2006 Hyundai Sonata

The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing.  There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

The Office of Defects Investigation (ODI) of the National Highway Traffic Safety Administration (NHTSA) received a petition letter dated October 10, 2021, requesting an investigation of possible defects in the electronic throttle control (ETC) system on certain Kia vehicles resulting in the opening of DP21-003. Accordingly, Model Year (MY) 2005-2016 Kia Optima/K5, MY 2006-2015 Kia Sorento, MY 2007-2016 Hyundai Elantra, MY 2007-2016 Hyundai Santa Fe, MY 2006-2015 Hyundai Sonatas are all part of the subject population. The petition was originally filed as a Vehicle Owner Questionnaire that can be reviewed at NHTSA.gov under reference (ODI) number 11439675.On November 12, 2021, ODI opened Defect Petition DP21-003 to evaluate the petitioner?s request. ODI performed trend analyses of the VOQs related to vehicle speed control issues for all the subject vehicles and found that none of the 52 Model/Model Year Hyundai/Kia vehicles demonstrated any actionable trend that warranted an investigation.Petitioners submitted 1119 VOQs and non-VOQ cases in which sudden uncommanded acceleration (SUA) or loss of motive power (LOMP) incidents were alleged.For the 1119 reports, 220 were incidents involving crashes, from which 69 subject Hyundai-Kia vehicles were inspected by Hyundai/Kia dealer technicians, Hyundai/Kia engineers, and/or third-party representatives.ODI found the inspections identified no vehicle defects related to the ETC system.Of the 220 crash-involved reports, 13 Event Data Recorder (EDR) records were downloaded successfully and 11 of those indicated driver error: (i.e.) pedal misapplication.A condition where the accelerator pedal is mistakenly applied instead of the brake pedal when the driver wants to stop the vehicle.In addition, ODI reviewed a scientific journal paper published in Forensic Science International in 2016 by Mr. Park et al ., as well as related test videos. ODI does not believe there is any evidence of uncontrollable SUA occurrences in any of the tests reviewed. NHTSA's Office of Vehicle Safety Compliance (OVSC) reviewed the allegations regarding the potential noncompliance with Federal Motor Vehicle Safety Standard No. 124.Based on the information provided, the Agency concludes there is insufficient information for us to determine if a possible non-compliance exists.Finally, both Hyundai and Kia informed ODI that all their vehicles manufactured after 2012 were equipped with an ETC management system, in which the engine speed will go to idle when the system sees signals from both the brake pedal and accelerator pedal at the same time; this is commonly known as the brake-throttle override system.After thoroughly assessing the material submitted by the petitioner, information already in NHTSA's possession, information submitted by Hyundai and Kia in response to an Information Request letter, and the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that a formal investigation is warranted. After full consideration of appropriate factors, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be published.

On July 22, 2014 the Office of Defects Investigation (ODI) opened a preliminary evaluation to further analyze allegations of seat belt pretensioner malfunctions on model year (MY) 2006-2008 Hyundai Sonata vehicles.ODI received 131 unique reports alleging a failure within the seat belt pretensioner system, which was typically preceded by SRS light illumination.ODI requested more information from Hyundai in order to understand the nature of the failure and how the airbag deployment algorithm, the seat belt pretensioners, and/or the airbag function may be affected. In response to ODI?s information request (IR), Hyundai submitted 764 unique consumer and field reports and 19,847 warranty claims related to a failure in the front seat belt buckle assembly potentially causing a malfunction of the seat belt pretensioners.In it's response, Hyundai advised that if the resistance specifications for the seat belt buckle pretensioner circuit, located in the seat belt stalk, exceed the nominal range, a diagnostic trouble code will be set and the SRS warning indicator lamp will illuminate.The presence of this stored code will not affect the ability of the SRS Control Module (SRSCM) to detect a collision and command deployment of the pretensioners and airbags, if warranted.In fact, the wiring harness connector may be unplugged from the seat belt buckle pretensioner, and the signal to deploy the pretensioner will still be commanded and recorded.MY 2006-2008 Sonata?s utilize a dual pretensioner system by incorporating pretensioners into both the driver and front passenger seat belt retractor and the seat belt buckle assembly.The retractor pretensioner is located inside the B-pillar and winds (pretensions) the seat belt webbing back into the retractor housing during a collision, helping to remove seat belt slack and restrain the upper torso and hips.In contrast, the buckle pretensioner is located within the stalk of the seat belt assembly and acts to supplement lower limb protection.Both pretensioners are controlled by the SRSCM but utilize separate wiring and connectors.The seat belt retractor pretensioner circuitry and operation is independent of the seat belt buckle pretensioner connector and circuitry.Hyundai produced analysis indicating that increased resistance in the seat belt pretensioner which occurs in vehicle service does not result in a loss of buckle pretensioner.Hyundai further advised that in the unlikely event that a seat belt buckle pretensioner may not deploy due to increased resistance, the retractor pretensioner would still activate.Hyundai advised that the subject vehicles maintain their 5 STAR NHTSA safety rating using the retractor based pretensioner only.ODI notes that MY 2009-10 Sonatas reverted back to a single pretensioner system, and do not utilize seat belt buckle pretensioners. Hyundai advised its intention to initiate a warranty extension program to address concerns with the seat belt buckle prentensioner faults in MY 2006-2008 Hyundai Sonata vehicles.This action will extend the warranty coverage for this issue for 15 years or 250,000 miles, whichever occurs first.Given Hyundai's action and the minimal safety consequence this issue presents, further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor the issue and reserves the right to take further action if warranted by the circumstances. The ODI complaints cited above can be reviewed at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID, se

