BEEN EXPERIENCING PULLING TO THE RIGHT AND I WAS REPLACING THE RIGHT FRONT TIRE EVERY WEEK. IT FELT AS IF THE TIRE WAS GOING TO FALL OFF. I TOOK IT TO MY DAD WHOM IN TURN GOT A MECHANIC TO LOOK AT IT. THE MECHANIC SAID THAT THE K FRAME WAS BROKEN. HE TRIED WELDING IT. THE WELD HELD FOR ABOUT TWO WEEKS. AFTER RESEARCHING THE PROBLEM I FOUND THAT THERE IS A RECALL AND SETTLEMENT FROM HYUNDAI. I CALLED THE CUSTOMER SERVICE DEPARTMENT WHO IN TURN GAVE ME A CASE NUMBER AND HAD BE TAKE THE CAR TO THE DEALERSHIP. THEY INSPECTED THE CAR AND DETERMINED THAT MY CAR DIDN'T FIT THE CRITERIA. I'M CONFUSED BY THE FACT THAT SO MANY VEHICLES LIKE MINE HAVE THE SAME PROBLEM BUT THEY DON'T FIT THE "CRITERIA". SOMETHING IS WRONG. AND IT'S MORE THAN CORROSION OR THE LACK OF. *TR

NHTSA ID

10531709

Incident

Sep 28, 2012

Mileage

260,000 mi