2003 Hyundai Sonata Body & structure Problems

The contact owns a 2003 Hyundai Sonata. The contact stated that while the vehicle was at Valvoline for a service appointment, the contact was made aware of NHTSA Campaign Number: 09V124000 (Suspension). The vehicle was taken to the dealer, who informed the contact that the subframe assembly and additional unknown parts were not included in the recall repair. In addition, the contact was informed that the recall could not be performed because other repairs were needed prior to the recall repair. The vehicle was not repaired. The contact stated that the vehicle was unsafe to drive. The manufacturer was made aware of the failure, and a case was filed. The contact was informed that the repair was not covered under the recall. The failure mileage was approximately 170,000.

NHTSA ID

11743571

Incident

Mar 18, 2026

Mileage

170,000 mi

NHTSA Campaign ID Number: 09V124000 NHTSA Action Number: EA08016 Recall calls for repair or replacement of front sub-frame, due to corrosion. Local dealer responded, “ . . . we will not be able to perform recall”. I was told the corrosion was too far gone to repair. They refuse to replace the defective part.

NHTSA ID

11675456

Incident

May 23, 2025

The contact owns a 2003 Hyundai Sonata. The contact stated that while self-inspecting the vehicle, he noticed that the subframe was extremely rusted. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 69,425. The contact stated that no assistance has been offered from the dealership from which the vehicle was purchased from.

NHTSA ID

11533052

Incident

Nov 20, 2022

Mileage

69,425 mi

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. WHILE DRIVING 30 MPH, THE VEHICLE BEGAN TO VEER TO THE RIGHT WITHOUT WARNING AND THE POWER STEERING FAILED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FRONT SUBFRAME WAS CORRODED. THE DEALER WAS NOT CONTACTED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND INFORMED THE CONTACT THAT THE VEHICLE WAS NOT INCLUDED IN A RECALL. THE FAILURE MILEAGE WAS 117,000.

NHTSA ID

11115140

Incident

Jun 15, 2016

Mileage

117,000 mi

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 25 MPH AND MAKING A RIGHT TURN, THERE WAS A LOUD NOISE COMING FROM THE VEHICLE. IN ADDITION, THE VEHICLE BEGAN TO SHAKE VIOLENTLY. UPON INSPECTION, IT WAS DISCOVERED THAT THE SUB FRAME HAD FRACTURED DUE TO RUST AND CORROSION. THE CAUSE OF THE FAILURE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 139,000.

NHTSA ID

10928450

Incident

Nov 25, 2006

Mileage

139,000 mi

2003 HYUNDAI SONATA AFFECTED BY PROGRESSIVE, INTERNAL CORROSION OF THE RIGHT FRONT SUB-FRAME ON THE VEHICLE, AND RESULTING IN THINNING, RUSTING OR PERFORATION OF THE SUB-FRAME STEEL. THE CORROSION/RUST IS VISIBLE AND DISCOVERED DURING INSPECTION & ROUTINE MAINTENANCE, AND ALSO HEAR NOISES & NOTICE TIRE MISALIGNMENT AND STEERING PULL.THESE SIGNALS ARE DETECTING THE CORROSION PROGRESSING AND THE FORWARD MOUNTING OF THE LOWER CONTROL ARM DETACHING FROM THE SUB-FRAME. THE VEHICLE WAS BOUGHT NEW IN NEBRASKA, AND HAS REMAINED IN NEBRASKA ITS ENTIRE LIFE. NEBRASKA USES SALT ON ITS ROADS IN THE SAME CAPACITY AS IOWA AND OTHER "SALT STATES". SUCH CARS SHOULD BE INCLUDED IN THE RECALL WHEN CONSIDERING THE LACK OF SAFETY AND DANGERS INVOLVED WHEN THE SUBFRAME DETERIATES DUE TO DEFECTS IN THE MANUFACTURE OF SAID CAR. HYUNDAI SHOULD HONOR AND EXTEND THE RECALL OF SAID CAR IN THE STATE OF NEBRASKA BECAUSE THE DEFECT IN THE SUBFRAME HAS BEEN AFFECTED IDENTICALLY AS IN OTHER "SALT STATES".

