2005 Hyundai Sonata

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?

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.

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)

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

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.

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.

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.

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.

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.

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

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.

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).

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

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.

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.

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.

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...

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.

FRONT SUBFRAME SEVERE RUST THROUGHOUT THE FRAME