2006 Hyundai Sonata: engine knocking or ticking

Filed May 25, 2025 · Engine, Transmission · WI

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 the federal safety agency 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.

Filed May 31, 2019 · Suspension · 15 miles · TX

Front suspension "wheel control fork" bolts must constantly be tightened every few weeks or the bolts will come loose causing a "knocking" noise while driving. If left untightened the fork will come disconnected from the suspension causing loss of control and possible car crash.

Filed Aug 10, 2016 · Engine · 50,000 miles · MN

Purchased this sonata used 3 months ago with 45,800 miles on it, drove it 4,000 miles and it developed a engine ticking noise which now has turned into a knocking sound at 1800 rpms goes away, then comes back at 2200 rpms. I contacted hyundai customer service to establish a case number. The dealer has removed the oil pan and found shavings saying it needs a "short block" motor replacement at a cost of $5,800. Hyundai motor america denied the request for repair totally. I find that at 50,000 miles and being only the second owner, this motor had a defect that should be acknowledged as a defect and they should stand behind there product! This is my third hyundai, new 2005 and new 2007 and I'm seriously in the market for a new SUV but if hyundai won't stand behind a costly defect like this they will loose a 10 year very loyal customer forever.

Filed Dec 20, 2015 · Airbags, Driver assistance · 85,000 miles · CA

Air bag light in instrument panel remains on at all times. Esc indicator turns off at random times while driving. Rear suspension knocks when fuel tank is low (I.e. Near empty).

Filed Dec 16, 2015 · Electrical, Engine · 100,000 miles · CA

I own a 2006 hyundai sonata, at 100,000 (hwy miles) the front upper control arms became squeeky and detatched from the rubber bushings, making a horrible ride and clunking sound when I would put the car into gear. This problem makes the car bouncy and unstable. There is also a knocking or loud clicking sound in the engine at crusing speeds, when I barley push the gas pedal. It sounds like the air intake control valve. It goes away when I accelerate. The radio and cruise control electornics seem to work only when they want too!

Filed Oct 23, 2015 · Engine · 105,000 miles · MI

In jan. 2015 it was on a 100 mile highway trip. Upon arrival he noticed the engine developed a knocking noise. I found many 2.4l hyundai's with the same problem on the internet. The engine was made in indiana. It sounds the same as nhsta campaign #15v‑568. It needs a new engine. I can't upload it, but I have video of the knocking. I believe the recall needs to be expanded to earlier years

Filed Oct 4, 2015 · Engine · 125,000 miles · NY

The car was expertly maintained, followed the severe duty maintenance schedule. Never had a problem until 125,000 miles. Metallic debris in the crankcase caused the oil pump not to spray oil onto the connecting rod bearing causing a complete engine failure. This is the same thing that was recently recalled on the newer 2011-up theta ii. The theta I and theta ii are the exact same short blocks except for the theta ii's direct injection system. My mechanic who did the repair was very surprised since he always inspected my car annually and knew I used to be a mechanic and maintained all my cars like clockwork. The repair cost was $4,113.53, see attached invoice. The existing recall should be for all theta engine since 2006-up not just for the 2011-up.

Filed Sep 29, 2015 · Engine · 96,500 miles · PA

At approx. 79k miles, when vehicle was turned on you could hear a mild knocking noise, and then it would fade. Took to dealer they could not identify the problem. At approx. 96k miles vehicle was driving on highway and vehicle shut off. Could not restart. Towed the vehicle after wards vehicle started up and knocking noise got louder. The noise is now on all the time and has a cyclic knocking noise from the engine. Advised manufacturer of other problems with vehicle in july of 2015. The engine stall happed in mid aug of 2015. Had vehicle diagnosed on aug 27, 2015. I have uploaded that diagnosis. Dealer advised possible metal debris, but said I would have to pay addistional fees to determine the cause. The diagnosis states the same problems as the federal safety agency campaign number: 15v‑568 and hyundai campaign # 132. Loud tapping noise when running coming from bottom end rod. Need engine replaced. This was documented before the news broke out about the engine recall.

Filed May 26, 2014 · Suspension · 111,000 miles · FL

At 110,615 mileage on car had installed link assy fr stabilizer, bush-stabilizer, link assy-fr stabilizer, joint assy-cv lh and washer-inr also replaced: lf cv axle shaft and swaybar linkages and bushings. Above was due to clunk type noise front when turning both direction:they found swaybars bushings worn and swaybar linkages had excessive play causing knocking type noise. They also mentioned something was rusted? Not sure, as they did not note that verbal comment on service report. Since I had this car brought in at 99,000 miles for a complete warranty check and was told all was good and I have had all my maintenance done at the dealership repairs were a onetime goodwill repair. Now my car is brought back in at 111,000 due to a clunking, knocking in the back! Seems to happen when at 20-30mph and breaking. Car has been with the dealer since may 21, 2014 today is may 26, 2014 and they still do not know what is wrong.

Filed Mar 14, 2012 · Electrical · 77,000 miles · FL

Headlights dim momentarily, radio goes off momentarily, passenger seat side kick panel relay goes "ticking" momentarily, car jerks momentarily when gas pedal is applied and gear is changed from 1 to 2 or 2 to 3 when I just start my journey (I.e. Just start the engine and start driving, usually). If gas pedal is released while any or all of these are happening, ABS, brake and ESC warning lights come on and stay on the dashboard. These warning lights remain on till the next time I start a new journey and will only go off if the problems mentioned above don't happen as the gear changes from 1 to 2 or 2 to 3. I've been to a hyundai dealer countless number of times. Alternator and battery has been replaced. Ground wires have been checked. They have no clue what is wrong with the electrical system. Please fix this. It has been a known problem and still is creating problems for hyundai sonata owners.

Filed Sep 21, 2008 · Engine · 43,191 miles · PA

Heard small knock in engine, told it was standard fuel injector knock. At 43k, my husband driving on pa turnpike -- knock starts pounding. But no check engine light. As he is getting off to a rest area, knock goes crazy, engine starts smoking, and the check engine light comes on. Engine overhauled, not replaced under warranty. Three subsequent related repairs. 2006 hyundai sonata.

Filed Oct 9, 2007 · Body, Engine · 12,000 miles · FL

Tl*the contact owns a 2006 hyundai sonata. While driving 20 MPH, he heard a loud banging noise coming from the rear of the vehicle. The contact stated that the noise was louder while making a turn with a passenger seated in the rear. The dealer inspected the vehicle on two occasions; the first time they were unable to diagnose the failure and the second time the dealer adjusted the rear suspension. The suspension adjustment failed to solve the failure. As of october 9, 2007, the dealer had not repaired the vehicle. The failure mileage was 12,000 and the current mileage was 16,997. The dealer stated the front right door lock inoperable, passenger seat area makes a rattling sound, right trunk trim vibrates when vehicle in motion and hears knocking sound in the engine. Updated 10/23/07