NHTSA ID

10917241

Incident

Aug 10, 2016

Mileage

87,560 mi

REPEATED USE OF THE INTERIOR DOOR HANDLE MAY CAUSE WEAR OF THE CHROME PLATE. IF THE TOP EDGE OF THE HANDLE HAS VERY THIN CHROME PLATING, THAT PORTION OF THE PLATING MAY WEAR AWAY MORE EASILY THAN MORE THICKLY PLATED AREAS AS THE DOOR HANDLE IS USED. THE WORN CHROME PLATING ON THE UPPER EDGE OF THE HANDLE MAY RESULT IN A CRACK OR SEPARATION BETWEEN THE CHROME PLATING ON THE INBOARD AND OUTBOARD SURFACES OF THE HANDLE, WHICH MAY FORM A SHARP EDGE. CONSEQUENCE: THIS MAY INFLICT LACERATION INJURIES TO ANYONE USING THE DOOR HANDLE. BASICALLY WHEN YOU GO TO USE THE INSIDE DOOR HANDLES THE PEELING CHROME IS SHARP AND CUTS YOUR FINGERS. HYUNDAI RECALL #93 ENDED IN MARCH 2003, MY CAR WAS MANUFACTURED IN MAY 2003. THE PROBLEM IS IDENTICAL TO THE MODELS IN RECALL #93.

NHTSA ID

10854985

Incident

Mar 1, 2012

Mileage

120,000 mi

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. WHEN THE VEHICLE WAS TAKEN TO BE INSPECTED, THE INSPECTOR OBSERVED THAT THE SUBFRAME WAS SEVERELY CORRODED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

10766303

Incident

Sep 20, 2015

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT THE FOUR INTERIOR DOOR CHROME HANDLES EXHIBITED EXTREMELY SHARP EDGES. THE CONTACT SUFFERED FROM A TWO INCH LACERATION TO BOTH FINGERS ON THE LEFT HAND. THE FRONT DRIVER AND PASSENGER UPPER DOOR HANDLES CAUSED THE INJURIES. THE CONTACT APPLIED TAPE TO THE FOUR DOOR HANDLES TO AVOID ADDITIONAL INJURIES. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V171000 (LATCHES/LOCKS/LINKAGES). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 95,000.

NHTSA ID

10720963

Incident

May 9, 2013

Mileage

95,000 mi

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING AT 50 MPH, THE VEHICLE VEERED TO THE LEFT AND RIGHT INDEPENDENTLY. THE FAILURE OCCURRED INTERMITTENTLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE SUBFRAME NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 80,000.

NHTSA ID

10667641

Incident

Nov 10, 2014

Mileage

80,000 mi

IN 2005, I PURCHASED A 2003 HYUNDAI SONATA. AFTER PURCHASING MY CAR, I FOUND OUT THAT IT HAD A RECALL ON THE FUEL VALVE THAT THE COMPANY HAD TO RE-INSTALL. THIS RECALL INFORMATION WAS NOT ON MY CARFAX REPORT. LATER, THE MANUFACTURER HAD A RECALL ON INTERIOR DOOR HANDLES THAT PEELED AND CUT HANDS. THEIR SOLUTION WAS TO WRAP MY HANDLES WITH ELECTRICAL TAPE; AFTER MY OBJECTION, THEY INSTALLED THE SAME RECALLED HANDLES. I'VE HAD MY INTERIOR HANDLES REPLACED THREE TIMES BECAUSE THE MANUFACTURER DIDN'T MAKE THE HANDLES OUT OF A DIFFERENT MATERIAL AND CHOOSES TO REINSTALL THE SAME RECALLED HANDLE. ON NOVEMBER 22ND, I WENT TO CAPITOL HYUNDAI TO HAVE THEM REPLACE THE RECALLED FUEL VALVE, AND INTERIOR DOOR HANDLES ON MY 2003 HYUNDAI SONATA. A SERVICE REP INFORMED ME THAT ONCE THE COMPANY REPLACES ANY RECALLED ITEMS THE FIRST TIME, IT IS THE CUSTOMER'S RESPONSIBILITY TO PAY FOR THEM IF THEY FAIL AGAIN. SURELY, THIS CANNOT BE CORRECT! RECALLS DO NOT EXPIRE AND AS LONG AS THE OWNER HAS THE VEHICLE, THE MANUFACTURER/DEALERSHIP SHOULD BE RESPONSIBLE IF THEIR MATERIALS ARE CONTINUOUSLY FAILING TO MEET SAFETY REQUIREMENTS. WHAT ARE FOLKS MAKING PAYMENTS OR CAN'T AFFORD ANOTHER VEHICLE NOW SUPPOSED TO DO? DRIVE AROUND IN A DANGEROUS VEHICLE? BE IT 1 TIME OR 1 MILLION TIMES, I WANT CAPITOL HYUNDAI TO INDEFINITELY HONOR THEIR RECALLS--AT THEIR EXPENSE. *TR

NHTSA ID

10660455

Incident

Nov 22, 2014

Mileage

162,000 mi

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT THE CHROME COVERING ON THE INTERIOR DOOR HANDLE WAS CORRODED AND CRACKED, WHICH CREATED SHARP EDGES ON THE HANDLE. WHEN USING THE DOOR HANDLE TO EXIT THE VEHICLE, THE CONTACT EXPERIENCED SCRATCHES AND SMALL LACERATIONS DUE TO THE SHARP EDGES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER STATED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V317000 (LATCHES/LOCKS/LINKAGES). THE FAILURE MILEAGE WAS 105,000.

