Tl* the contact owns a 2002 hyundai sonata. While driving approximately 5 MPH, the engine fell through the cradle assembly and crushed the axle. There was no warning indicator illuminated. Prior to the failure, the contact heard a lot of squeaking while driving various speeds and making turns. The dealer was not called. The manufacturer was made aware of the failure and stated that there was no recall. The vehicle was not repaired. The failure mileage was 155,000.
2002 Hyundai Sonata body problems
88 complaints (28% of all complaints for this car). Typical mileage when it fails: 105,000. 2 crashes reported.
- owner complaints
- 88
- of this car's complaints
- 28%
- typical mileage
- 105,000
- crashes
- 2
- recalls
- 0
Which part fails
- Frame and members53
- Body14
- Frame and members: underbody shields10
- Body: door5
- Body: door: hinge and attachments1
At what mileage
Complaints by mileage at the time of the problem.
0k-25k
25k-50k
50k-75k
75k-100k
100k-125k
125k-150k
150k-175k
175k-200k
200k+
Hyundai Sonata body problems in other years
Related recalls
No recalls on record for this model year.
Related investigations
Front sub-frame corrosion
In a letter dated april 14, 2009, hyundai-kia america technical center, inc (hyundai) notified the federal safety agency that hyundaiis conducting a safety recall of model year (my) 1999 through 2004 hyundai sonata vehicles manufactured prior to november 20, 2003 that are registered and operated in the following 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 is recalling the vehicles to remedy a condition where internal corrosion of the front subframe may lead to separation of the lower control arm at the forward mounting point and/or separation of the axle from the transaxle.this could result in a loss of vehicle control and/or vehicle disablement. The subframes will be inspected in the recalled vehicles using a procedure developed by hyundai to measure metal thickness.parts with perforations from corrosion or with metal below the specified thickness will be replaced with redesigned subframes.if the minimum metal thickness is met, drainage holes and rust proofing material will be added to the existing subframe. Odi's analysis of complaint data revealed that 98% of the consumer complaints were from vehicles either originally sold or operated in saltbelt states. Similarly 99.7% of the warranty claims were from vehicles originally sold or operated in saltbelt states.odi identified 105 reports of lower control arm detachment and/or axle separation from the transaxle through analysis of warranty and complaint information and consumer interviews.one hundred three (103) of the 105 incidents involved vehicles in states covered by the recall.in addition to the subject vehicles, hyundai also noted in the april 14, 2009 letter that my 2001 through 2004 xg300 and xg350 were also being recalled as they were manufactured with subframes similar in design the subject vehicles.based on hyundai's decision to conduct a safety recall this engineering analysis is closed.
EA08016
Front sub-frame corrosion
The office of defects investigation (odi) opened preliminary evaluation, pe08-029, on april 22, 2008, based on 40 consumer complaints alleging front sub-frame corrosion in model year (my) 1999 through 2002 hyundai sonata vehicles.complaints describe severe corrosion of the vehicle sub-frame in the area where the right-front lower control arm is attached.in some vehicles, sub-frame corrosion has caused complete or partial detachment of the control arm, resulting in wheel collapse or separation. In response to odi's information request letter for pe08-029, hyundai provided owner complaints, field reports, and warranty claim data for approximately 197,906 my 1999 through 2002 subject vehicles sold or leased in the united states.the base warranty for the subject vehicles is 60 months or 60,000 miles, whichever occurs first.according to hyundai, prolonged exposure to the road salts may result in corrosive damage to the subframe.hyundai redesigned the sub-frame early in the my 2004 production (november 2003) to address problems with premature corrosion of the crossmember near the right-front suspension attachment. Odi's analysis of both complaint and warranty data for the my 1999 through 2002 sonata vehicles shows that the failure rates are significantly higher in salt belt states, which account for approximately 50 percent of vehicle sales and over 90 percent ofcomplaints and warranty claims related to the alleged defect (note:for purposes of this investigation the salt belt includes connecticut, delaware, the district of columbia, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia and wisconsin).according to hyundai, the alleged defect results in a progressive loss of structural integrity of the subframe and there is ample opportunity for the problem to be detected (by inspection, steering feel or tire wear anomalies) and repaired before it reaches a state where a safety related incident may occur.hyundai identified 4 allegations of vehicle disablement and 1 allegation of a crash; where the lower control arm broke from the vehicle while driving at 55 MPH and the driver lost control and drove into a yard.there were no reported injuries.odi received a separate allegation of a crash, where the complainant alleged that while driving around a slight curve at 65 MPH on a freeway, the vehicle sub-frame fractured and the driver lost control of the vehicle and went off the road.again, no injuries were reported.approximately one-third of the complaints to odi allege that the sub-frame corrosion resulted in a loss of control and/or a vehicle disablement due to wheel collapse or separation.this investigation has been upgraded to an engineering analysis (ea08-016) covering my 1999 through early-2004 hyundai sonata vehicles in salt-belt states and equipped with the subject sub-frame design to further assess the frequency and safety consequences of the alleged defect.