In a letter dated August 9, 2013, Hyundai-Kia America Technical Center, Inc. (Hyundai) notified NHTSA that Hyundaiis conducting a safety recall (13V-354) involving approximately 239,000 vehicles involving model year (MY) 2006 through 2010 Hyundai Sonata vehicles (approximately 215,000)produced beginning on March 1, 2005 through January 21, 2010 and model year (MY) 2006 through 2011 Hyundai Azera vehicles (approximately 24,000) produced beginning on September 27, 2005 through November 22, 2010 that are registered in and operated or originally sold in the following 20 salt belt states and the District of Columbia: Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Hyundai will also inform dealers to inspect/repair vehicles that were previously registered in salt belt states but are currently registered elsewhere. Hyundai is conducting the recall to remedy a defect involving internal corrosion of the rear sub frame that may lead to separation of the rear upper/lower control arm(s) at their respective mounting points and/or separation of the axle from the transaxle where they meet.This could result in a loss of vehicle control and/or vehicle disablement which may increase the risk of a vehicle crash.In response to NHTSA?s Information Request (IR) letter, Hyundai stated the Azera vehicles utilizes the identical cross member and upper/lower rear control arm components as the subject (Sonata) vehicles.In analysis of both Vehicle Owner Questionnaire (VOQ) data submitted to the Office of Defects Investigation (ODI) and consumer complaint data submitted to Hyundai, ODI identified 19 non-duplicative reports alleging excessive corrosion of the rear sub frame. All of the complaint vehicles were either originally sold or registered at the time of the incident in one of the salt belt states.Of these 19 reports, 9 alleged either a suspension component separation or a fracture of the vehicle's rear cross member assembly.Similarly, ODI identified 8 warranty claims of rear sub frame replacement in data submitted by Hyundai due to excessive corrosion, all of which involved vehicles originally sold or operated in a salt belt state. Based on Hyundai's decision to conduct a safety recall, (13V-354) this investigation is closed.The VOQs cited above can be viewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10535115, 10534110, 10525976, 10524726, 10521520, 10508368, 10505463, 10490073, 10486752, 10486435, 1048354, 10473922, and 10437887.

The contact owns a 2006 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, the vehicle experienced a loss of automotive power. No warning light was illuminated. The contact was able to pull over to the shoulder of the roadway and noticed that engine oil was leaking onto the ground and the coolant level was abnormally low. The contact stated that the vehicle failed to restart and was towed to a local independent mechanic, where it was diagnosed with a valve cover leak. The vehicle was repaired at the owner's expense; however, the failure reoccurred. The local dealer was not contacted. In addition, the contact stated that several other unknown repairs were made; however, the failure reoccurred. The contact related the failure to an unknown NHTSA Campaign; however, the VIN was not included. The manufacturer was made aware of the failure. The failure mileage was approximately 112,000.

NHTSA ID

11706449

Incident

Nov 20, 2025

Mileage

112,000 mi

I am filing this complaint regarding a serious engine issue with my 2006 Hyundai Sonata equipped with a 2.4L GDI engine. My vehicle experienced [engine knocking, stalling, and then seized up indicating complete Engine failure] without warning, posing a potential safety hazard while driving. The issue appears to be identical to the known manufacturing defects that Hyundai has acknowledged in its recall of 2013–2014 Sonata models with the same engine Class Type. Although my vehicle is not currently included in the official recall “ SONATA ENGINE RECALL CAMPAIGN it contains the Theta II MPI Engine which constitutes and Further solidifies proof of the ongoing Manufacturing Defects of Theta Model Engine design and exhibits the same symptoms of sudden engine failure. This raises concerns that the defect may affect a broader range of model years than Hyundai has acknowledged. I urge NHTSA to investigate this issue and determine whether the scope of the current recall should be expanded to include earlier model years such as 2006. The defect creates a significant safety risk to drivers and passengers, and Hyundai should be held accountable for all affected vehicles—not just those produced within a narrow window.