NHTSA ID

10640874

Incident

Sep 15, 2014

Mileage

105,000 mi

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE INSPECTING THE VEHICLE, THE FRONT WHEELS APPEARED TO BE ANGLED INWARD. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DISCOVERED THAT THE FRONT PASSENGER SIDE OF THE ENGINE CRADLE WAS RUSTED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 131,000.

NHTSA ID

10618738

Incident

Jul 21, 2014

Mileage

131,000 mi

PASSENGER SIDE CRADLE RUSTED THROUGH. DRIVER SIDE IS FINE. RECALL # 089. *TR

NHTSA ID

10618358

Incident

Jul 31, 2014

VERY HEAVY RUST ON RIGHT SIDE ,THE SUB FRAME GAVE WAY AND RIPPED THE CV AXLE OUT OF ITS HOUSING. *TR

NHTSA ID

10617782

Incident

Jul 3, 2014

Mileage

150,000 mi

CHROME ON INTERIOR DOOR HANDLES PEELS AND CREATES LACERATION HAZARD. THE MANUFACTURER ISSUED A RECALL TO REPLACE AFFECTED HANDLES BECAUSE OF A STATED LACERATION HAZARD. THE DEALER REPLACED HANDLES UNDER THE RECALL. HOWEVER, THE REPLACEMENT HANDLES ARE NOT AN IMPROVED PRODUCT AND THE CHROME PEELS LIKE THE ORIGINALS. THE DEALER ONLY ALLOWS ONE REPLACEMENT UNDER THE RECALL, WHICH CREATES A CONTINUING HAZARD TO THE OWNER AND PASSENGERS. *TR

NHTSA ID

10586392

Incident

Oct 23, 2007

Mileage

55,000 mi

BOUGHT CAR USED FROM LOT...CHROME PLATING ON HANDLES PEELING AND CUT YOU IF YOUR NOT CAREFUL. JUST FOUND OUT THERE WAS A RECALL FOR THIS BEFORE I PURCHASED THE CAR. IS THERE ANYTHING I CAN DO? *TR

NHTSA ID

10565479

Incident

Feb 1, 2011

THE INTERIOR DOOR HANDLES OF MY 2003 HYUNDAI SONATA WENT UNDER A RECALL IN JULY 2009 BECAUSE THE CHROME PLATING WAS SPLITTING OPEN AND CUTTING PEOPLE. THREE DOOR HANDLES WERE REPLACED AND ONE WAS REWRAPPED TO FIX THE PROBLEM. IN SEPTEMBER 2013 THE SAME ISSUE AROSE WHEN MY WIFE AND BROTHER-IN-LAW CUT THEIR HANDS ON THE DOOR HANDLES, WHOSE CHROME PLATING HAS AGAIN BEGUN TO SPLIT. HYUNDAI HAS SAID THAT NO REPAIRS WILL BE MADE, SINCE THE HANDLES WERE TREATED AND THE 2009 RECALL HAS FINISHED. *TR

NHTSA ID

10556483

Incident

Sep 1, 2013

Mileage

110,000 mi

REAR ENDED THE VEHICLE IN FRONT AT A STOP LIGHT. THE AIRBAGS NEVER DEPLOYED. NOW THE AIRBAG LIGHT IS ON IN THE VEHICLE. REPAIRS ARE $1349.00 REPLACE THE WIRE HARNESS. I NOTICED THIS HAS HAPPENED REPEATEDLY WITH THESE VEHICLES, WHY HAS NOTHING BEEN DONE. THIS IS A SAFETY HAZARD, BUT THE CHROME WEARS OFF THE DOOR HANDLE AND A RECALL IS ISSUED. SOMETHING IS ROTTEN HERE. *TR

NHTSA ID

10514819

Incident

Apr 23, 2012

Mileage

109,123 mi

THE CHROME ON THE INTERIOR DOOR HANDLE OF DRIVER SIDE EXHIBITED A CRACK AND SEPARATED. MY WIFE CUT HER FINGER ON THE CRACKED CHROME PLATING. I CONTACTED HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151 AND WAS TOLD THAT MY VEHICLE WAS NOT INCLUDED IN THE DOOR HANDLE RECALL (I.E., NHTSA CAMPAIGN ID NUMBER: 09V171000). I DON'T UNDERSTAND HOW ONE VEHICLE CAN BE RECALLED WHILE OTHERS OF THE SAME YEAR AND MODEL ARE NOT. *TR

NHTSA ID

10501051

Incident

Feb 13, 2013

Mileage

156,000 mi

TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 50 MPH, HE HEARD A LOUD, ABNORMAL NOISE. THE CONTACT PULLED OVER AND INSPECTED THE VEHICLE WHEN HE NOTICED THAT THE SUB FRAME WAS FRACTURED. THE VEHICLE WAS LATER TOWED TO AN INDEPENDENT MECHANIC WHERE THEY CONFIRMED THAT THE FRONT SUB FRAME WAS FRACTURED AND ALSO ADVISED THAT IT NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 160,000.

