2005 Hyundai Sonata Owner Complaints

Air Bag light stays on and cannot pass stare inspection without repair. NHSTA site has 54 reports of this issue and dealer cannot figure out how to repair. What can be done?

NHTSA ID

11664220

Incident

May 31, 2025

My car's engine cradle, cross member or subframe is rusted out and the OEM replacement for my VIN number won't fit it correctly I'm getting really upset because this could be dangerous for me and my two young kids. I've already paid the mechanic $600 for the replacement part when it really only costs $450 at the most and the two he has ordered before have both been either too big and it says that it is the correct replacement part. What is going on?!!! If something isn't fixed soon and something happens to me or my kids there is going to be a lawsuit.

NHTSA ID

11560872

Incident

Aug 27, 2023

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

Clunking sound when turning corners, took to mechanic, sub frame rotted through. Unsafe to drive.

NHTSA ID

11511937

Incident

Mar 3, 2023

The contact owns a 2005 Hyundai Sonata. The contact stated that while her daughter was driving at 45 MPH, the vehicle rode over a pothole which caused a fracture in the subframe. The contact had taken the vehicle to several independent mechanics and was informed that the failure was caused by severe salt corrosion. The dealer and the manufacturer were notified of the failure and informed her that there were no recalls associated with the VIN. The vehicle was not repaired. The failure mileage was approximately 134,000. Consumer stated part# FC112 is used for 2003, 2004 AND 2005. 2003 AND 2004 of the same make and model are already recalled for the same issue with the subframe having rust due to excessive salt exposure, but SOMEHOW the 2005 which is EXACTLY the same part and problem has not been recalled.

NHTSA ID

11449147

Incident

Dec 15, 2021

Mileage

134,000 mi

My mechanic just took a picture of the subframe of the car which is almost completely rusted through. He said that this is extremely dangerous and that if it was to break while driving the car, I would loose control. I have seen numerous complaints about this on the 2005 Hyundai Sonata on the internet which makes me think this is a common issue.

NHTSA ID

11437887

Incident

Oct 23, 2021

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

The contact owns a 2005 Hyundai Sonata. The contact stated while having a state inspection performed, the inspector informed the contact that the sub-frame was completely rusted. Upon investigation, the contact associated the failure with NHTSA Campaign Number: 09V124000 (Suspension) however, the VIN was not included. The manufacturer was informed of the failure and informed the contact that the vehicle was not included in a recall. The failure mileage was approximately 129,000.

NHTSA ID

11430777

Incident

Aug 27, 2021

Mileage

129,000 mi

I had taken my 2005 Hundai Sonata to my local mechanic for a tire alignment, and it is then when I was told that the front subframe was rusted from the inside. There was no indicator of this beforehand, and had it been let be, I could have lost control of the car while driving and been in an accident.

NHTSA ID

11420241

Incident

Jun 8, 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

THE AIR BAG LIGHT IS ON AND IT WON'T GO OFF. THIS IS ALL THE TIME WHEN THE CAR IS STATIONARY, OR MOVING. WHEN YOU TURN THE CAR ON AND OFF, IT'S STILL ON.

