2005 Hyundai Sonata Body & structure Problems

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.

NHTSA ID

11552697

Incident

Oct 30, 2023

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)

NHTSA ID

11537055

Incident

Jul 2, 2023

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.

NHTSA ID

11436685

Incident

Oct 10, 2021

BOTH THE REAR AND FRONT SUBFRAME HAVE HOLES FROM RUST WHICH HAS STARTED TO CAUSE NUMEROUS OTHER ISSUES SUCH HAS BALL JOINTS TIE ROD ENDS

NHTSA ID

11364057

Incident

Aug 20, 2020

Mileage

169,000 mi

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. WHILE THE VEHICLE WAS BEING SERVICED BY AN INDEPENDENT MECHANIC, THE CONTACT WAS NOTIFIED THAT THE SUBFRAME WAS COMPLETELY RUSTED. THE CONTACT ASSOCIATED THE FAILURE WITH NHTSA CAMPAIGN NUMBER: 09V124000 (SUSPENSION). THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 147,000. *LN*JB

NHTSA ID

11287847

Incident

Dec 6, 2019

Mileage

147,000 mi

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.

NHTSA ID

11252730

Incident

Sep 1, 2019

Mileage

122,034 mi

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. WHILE THE CONTACT WAS REPLACING THE BRAKES ON HIS VEHICLE AT HIS HOME, HE NOTICED THE SUBFRAME WAS COMPLETELY CORRODED. THE VEHICLE WAS TAKEN TO ELYRIA HYUNDAI (845 LEONA ST, ELYRIA, OH 44035, (440) 374-8700) WHERE IT WAS DETERMINED THAT THE SUBFRAME WAS RUSTED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND PROVIDED CASE NUMBER: 15927053. THE FAILURE MILEAGE WAS 49,429.

NHTSA ID

11232094

Incident

Jul 8, 2019

Mileage

49,429 mi

THE FRONT SUBFRRAME IS RUST AND CORROSION VERY BAD

NHTSA ID

11186786

Incident

Mar 13, 2019

RUST UNDERNEATH ENGINE PART OF BODY FRONT PASSENGER SIDE I THINK THIS METAL SUPPORT BREAK ANYTIME WHILE DRIVING IN RAIN

NHTSA ID

11139995

Incident

Oct 1, 2018

Mileage

95,000 mi

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. WHILE THE VEHICLE WAS AT AN INDEPENDENT MECHANIC FOR ROUTINE MAINTENANCE, THE TECHNICIAN INFORMED THE CONTACT THAT THE SUBFRAME WAS RUSTED. THE VEHICLE WAS THEN TAKEN TO SUNTRUP HYUNDAI WENTZVILLE (971 WILMER RD, WENTZVILLE, MO 63385, (636) 887-8711) WHERE IT WAS CONFIRMED THAT THE SUBFRAME WAS RUSTED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND A CASE WAS FILED. THE FAILURE MILEAGE WAS 110,978.

NHTSA ID

11113136

Incident

Jun 7, 2018

Mileage

110,978 mi

PURCHASED CAR JUNE 4, 2018. TOLD BY MECHANIC FRAME IS RUSTED OUT AND UNSAFE TO DRIVE. WILL NOT PASS STATE INSPECTION.

NHTSA ID

11109549

Incident

Jun 6, 2018

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.

NHTSA ID

11101746

Incident

Jun 11, 2018

Mileage

116,400 mi

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. WHILE THE VEHICLE WAS BEING REPAIRED BY AN INDEPENDENT MECHANIC, THE TECHNICIAN NOTICED THAT THE SUBFRAME WAS RUSTED. THE CONTACT CALLED LESTER GLENN HYUNDAI AT 732-451-3016 AND WAS INFORMED OF THE COST FOR A DIAGNOSTIC TEST. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INFORMED THE CONTACT ABOUT A RECALL, BUT IT WAS NOT ON HIS SPECIFIC YEAR. THE APPROXIMATE FAILURE MILEAGE WAS 85,000. *TT UPDATED 8/22/18*JB

NHTSA ID

11054666

Incident

Aug 15, 2017

Mileage

85,000 mi

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.

NHTSA ID

11018689

Incident

Aug 1, 2017

Mileage

117,000 mi

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.

NHTSA ID

10993438

Incident

Jun 1, 2017

Mileage

144,000 mi

THE SUB FRAME IN THE FRONT RUSTED OUT JUST LIKE THE SALT BELT 1999-2004 THE CAR HAS ONLY TWO SPOTS OF RUST AT THE BACK FENDER. NO OTHER RUST I TOOK IT TO A SERVICE STATION BECAUSE IT WAS PULLING TO THE RIGHT HE LIFTED THE CAR AND THE SUB FRAME IS ROTTED OUT JUST LIKE THEY DID ON THE 1999-2004 BUT HYUNDAI WILL NOT FIX BECAUSE ITS A 2005 I THINK THE PART IS THE SAME AS THE 2004 AND THEY CANT TELL ME THAT AND WONT HELP ME.