NHTSA ID

11663025

Incident

May 16, 2025

There is a recall for the rear lower control arms for the 2006 Hyundai sonata getting rusty and not performing. My car was taken in for an alignment and the mechanic said he isn’t able to make the toe match up to be in good driving standards. I tried reaching out to a Hyundai dealership and they checked the VIN and said they couldn’t do anything about it because my car isn’t in a certain part of the United States. If I don’t get this fixed soon the mechanic said my when could fall out of alignment and cause some serious damage to me or someone else.

NHTSA ID

11659574

Incident

May 4, 2025

The contact owns a 2006 Hyundai Sonata. The contact stated while driving at an undisclosed speed, the contact heard a loud bang and scraping sound coming from the vehicle. The ABS and check engine warning lights were illuminated. The vehicle was taken to the dealer to be diagnosed. The contact was informed that the control arm and suspension had failed and needed to be replaced. The vehicle was not repaired. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was made not aware of the failure. The failure mileage was approximately 176,000.

NHTSA ID

11617849

Incident

Oct 3, 2024

Mileage

176,000 mi

The contact owns a 2006 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, the air bag warning light illuminated. The vehicle was not taken to the dealer or an independent mechanic. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 08V161000 (Air Bags); however, the VIN was not included. The manufacturer was notified of the failure but provided no assistance. The failure mileage was 140,000.

NHTSA ID

11607317

Incident

Aug 8, 2024

Mileage

140,000 mi

I have a 06 sonata 2.4l that had rear control arms rotted out plus the subframe. And my esc light is on not really sure what to wit that. But my car is down now due to rear control arms needed replaced.

NHTSA ID

11581825

Incident

Apr 7, 2024

The contact owns a 2006 Hyundai Sonata. The contact stated that while making a turn at 10-15 MPH, the contact heard a loud bang and scraping sound coming from the vehicle. The contact pulled over and discovered that the rear crossmember had detached. The vehicle was towed to an independent mechanic, who diagnosed that the lower and upper control arm bolts were severely corroded; however, the contact was not yet informed of what needed to be replaced. The vehicle was not repaired. The vehicle had previously been repaired under NHTSA Campaign Number: 13V354000 (Suspension); however, the failure occurred. The manufacturer was made aware of the failure. The failure mileage was approximately 97,000.

NHTSA ID

11573621

Incident

Feb 20, 2024

Mileage

97,000 mi

Rear lower control arm snapped

NHTSA ID

11562819

Incident

Dec 31, 2023

The National Highway Traffic Safety Administration (NHTSA) has issued an urgent safety advisory regarding dangerous, counterfeit driver‑side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN), that have been identified in U.S. vehicles following prior crashes, theft, or non‑certified airbag replacements. These inflators are not approved for use, may rupture during deployment, and have caused serious injuries and fatalities. Please see attached announcement, provided by NHTSA, for more details.

The National Highway Traffic Safety Administration (NHTSA) has identified the presence of substandard and dangerous driver’s-side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN). These inflators were not supplied, approved, or authorized by the vehicle manufacturers and have primarily been found in vehicles that previously experienced a crash and underwent airbag replacement using non-genuine parts. These dangerous inflators have ruptured during deployment, posing a serious risk of injury or death due to metal fragments entering the vehicle cabin. To date, Hyundai is aware of three people who have died while driving a Hyundai vehicle with one of these substandard replacement airbag inflators that deployed in what likely would have been a survivable crash. NHTSA has issued a public advisory urging vehicle owners and service professionals to have vehicles inspected if there is reason to believe that a non-genuine replacement airbag may have been installed. Vehicles with salvage or rebuilt titles, prior airbag deployments, or unknown repair histories may present a higher risk. NHTSA strongly cautions against self-inspection by vehicle owners and recommends inspection by trained technicians.

This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside the lamp assembly. Lamp assembly replacement is NOT necessary in most cases. This condition can be eliminated by turning on the lamps with the engine running for several minutes or during normal driving operation.

This bulletin contains information about the proper removal of the windshield wiper blade protective cover on all models. If the protective cover is not removed correctly, there is a possibility of the rubber insert and rail spring becoming partially separated on the inner side of the wiper blade, which could lead to poor wiping performance and/or possible scratching of the windshield glass. Follow the procedure in this bulletin to properly remove the windshield wiper blade protective cover on all new wiper blades.

This bulletin provides important checkpoint guidelines when performing engine oil and filter change services.

Hyundai 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 rain, and industrial fallout. In rare cases, the paint can become clouded under the PPF. These spots are the result of moisture trapped between the PPF and the paint.