2005 HYUNDAI SONATA 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.

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)

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.

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

Mileage: 169,000

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

Mileage: 147,000

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.

Mileage: 122,034

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.

Mileage: 49,429

THE FRONT SUBFRRAME IS RUST AND CORROSION VERY BAD

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

Mileage: 95,000

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.

Mileage: 110,978

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

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.

Mileage: 116,400

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

Mileage: 85,000

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.

Mileage: 117,000

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.

Mileage: 144,000

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.

Mileage: 185,000

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.

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.

Mileage: 120,000

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

Mileage: 130,000

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

Mileage: 34,050

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

Mileage: 39,000

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

Mileage: 38,000

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

Mileage: 80,000

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.

Mileage: 140,000

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

Mileage: 36,500

THE DRIVERS DOOR HANDLE HAS A CHROME COVER ON IT, THAT AT ONE POINT WAS GLUED TIGHT TO THE HANDLE, BUT NOW DUE TO WEAR AND TEAR, THE EDGE OF THE PLASTIC CHROME PIECE IS EXPOSED AND IT YOUR NOT PAYING ATTENTION AND SLIDE YOUR HAND ACROSS IT WHEN OPENING THE DOOR, IT CAN RESULT IN A CUT.GASH IN SOMEONE'S HAND. (INJURY) I HAVE GOTTEN A FEW CUTS, NOTHING SERIOUS, BUT IF SOMEONE REALLY WAS IN A RUSH, IT COULD BE QUITE A DEEP CUT/GASH IN YOUR HAND. *TR

Mileage: 105,000

PAINT IS PEELING FROM EXTERIOR DOOR HANDLES OF MY 2005 HYUNDAI SONATA. *TR

Mileage: 30,000

THE 2005 HYUNDAI SONATA GLS HAS SEVERAL PROBLEMS THAT SHOULD BE UNDER WARRANTY AND RECALLED, CLOSE TO THE 2006 RECALLS. WE OWN A COMPANY AND HAVE PURCHASED OVER 12 TO 14 HYUNDAIS. WE HAVE FOUND THAT THE SONATA GLS 2005 HAS PROBLEMS WITH THE AIRBAG DEPLOYMENT, SEATBELT RESTRAINT, THE FRONT TIRES ARE CLOSER TO THE BACK & NOT CENTERED ON THE WHEEL WELL (HAS BEEN THIS WAY SINCE PURCHASED, BUT THEY DO NOT CORRECT.), HAVE ELECTRICAL PROBLEMS & THAT UNIBODY TYPE FRAME & SO ON. IN AN ACCIDENT WHERE A TRUCK LEFT THE TAIL GATE DOWN & A LADDER HIT THE WINDSHIELD, THE CAR WAS THEN PARKED, TURNED OFF , THE KEYS TAKING OUT OF THE IGNITION & THEN BEGAN LOOKING FOR THE CELL PHONE THEN PROCEEDED TO OPEN THE DOOR TO GET OUT INFER ALL THAT THE DRIVER'S SIDE AIRBAG DEPLOYED WHICH ALSO CAUSED THE FRONT DRIVER'S SEAT BELT TO LOCK UP & CAN NOT BE PULLED OUT TO WEAR. HYUNDAI STATES THAT THIS IS NOT WARRANTED EVEN THOUGH IT WAS DEPLOYED AFTER THE ACCIDENT OCCURED. HYUNDAI HAD A GREAT WARRANTY 10 YEARS AGO. THEY DO NOT STAND UP TO THEIR WARRANTY AS BEFORE & I HAVE FOUND THAT SOME OF THE WARRANTY HAS CHANGED. I HAVE SWITCHED TO TOYOTA. HYUNDAI HAS DONE NOTHING SO FAR TO CORRECT. *TR

I PURCHASED A 2005 HYUNDAI SONATA NEW ON 2/18/05 AND THE DEALER, PARR HYUNDAI IN BREMERTON INSTALLED A PLASTIC HOOD DEFLECTOR. IN THE SPRING OF 2007, I REPORTED THAT THE DEFLECTOR WAS VIBRATING AND THE DEALER CHECKED IT OUT. SAID NOTHING WAS WRONG. IN JULY 2007, WHILE DRIVING ON HIGHWAY I 5 FROM OLYMPIA TO TACOMA, WA., THE DEFLECTOR SUDDENLY FLEW OFF. I WAS GOING ABOUT 65 MILES PER HOUR. IT WAS DARK AND I DID NOT SEE WHERE IT WENT. LUCKILY, IT DID NOT HIT ANYONE. HAD THAT HAPPENED, IT WOULD HAVE CAUSED SERIOUS DAMAGE TO ANY VEHICLE FOLLOWING OR PERHAPS KILLED SOMEONE. I REPORTED IT TO THE DEALER, BUT THEY CLAIMED A ROCK HIT MY CAR. I DO NOT BELIEVE THIS IS TRUE. THE VIBRATIONS WERE GETTING WORSE AND I HAD DECIDED TO RETURN TO THE DEALER AND HAVE THE DEFLECTOR REMOVED. I WAITED TOO LONG, HOWEVER, AND THE DEFLECTOR FLEW OFF. THE DEFECTOR PART NUMBER IS 00239-F2000. MY CONCERN IS NOT FINANCIAL, SINCE MY LOSS WAS ONLY $66.13. WHAT DOES CONCERN ME IS THAT FUTURE FAILURES OF THE DEFLECTORS COULD CAUSE GREAT BODILY HARM AND PROPERTY DAMAGE. THE AUTO DEALER DOES NOT APPEAR TO BE CONCERNED. *TR

Mileage: 44,000

TL*THE CONTACT OWNS A 2005 HYUNDAI SONATA. WHEN IT RAINS, WATER ENTERS INTO THE VEHICLE AND COLLECTS ON THE STEP PLATES. AS A RESULT, THE SCREWS HAVE RUSTED. THE CONTACT STATED THAT THE PAINT HAS REMOVED FROM HER VEHICLE IN THREE DIFFERENT PLACES. SHE ALSO STATED THAT THE STEERING WHEEL COVER HAS DETACHED AND HER DOOR IS EXPERIENCING ELECTRICAL FAILURE. IF SOMEONE WERE TO LEAN AGAINST THE DOOR, ALL OF THE INTERIOR LIGHTS WOULD ILLUMINATE. THE DEALER HAD TO CHANGE THE SWITCH INSIDE THE DOOR. THE CONTACT STATED THAT THE HOOD SMASHES THE HEADLIGHTS AND ALSO CONTAINS A GAP. THE VEHICLE FAILS TO START INTERMITTENTLY AND THE TURN SIGNALS AND INTERIOR LIGHTS ON THE INSTRUMENT PANEL ILLUMINATE DUE TO ELECTRICAL FAILURE. THE DEALER DOES NOT KNOW WHY ALL OF THE FAILURES ARE OCCURRING. THE CURRENT MILEAGE WAS 26,000 AND FAILURE MILEAGE WAS 22,000. UPDATED 02-01-08 *BF THE CONSUMER STATED NO ONE IS ABLE TO INFORM HER ABOUT THE DEFECT DUE TO THE FACT THE VEHICLE BEING IN HURRICANE KATRINA. THE CONSUMER STATED THE VEHICLE'S WINDSHIELD HAS BEEN REPLACED BUT TO NO AVAIL. UPDATED 02/01/08 *TR

Mileage: 22,000