Problems owners report
Complaints filed with NHTSA about the 2004 Hyundai Sonata, by the system named in each complaint. One complaint can name several.
- Suspension56
- Structure47
- Air bags46
- Electrical system17
- Wheels13
- Steering13
- Latches/locks/linkages12
- Unknown or other12
- Power train10
- Service brakes, hydraulic8
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 32 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 23 2004 Sonata vehicles were involved in crashes on US public roads in which someone died; 17 people died inside them, and 6 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2004 Hyundai Sonata failed the safety check 2.38% of the time — 8% more often than the average 2004 passenger car (2.21%). Median odometer at inspection: 101,251 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
In the United Kingdom
26 cars built in 2004 were licensed for the road at the end of 2025, and 23 more were declared off the road (SORN).
Department for Transport and DVLA, vehicle licensing statistics (table VEH0124, year of manufacture) · Open Government Licence v3.0
In Finland
33 of these cars first registered in 2004 were in use in Finland on 30 Jun 2026, with an average of 244,000 km on the odometer at their last inspection.
Traficom (Finnish Transport and Communications Agency), open data on vehicles in use · CC BY 4.0
In New Zealand
63 2004 cars are on the New Zealand register.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Fuel consumption
Official Canadian test results for 2 variants: combined 10.6–11.8 L/100 km (about 20–22 mpg US), CO₂ 244–271 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Sonata · Mid-size · Regular gasoline | 12.3 | 8.6 | 10.6 |
| Sonata · Mid-size · Regular gasoline | 13.8 | 9.4 | 11.8 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
1 Transport Canada recall for the 2004 Hyundai Sonata.
| 2009123 23 Apr 2009 | Structure On certain vehicles operated in areas of heavy road salt usage (Ontario, Quebec, New Brunswick, Nova Scotia, Prince Edward Island, and Newfoundland & Labrador),… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
HYUNDAI IS RECALLING 188,282 MY 2001-2004 SONATA AND MY 2001-2004 XG300 AND XG350 VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. ROAD SALT APPLIED IN THESE JURISDICTIONS DURING THE WINTER MONTHS MAY RESULT IN PROGRESSIVE, INTERNAL CORROSION OF THE FRONT SUB-FRAME ON THE VEHICLES, AND MAY RESULT IN THINNING OR PERFORATION OF THE SUB-FRAME STEEL. THE CORROSION IS FREQUENTLY VISIBLE AND OFTEN DISCOVERED DURING INSPECTION OR ROUTINE MAINTENANCE, AND OWNERS MAY ALSO HEAR NOISES OR NOTICE TIRE MISALIGNMENT AND STEERING PULL. IF THESE SIGNALS ARE UNDETECTED OR UNHEEDED, THE CORROSION MAY PROGRESS AND THE FORWARD MOUNTING OF THE LOWER CONTROL ARM MAY DETACH FROM THE SUB-FRAME.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Hyundai told its dealers about the 2004 Hyundai Sonata: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 10251285 | This bulletin contains information about the proper removal of the windshield wiper blade protective cover on all models. If the protective cover is not removed correctly, there is a possibility of the rubber insert and rail spring becoming partially separated on the inner side of the wiper blade, which could lead to poor wiping performance and/or possible scratching of the windshield glass. Follow the procedure in this bulletin to properly remove the windshield wiper blade protective cover on all new wiper blades. |
| 10247189 | This bulletin provides important checkpoint guidelines when performing engine oil and filter change services. |
| 10235566 | Hyundai applies a Paint Protection Film (PPF) on new vehicles before delivery to dealerships. It provides a barrier between the paint and contaminants, such as rail dust, acid rain, and industrial fallout. In rare cases, the paint can become clouded under the PPF. These spots are the result of moisture trapped between the PPF and the paint. |
| 10230904 | This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside the lamp assembly. Lamp assembly replacement is NOT necessary in most cases. This condition can be eliminated by turning on the lamps with the engine running for several minutes or during normal driving operation. |
| 10217258 | Effective June 2, 2008, Federal Motor Vehicle Safety Standard 110 (FMVSS 110) established a threshold for correcting load carrying capacity information indicated on tire placards when vehicle weight has been increased before retail sale. This limit is the lesser of 1.5% of GVWR or 100 pounds. If the total added weight exceeds the lesser of the limit, a label must be added to the driver-side B-pillar within 25mm (1 inch) of the original tire placard. |
| 10217251 | Follow the guidelines outlined in this bulletin to inspect and clean or replace certain components of the engine intake system accordingly during engine short block or sub-assembly replacement. |
