2004 Hyundai Sonata: ball joint or control arm failure

Filed Apr 29, 2026 · Steering, Suspension · MI

2004 Hyundai Sonata GLS front sub frame (K Frame) has rusted out but I guess for certain VIN numbers there was a recall. Mine has the same issue and has caused suspension issues with the control arms and axles, subframe has snapped due to rusting in Michigan.

Filed Apr 20, 2023 · Suspension · 147,000 miles · PA

The contact owns a 2004 Hyundai Sonata. The contact stated while driving approximately 30 MPH, the accelerator pedal was depressed, and the vehicle started shuddering. The contact stated she heard abnormal creaking and cracking sounds. The contact stated no warning light was illuminated. The contact stated that the failure had become more frequent. The contact had taken the vehicle to an independent where it was diagnosed and determined that the front subframe, lower panels, and control arms needed to be replaced. The vehicle had not been repaired. The manufacturer had been informed of the failure. The contact researched online and related the failure to the federal safety agency Campaign Number: 09V124000 (Suspension) however, the VIN was not included. The failure mileage was approximately 147,000.

Filed Apr 18, 2023 · Steering, Suspension · VI

the federal safety agency Campaign 09V124000 (Hyundai Recall #089) - excessive corrosion, thinning of the metal and perforation of the front sub-frame steel, due to road salt, resulting in separation of the forward mounting of the lower control arm increasing the risk of a crash. The recall was issued in 2009 for 1999-2004 Hyundai Sonatas. The present owner purchased the vehicle in 2014 with no knowledge of previous recall. The excessive corrosion and perforation of the sub-frame was brought to the owner's attention in December 2022 during a routine oil change by a Meineke shop and reported as unsafe to drive. The vehicle was towed to Route 1 Hyundai in Monmouth Junction, New Jersey, for inspection and repair estimate on December 30, 2022 and an online complaint filed with Hyundai Motor America for the recall (Case #[XXX]). Following numerous email communications to Hyundai Consumer Affairs, it was confirmed by a National Consumer Affairs representative that the vehicle was covered in Hyundai Recall #089. Route 1 Hyundai took photos of the front sub-frame and H-frame, completed a report and submitted it to Hyundai Motor America. Hyundai Motor America responded that they are declining assistance due to the failure being out of warranty caused by the time in service and mileage of the vehicle. The vehicle has 80,000 miles on the odometer. I am of the understanding that safety recalls are never out of date. Please verify if the response made by Hyundai Motor America is justified. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

Filed Jan 4, 2021 · Suspension · RI

There is a recall on 2004 hyundai sonata for bad subframes that has been an ongoing issue since at least 2001. The subframes rust and rot out! My 2004 sonata has only 84k original miles and I recently took the car to a mechanic to replace a control arm and I was told that the repair could not be performed due to a rotted subframe! I called hyundai motors of america and spoke with consumer affairs. I was told that according to the VIN number on my car that the recall was not on my car! There is a known issue and recall for the very same issue that I am having. How can they tell me that the recall is not applicable ? There probably has been thousands of 2001-2004 sonata's that have had the subfram replaced under this recall .. I dont understand why hyundai would not acknowledge the issue and cover it under the recall .. This car has 84660 miles and the car is otherwise mint ! Not a speck of rust on the original body!

Filed Jul 19, 2019 · Suspension · 150,000 miles · AZ

Suspension: I have changed both lower control arms and now my struts and shocks are out I called and have been told my VIN number is not part of the recall but I dont understand how that is when I have a 2004 sonata and that is the car part of the recall

Filed Jul 10, 2019 · Steering, Suspension · 220 miles · RI

I have a 04 hyundai sonata which was recalled for the subframe rot and the dealership says it doesnt come up with my VIN but iv had to replace 2 tired and a tie rod and the sub frame is getting worse causing more damage my car pulls bangs and one day my whole suspension will detach and how is it not under the recall I have a house and two children and can not afford a new car so please help me understand