NHTSA ID

10488774

Incident

Dec 6, 2012

Mileage

160,000 mi

VEHICLE HAD BEEN RECALLED IN 2009 (PE08071) DUE TO DEFECTIVE CHROME ON DOOR HANDLES. THIS VEHICLE HAD BEEN TAKEN TO DEALERSHIP, CHROME WAS REPAIRED AS IT HAD CAUSED A SMALL LACERATION. CHROME IS AGAIN DEFECTIVE, CAUSED LACERATION ON HAND AGAIN TODAY WHEN ATTEMPTED TO OPEN DOOR. THIS OCCURRED ON THE PASSENGER SIDE DOOR WHICH IS VERY RARELY USED. CHROME IS ALSO PEELING OFF OF EMERGENCY BRAKE HANDLE, RISKING FURTHER LACERATION. CONTACTED DEALERSHIP (GO HYUNDAI - 104TH & FEDERAL, WESTMINSTER, CO), DEALERSHIP SAID THIS IS NO LONGER COVERED AS THEY DO NOT WARRANTY THE WORK DONE AS PART OF A RECALL. IN ADDITION, CAR IS TOO OLD FOR IT TO BE COVERED UNDER WARRANTY. CAR DOES CONTINUE TO BE COVERED UNDER WARRANTY FOR POWERTRAIN ONLY. I HAVE NEVER EXPERIENCED THIS TYPE OF PROBLEM ON ANY MODEL OF CAR REGARDLESS OF AGE. THIS APPEARS TO BE UNIQUE TO HYUNDAI. *JS

NHTSA ID

10461019

Incident

Jun 8, 2012

Mileage

92,000 mi

I TOOK MY CAR IN TO HAVE A FAULTY DOOR HANDLE REPLACED WHICH I CUT MY HAND ON. IT HAD ALREADY BEEN REPLACED ONCE DURING A RECALL. OBVIOUSLY THE SAME FAULTY PART WAS PUT ON AGAIN. I WAS ADVISED THAT I WOULD HAVE TO PAY $125.00 FOR A NEW HANDLE BECAUSE THEY ONLY PERFORM A RECALL ONCE. I THOUGHT THAT RECALL PARTS WERE REPLACED WITH DIFFERENT PARTS THAT ARE NOT FAULTY AND THE PARTS WERE GUARANTEED. I SHOULD NOT HAVE TO PAY FOR THIS SERVICE DUE TO ANOTHER FAULTY HANDLE THAT THEY REPLACED. I NEVER EXPECT TO OPEN MY CAR DOOR AND CUT MY HAND NOR SHOULD I HAVE TO WRAP MY DOOR HANDLE AS THEY SUGGESTED. I AM SO UPSET OVER THIS AND WILL NEVER PURCHASE ANOTHER HYUNDAI AND EVEN HAVE MY CAR SERVICED THERE AGAIN. ALL I AM ASKING IS FOR HYUNDAI TO TAKE RESPONSIBILITY AND REPLACE THIS HANDLE WITH ONE THAT WILL NOT CHIP. *JS

NHTSA ID

10457043

Incident

Apr 27, 2012

NHTSA ACTION # EA08016 MY 2003 SONATA WHICH WAS PURCHASED IN NY OPERATED THERE UNTIL 06/2008 WAS NOT RECALLED UNDER THE ABOVE ACTION #. I FEEL THIS IS A MISTAKE AS THIS CAR IS SHOWING SYMPTOMS DESCRIBED IN THE RECALL # 09V124000. I CALLED HYUNDAI AMERICA WITH NEGATIVE RESULTS. *KB

NHTSA ID

10413553

Incident

Jul 17, 2011

Mileage

50,000 mi

CHROME ON INTERIOR - DRIVERS SIDE DOOR HANDLE HAS ERUPTED IN ONE SPOT PRODUCING A PIERCING SHARP NEEDLE-POINT WHICH CAN PIERCE THE FINGER OR HAND WHEN OPENING THE DOOR. CARE IS REQUIRED TO AVOID SKIN PIERCING INJURY. *KB

NHTSA ID

10413406

Incident

Jun 20, 2011