NHTSA ID

10944300

Incident

Jan 10, 2017

Mileage

185,000 mi

I HAVE A HYUNDAI SONATA 2005 AND THE MECHANIC FROM HYUNDAI DEALERSHIP NOTIFIED ME THE SUBFRAME CORROSION ISSUE. THE SYMPTOM OF MY CAR EXACTLY SAME AS THE CASE FROM NICHOLAS CIRULLI AND ROBERT D'ELIA V. HYUNDAI MOTOR COMPANY AND HYUNDAI MOTOR AMERICA, WHICH EVENTUALLY RECALLED 2000 - 2004 HYUNDAI SONATA DUE TO THE SUBFRAME CORROSION ISSUE. I AM WONDERING WHETHER 2005 HYUNDAI SONATA OWNERS EXPERIENCE A SIMILAR ISSUE AND THIS VEHICLE SHOULD BE INCLUDED ON THE RECALL AS WELL. I WOULD APPRECIATE IF NHTSA WOULD REVIEW THIS CASE. THANKS.

NHTSA ID

10910653

Incident

Sep 27, 2016

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.

NHTSA ID

10898766

Incident

Aug 26, 2016

Mileage

120,000 mi

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 *BF

NHTSA ID

10859865

Incident

Apr 11, 2016

Mileage

130,000 mi

THE EXTERIOR PAINT ON THE DOOR HANDLES CAME OFF BOTH THE DRIVERS SIDE AND THE PASSENGER SIDE..THE METAL WRAPPING OF THE INTERIOR DOOR HANDLES BECAME DANGEROUSLY SHARP, AND CUT ME ON MY FINGER. THIS ALL HAPPENED AROUND 2009.SINCE THEN THE INTERIOR CLOTH HEADER HAS COME LOOSE FROM THE ROOF, AND IS NOW HANGING. *TR

NHTSA ID

10683009

Incident

Dec 1, 2009

Mileage

34,050 mi

CHROME INTERIOR DOOR HANDLE. THE CHROME ON THE HANDLE IS CRACKING AT THE CHROME EDGE. IT HAS A SHARP EDGE AND CUT MY PASSENGERS HAND. I HAD THIS HANDLE REPLACED UNDER WARRANTY ONCE BEFORE FOR THIS ISSUE AND NOW IT IS HAVING THE SAME ISSUE AS BEFORE. THEY HAVE A RECALL ON THE 2002 - 2003 SONATAS PERSONALLY I DON'T THINK THEY FIXED ANYTHING AND THIS SHOULD BE INCLUDED FOR THE RECALL AS WELL. *TR

NHTSA ID

10619045

Incident

Jun 16, 2014

Mileage

39,000 mi

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. *JS

NHTSA ID

10585475

Incident

Sep 16, 2011

Mileage

38,000 mi

ABOUT TWO YEARS AGO THE CHROME PLATING ON THE INTERIOR DOOR HANDLES STARTED TO PEEL OFF, RESULTING IN HAZARDOUS SHARP EDGES BEING FORMED. SINCE THEN IT HAS ONLY GOTTEN WORSE AND EVERYONE IN MY FAMILY HAS RECEIVED AT LEAST ONE CUT OR LACERATION FROM THESE SHARP EDGES. YESTERDAY (03/02/2014) AS I WAS GETTING OUT OF MY VEHICLE I RECEIVED A CUT ON MY HAND ABOUT AN INCH LONG AND A QUARTER INCH DEEP. IT REQUIRED STITCHES TO CLOSE THE OPEN WOUND.I KNOW THAT HYUNDAI HAS ISSUED RECALLS FOR THIS SAME EXACT PROBLEM ON THEIR 2003-2004 MODELS. CLEARLY MY 2005 NEEDS TO BE INCLUDED IN THIS RECALL. *TR

NHTSA ID

10566756

Incident

Mar 1, 2012

Mileage

80,000 mi

TL*THE CONTACT OWNS A 2005 HYUNDAI SONATA. THE CONTACT STATED THAT THE CHROME TRIM ON THE INTERIOR DOOR HANDLES STARTED TO SEPARATE, LEAVING SHARP EDGES AND LACERATIONS TO WHOMEVER OPENED THE DOOR. THE CONTACT STATED THAT HE RECEIVED SMALL LACERATIONS TO HIS LEFT HAND AS A RESULT OF OPENING THE DOOR. THE VEHICLE WAS NOT INSPECTED BY A DEALER OR AN INDEPENDENT MECHANIC. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 140,000. THE CURRENT MILEAGE WAS APPROXIMATELY 155,000. THE VIN WAS UNAVAILABLE.

NHTSA ID

10486596

Incident

Sep 1, 2012

Mileage

140,000 mi

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 45 MPH, THE PASSENGER SIDE REAR MOLDING TO THE WINDOW FRACTURED AND DETACHED FROM THE VEHICLE. THE DEALER WAS CONTACTED AND THEY ADVISED HIM THAT THERE WAS ONLY A ONE YEAR WARRANTY ON THE MOLDING. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGES WERE APPROXIMATELY 36,500. ....UPDATED 12/03/12 *BF THE CONSUMER STATED THE CHROME ON TOP OF THE MOLDING, ABOVE THE RIGHT REAR DOOR, BECAME DETACHED AND FLEW OFF. UPDATED 01/10/12

NHTSA ID

10437512

Incident

Nov 27, 2011

Mileage

36,500 mi