| 10196546 | Hyundai approves only the ATF, DCT gear oil and IVT gear oil specified in the vehicles owners manual. Use of other ATF may result in improper shift quality or other drivability conditions. Use of other DCT and IVT gear oil may result in reduced durability. Hyundai does not approve the use of any aftermarket ATF or gear oil additives. |
| 10190044 | This bulletin provides the service procedure for engine connecting rod bearing clearance testing. Perform the procedure outlined in this bulletin to fulfill the Bearing Clearance Test inspection requirements to determine next required steps. |
| 10190038 | This bulletin provides best practice recommendations when performing brake service procedures. |
| 10189989 | This bulletin provides the inspection procedure and repair guidelines for certain vehicles listed below. |
| 10183963 | This bulletin describes the procedure to inspect and identify fluid which may appear around the brake caliper area. |
| 10183960 | This bulletin provides tire vibration service procedures, including how to optimize vehicle vibration performance. For all wheel/tire balance claims, the Tire Balance Data Sheet must be fully completed including imbalance and Road Force Variation (RFV) data. The Data Sheet can be found at the end of this bulletin. |
| 10178175 | This bulletin provides information regarding condensation related to moisture accumulation in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. The TSB illustrates the various causes of condensation inside the lamp assembly. Lamp assembly replacement is NOT necessary in most cases. This condition can be eliminated by turning on the lamps with the engine running for several minutes, or during normal driving operation. |
| 10176182 | This bulletin provides information on tire maintenance best practices and procedures for dealers and customers to maximize tire life and performance. |
| 10176178 | This bulletin describes the general guidelines to help disinfect and protect vehicle exterior/interior surfaces using recommended safe chemical products. |
| 10174808 | This bulletin provides information on identifying dealer stock vehicles with either: A Battery SOC alert - low Battery State of Charge (SOC) at or below 50%. A 30 Day alert - vehicle has not started and reported an SOC in 30 days. |
| 10174807 | The automatic transmission warranty repair policy authorizes in-dealership repairs of the following components for both OEM (new) and remanufactured automatic transmissions: |
| 10173546 | This bulletin describes the general guidelines to disinfect and protect vehicle interior surfaces using certain safe chemical products. |
| 10172142 | This bulletin describes the requirements for all wheel alignment and/or vehicle tracking claims and best practices when diagnosing and conducting alignment-related repairs for all models and model years. |
| 10170883 | This bulletin provides guidelines to inspect the USB, head unit, and multi-box for common connection conditions. 2. This bulletin presents guidelines to inspect for common Android Auto and Apple CarPlay connection conditions. 3. This bulletin provides physical differences between the USB 2.0 port and USB 3.0 port. |
| 10169370 | The Blind Spot Detection (BSD) or Blind-Spot Collision Warning (BCW) is a system that measures the speed of and distance from the following vehicles by using two magnetic wave radar sensors attached in the rear bumper. The BSD/BCW detects vehicles within the blind spot zone and gives off an alarm (visual and audible). The two magnetic radar sensors provide these functions for BSD/BCW: ? Senses other vehicles in the BSD/BCW zone and turns on the BSD/BCW warning lamp for the driver. The warning lamp starts blinking, along with an audible sound, when the driver turns on the turn signal lamp to en |
| 10167253 | This bulletin provides instruction detailing the proper methodology for scanning and uploading captured GDS data files to the Techline Repository. Compliance with this bulletin ensures that the GDS data files are correctly transferred and matched with a Techline Case number. |
| 10128154 | This SKU is an Air Conditioning Bypass Pulley. The Customer communication requested return of unsold inventory to inspect for potential bracket cracking. Bracket cracks may cause the engine drive belt to slip or jump off the pulley causing loss of power steering assist and electrical system charging. |
| 10128153 | This SKU is an Air Conditioning Bypass Pulley. The Customer communication requested return of unsold inventory to inspect for potential bracket cracking. Bracket cracks may cause the engine drive belt to slip or jump off the pulley causing loss of power steering assist and electrical system charging. |
| 10128119 | This SKU is an Air Conditioning Bypass Pulley. The Customer communication requested return of unsold inventory to inspect for potential bracket cracking. Bracket cracks may cause the engine drive belt to slip or jump off the pulley causing loss of power steering assist and electrical system charging. |
NHTSA manufacturer communications (public domain)
NHTSA investigations
FRONT SUB-FRAME CORROSION
NHTSA Office of Defects Investigation