Filed Aug 27, 2018 · Body, Suspension · MA

Tl* the contact owns a 2004 hyundai sonata. While the vehicle was undergoing routine maintenance, an independent mechanic diagnosed that there was extensive rust and corrosion concerning the front frame, rear frame, near the front passenger side tire, and near the front rear tire tie rods pertaining to the subframe. The independent mechanic advised the contact to call the manufacturer for a recommendation. The manufacturer had key hyundai of salem (470 s broadway, salem, nh 03079, (603) 841-3099) schedule an appointment on august 28, 2018 to diagnose and repair the vehicle. The contact was not included in the federal safety agency action number: ea08016 (suspension, structure) and the federal safety agency campaign number: 09v124000 (suspension). The manufacturer provided no remedy and advised that the dealer repair the vehicle. The failure mileage was not available.

Filed Oct 26, 2017 · Steering, Suspension · 200,000 miles · VA

The 2004 hyundai sonata has a recall for the front sub frame rusting to the point where the front suspension mount rust to the extent that the lower control arm separates from it's mounting bracket which can cause loss of control and possible accident. There is a recall for this for cars that were sold or registered in the salt belt states. Every state in my area are listed except my state of virginia. My cars sub frame completely rusted through to where the lower control arm separated from it's brackets while moving entering an exit onto a major highway i95 causing severe damage which isn't covered. The recall is 09v124000. I believe virginia should be added to this recall due to it being in the same area as the other states with the same weather pattern.

Filed Apr 30, 2017 · Electrical, Suspension · 127,949 miles · PA

Suspension failure july 2016-both engine mounts and lower control arms failed. Replaced 2016 july. April 2017 both engine mounts and lower control arms failed again. In addition violent jerking while driving,then loss of power. Usually occurred going up hills,coming off from making a turn or driving speeds under 25mph.brake lights remain on unable to indicate stopping to other cars.unable to safely drive and maneuver the vehicle. Brake lights remain on whether driving or in park. Jerking does not occur when putting vehicle in gear,but while driving speed decreases rapidly and car becomes difficult to steer. Suspension feels lose in addition there are noises as if bolts are broken. Per a recall search campaign 089 is open meaning under body isn't coated. Upon further reading of the campaign suspension failure can occur and other issues. Unsure if all related,but the brake lights,and jerking occurred the same time as suspension failed,which was previously replaced.huge safety issues for the driver and other motorists around,especially when jerking occurs. It should be noted,per an internet search these issues are known issues with this make model and year. All issues seen online happen with cars at or around the 130,000 mile mark.

Filed Oct 25, 2016 · Body · 95,000 miles · NY

Front lower control arm broke due to rust while being driven. Pulled off the road and called tow truck. Operator told me to look up sonata recalls because it looked like one. It was recall # 09v124000. Called local dealership 6 times in two days always going to answering machine. Third day drove to dealership. They told me to bring it in and they would look at it. Tow guy said every time it it was moved more damage would be done. He didn't want the responsibility. Dealership wouldn't pick it up. Tow guy called another dealership and he brought it there (8/20/16) five days after the breakdown. After 5 days second dealership said it was a recall item and said to call hyundai america. Began discussions with hyundai america- many calls- and after over 60 days they decided it was between the dealership and some other department of hyundai america and they couldn't do anything. Dealership gave me another # to call but that # had no knowledge of my case. The expense of being without the car has been quite draining. Case # with hyundai america is 9566309. I would like the car completely repaired but can't get anyone to do anything. Thanks

Filed Nov 22, 2015 · Body, Steering · 70,000 miles · NY

Front sub frame rusted. Crack in the sub frame near the right front wheel. Car has 70,000 miles on it. Danger of subframe breaking and control arm disconnect.

Filed Oct 20, 2015 · 38,000 miles · FL

Extensive undercarriage rust and corrosion even though vehicle looks brand new on body and interior and has <40,000 miles. Rust has extended into brakes submounts. Been told by mechanic it may be unsafe to drive as lower control arm or brake lines could corrode through and cause collision. Hyundai states is not covered under recall, even though purchased and driven in pa.