PE08029
What 2002 Hyundai Sonata owners say
Most recent owner complaints, unedited.
Tl* the contact owns a 2002 hyundai sonata. While making a right turn, the contact heard an abnormal noise underneath the vehicle. The contact stated that the vehicle started to wobble and then stalled without warning. The vehicle was towed to an independent mechanic where it was diagnosed that the subframe was corroded and needed to be replaced. The vehicle was not repaired. The contact called lancaster hyundai at (866) 528-2534 (located at 5260 main st, east petersburg, pa 17520) and was informed that the VIN was not included in a recall. The manufacturer was notified of the failure and also informed the contact that the VIN was not included in a recall. The approximate failure mileage was 127,028.
Paint is flaking off of all the door handles on my 2001 sonata gold color. When it was only happening on one door, my dealer said it was not there problem. Now that it is happening on all of them, it is obvious to me that it is a defect. Has anyone else had this problem and could they get it resolved?
Tl* the contact owns a 2002 hyundai sonata. The contact stated that premature rust and corrosion occurred on the front subframe. The rust went through the front subframe, causing it to fracture. The vehicle was serviced by checkered flag hyundai (3033 virginia beach blvd, virginia beach, va 23452, (757) 687-3462) for the federal safety agency campaign number: 09v124000 (suspension). The dealer had to disassemble the vehicle. Other parts were damaged. The dealer refused to replace the damaged parts and stated that they would only service the recall, which was completed. Also, the vehicle was included in the federal safety agency campaign number: 09v317000 (latches/locks/linkages). The contact was not notified by the manufacturer of the two recalls. The manufacturer was notified of the failure. The parts were damaged from the completion of the recall repair. The manufacturer refused to provide coverage for the replacement of the damaged parts, stating that the dealer provided the remedy for the recall repair. The dealer and the manufacturer expected the contact to replace the parts that were damaged. The approximate failure mileage was 94,724.
Tl* the contact owns a 2002 hyundai sonata. The contact stated that the heat shield fell off the vehicle. The vehicle was taken to an independent mechanic who diagnosed that the subframe was severely rusted and corroded. The contact stated that the vehicle was taken to another independent mechanic who diagnosed that the undercarriage had severe rust and corrosion, and was unsafe to drive. The vehicle was then taken to grossinger hyundai of palatine (221 e lake cook rd, palatine, il 60074 (847) 348-6700) where it was diagnosed that the rear subframe was severely rusted, needed replacement, and was unsafe to drive. The vehicle was not repaired. The manufacturer was notified and did not assist. The failure mileage was approximately 165,000.
Tl* the contact owns a 2002 hyundai sonata. While attempting to drive the vehicle straight, the vehicle swayed from left to right without the driver steering in those directions. The contact took the vehicle to a certified mechanic who diagnosed that the subframe was completely corroded. The vehicle was not repaired. The contact took the vehicle to the dealer where it was determined that the vehicle was too dangerous to drive and would not be repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 100,000.
Severe crack in the rear subframe which is corroded and rusted throughout. The rear tire is sticking out and the car swerves and is dangerous to drive.
Corrosion of the front sub-frame. Ea08016 front sub-frame corrosion. You issued a recall for "salt-belt" states, I live in northern virginia with the same salt issue as dc and west virginia.
Tl* the contact owns a 2002 hyundai sonata. While driving approximately 35 MPH, the subframe fractured without warning. The vehicle was not diagnosed nor repaired. The vehicle was serviced per the federal safety agency campaign number: 09v124000 (suspension); however, the remedy failed to repair the vehicle. The manufacturer was not made aware of the failure. The approximate failure mileage was 133,000. The VIN was not available.
The vehicle started making a noise and driving weird. It looked like one tire was pointed straight and the other tire turned slightly. I stopped at a gas station to see what was wrong and they said the a frame was almost rusted into. I had already had the metal in the rear of the car replaced from being rusted out near were the shock attaches. I have researched and seen where several sonatas have been recalled due to severe rust issues. The body even has been rusting badly. The bigger concern is the frame. I am afraid to drive it now. Do not know what recourse I have. This happened while driving. The car is now parked and am afraid to move it, even to a garage.
Questions about the 2002 Hyundai Sonata body
Does the 2002 Hyundai Sonata have body problems?
Owners have filed 88 complaints about the body of the 2002 Hyundai Sonata, 28% of all its complaints, more than any other problem.
At what mileage do 2002 Hyundai Sonata body problems start?
The typical (median) mileage in owner complaints is 105,000 miles.
Was there a recall on the 2002 Hyundai Sonata body?
There is no recall for this problem on this model year.
What year does the Hyundai Sonata have the most body problems?
The Hyundai Sonata model years with the most body complaints are 2010 (164 complaints), 2000 (109 complaints) and 2002 (88 complaints).
Other 2002 Hyundai Sonata problems
Suspension 63Airbags 51Brakes 26Fuel system 25Steering 24Electrical 23Engine 21Transmission 11Wheels 11Tires 10Locks 9Acceleration 8Seat belts 5Driver assistance 4Visibility 3Lights 2
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