NHTSA ID

11363791

Incident

Jul 5, 2020

2005 HYUNDAI SONATA FRONT SUB-FRAME FAILURE. THE SUB FRAME HAS RUSTED THROUGH AND WHILE DRIVING IT BROKE. THIS COULD HAVE CAUSED A TERRIBLE ACCIDENT. HYUNDAI WAS SUED IN A CLASS ACTION LAWSUIT FOR MODEL YEARS 1999-2004 IN UNITED STATES DISTRICT COURT OF CALIFORNIA. MY MODEL YEAR WAS NOT INCLUDED IN THIS LAWSUIT. HOWEVER, MY SONATA HAS THE SAME ISSUE. I HAVE MADE SEVERAL ATTEMPTS TO CONTACT HYUNDAI ASKING THAT THEY REPAIR MY VEHICLE. LISTED BELOW IS A PARTIAL LIST OF MY CORRESPONDENCE WITH THEM. 1/29/2020 CALLED HYUNDAI TALKED TO DANIELLE TO FILE INITIAL COMPLAINT, SHE INSTRUCTED ME TO TAKE THE VEHICLE TO MY LOCAL DEALER ( MIKE MILLER OF PEORIA, IL ) FOR AND INSPECTION. 2/3/2020 ' P.A. DENIED [XX] FROM HYUNDAI SAID THEY WILL DO A ONE TIME EXTENDED WARRANTY TO FIX THE DEFECT. BUT THEY DID NOT FIX THE VEHICLE. 2/5/2020 ' REQUEST THAT HYUNDAI CONSUMER AFFAIRS CALL ME. 2/6/2020 ' [XXX] (FROM THE WARRANTY TEAM) SAYS IT WILL COST $2,019 TO FIX 2/10/2020 ' FILED A COMPLAINT WITH THE BBB 2/13/2020 ' RESPONSE LETTER FROM BBB 2/25/2020 ' RESPONSE TO MY COMPLAINT LETTER TO HYUNDAI MOTOR AMERICA. ACKNOWLEDGING RECEIPT OF COMPLAINT. 4/7/2020 SENT A LETTER TO VP [XXX] COO ' NO RESPONSE. THIS LETTER MENTIONED THE CLASS ACTION LAWSUIT THAT WAS SETTLED ON MODEL YEARS 1999-2004 CASE #[XXX]. FILED IN THE STATE OF CALIFORNIA. 6/29/2020 RECEIVED A CALL FROM [XXX] (SERVICE MANAGER AT MIKE MILLER HYUNDAI) HE THREATENED TO HAVE MY VEHICLE TOWED AS ABANDONED. I OFFERED TO PAY 676.23 (HALF OF THE PARTS COST) TO HAVE THEM FIX THE VEHICLE. HE STATED HE WOULD SPEAK WITH CONSUMER AFFAIRS AND GET BACK TO ME. 7/6/2020 ' I CALLED [XXX] TO GET AN UPDATE. BECAUSE OF THE SERIOUS NATURE, I WOULD LIKE HYUNDAI TO COMPLETE THE REPAIR AT NO CHARGE. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ID

11337702

Incident

Jan 29, 2020

Mileage

101,780 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

RUST HOLES THROUGH ENGINE CRADLE OR SUB FRAME. THIS CAR HAS ONLY 39,900 MILES ON IT AND WAS WELL MAINTAINED. WHILE GETTING OIL CHANGED THE MECHANIC SHOWED ME THE PROBLEM AND TOLD ME TO CONTACT THE HYUNDAI DEALER AND TELL THEM ABOUT IT. I CALLED AND THEY TOLD ME THERE WAS NOTHING THEY WOULD DO, I HAD TO PAY FOR THE REPAIRS.

NHTSA ID

11287711

Incident

Nov 1, 2019

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. THE CONTACT STATED THAT THE REAR BRAKE LIGHTS WERE ALWAYS ILLUMINATED, WHICH DRAINED THE BATTERY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE DEALER AND MANUFACTURER WERE NOT NOTIFIED. THE FAILURE MILEAGE WAS 100,000.

NHTSA ID

11245804

Incident

Aug 20, 2019

Mileage

100,000 mi

MY HYUNDAI SONATA 2005 IS VERY UNSAFE! THE WHOLE FRAME OF THE CAR IS ROTTED OUT. I WAS DRIVING ON THE EXPRESSWAY WITH MY CHILDREN IN THE CAR AND MY TIRE BLEW! A NICE MAN DRIVE OFF FROM THE OTHER SIDE OF HIGHWAY CAME AROUND TO PUT A SPARE ON. I TOOK THE CAR GOT A NEW TIRE AND ALIGNMENT. THEN A FEW MONTHS LATER MY WHOLE STERLING WHEEL IS TURNED TO LEFT AND CAR IS PULLING HORRIBLY TO RIGHT AND MY RIGHT TIRE IS BENT IN. I TOOK IT IN TO GET CHECKED ASAP. THEY LOOKED AT IT AND TO MY UTTER BELIEF MY CAR IS ROTTED OUT! UNSAFE ! I FEEL THIS IS A REAL ISSUE FOR HYUNDAI! THERE ARE MANY DRIVERS OUT THERE WITH THE SAME ISSUE AND HYUNDAI IS DOING NOTHING TO HELP! YOU MADE THESE VEHICLES. NOW PLEASE HELP US DRIVE SAFELY WITH OUR FAMILIES! SO WE CAN GO TO OUR JOBS AND CONTINUE RAISING OUR FAMILIES. PLEASE DO SOMETHING SOON. I START A NEW JOB AUGUST 27 2019. I WILL NEED A SAFE CAR I AM A DEPENDABLE, RELIABLE , NANNY. SO YOU SEE I DEPEND I MY SAFE VEHICLE FOR ALL MY LITTLE LOVES I'M MY CAR ON A DAILY BASIS. STAND BY YOUR HYUNDAI NAME AND DO SOMETHING GOOD. HELP US PLEASE. THANK YOU. REMEMBER IT WAS YOUR MANUFACTURING THAT CAUSED THIS TO HAPPEN! SO PLEASE HELP. ( NOT SURE EXACTLY HOW LONG THOSE HOLES AND ROTTED OUT FRAME WERE LINGERING) UNTIL ALL THIS WENT WRONG WITH TIRES...

NHTSA ID

11241858

Incident

Aug 5, 2019

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

FRONT SUBFRAME SEVERE RUST THROUGHOUT THE FRAME

NHTSA ID

11231401

Incident

Jul 12, 2019

Mileage

49,419 mi

THE FRONT SUBFRRAME IS RUST AND CORROSION VERY BAD

NHTSA ID

11186786

Incident

Mar 13, 2019

AIRBAG LIGHT STAYS ON. I HAVE TAKEN IT BACK TO DEALER SEVERAL TIMES AND HAS NOT BEEN FIX CAR IS OUT OF WARRANTY.

NHTSA ID

11142522

Incident

Oct 1, 2010

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

"TAKATA RECALL" I THOUGHT I NEEDED A NEW INNER TIE ROD ON MY 2005 HYUNDAI SONATA. WHEN I WENT TO THE SHOP THE MECHANIC TOLD ME YOU HAVE BIGGER PROBLEMS. " YOUR SUB-FRAME ON THIS CAR IS RUSTED OUT AND THE CAR IS UNSAFE TO DRIVE." WITH THAT INFORMATION, I CALLED THE HYUNDAI SUPPORT NUMBER, THEY GAVE ME A REFERENCE NUMBER, I THEN WENT TO THE HYUNDAI DEALERSHIP TO GET AN ESTIMATE FOR REPAIRS AND TO SEE IF HYUNDAI WOULD REPAIR THE SUBFRAME. THE DEALERSHIP TOLD ME THAT HYUNDAI CORPORATION REFUSED TO PAY ANY GOODWILL MONEY TO FIX THE CAR BUT THEY DID TELL ME, " OUR ADVICE: " IS TO NOT DRIVE THE CAR, IT IS UNSAFE." THIS IS NOT A MECHANICAL ISSUE THIS IS A SAFETY ISSUE, AND EVEN THOUGH I DID NOT FIND ANY RECALLS FOR 2005 SUBFRAME, IT WAS OBVIOUS THAT HYUNDAI KNEW THEY DID HAVE A SLEW OF SONATAS THAT HAD A SERIOUS SUBFRAME CORROSION PROBLEM. IN MY BIT OF RESEARCH, THERE HAS BEEN A DEFINITE PROBLEM WITH THE SONATAS AND THE SUBFRAME ROTTING OUT, ALL DIFFERENT YEARS AND MILEAGE AND AGE THAT HYUNDAI DID REPAIR THE CARS THAT I FOUND ON EDMONDS.COM AND ON THE INTERNET.

NHTSA ID

11139668

Incident

Oct 1, 2018

Mileage

168,000 mi

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. THE CONTACT STATED THAT THE BRAKE LIGHTS FAILED TO SHUT OFF. AFTER EXITING THE VEHICLE, THE CONTACT NOTICED THAT THE BRAKE LIGHTS WERE ILLUMINATED. THE CONTACT OPENED THE HUB CAP AND SWITCHED THE WIRES IN ORDER TO TURN OFF THE LIGHTS. HUB HYUNDAI OF KATY (877- 773-4656, LOCATED AT 17007 KATY FWY, HOUSTON, TX 77094) WAS CONTACTED AND STATED THAT THE VEHICLE WAS NOT INCLUDED IN THE EXTERIOR LIGHTING RECALL AND TO CONTACT THE MANUFACTURER. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V280000 (EXTERIOR LIGHTING). THE APPROXIMATE FAILURE MILEAGE WAS 200,000.

NHTSA ID

11130955

Incident

Sep 3, 2018

Mileage

200,000 mi