2002 Hyundai SONATA: complaints, problems and recalls

WHILE SITTING IN VEHICLE WITH THE SEAT BELT ON, IF CONSUMER MAKES ANY KIND OF MOVEMENTSEAT BELT TIGHTEN UP. CONSUMER HAS TO UNHOOK THE SEAT BELT AND FASTEN IT. THIS IS VERY UNSAFE WHEN DRIVING OR IN AN EMERGENCY SITUATION. TS. *AK

Owner-reported narrative. Look up ODI 10004831 at NHTSA ↗

IMPACT TO DRIVERS DOOR AND THE SIDE AIRBAG FAILED TO DEPLOY.*JB

Owner-reported narrative. 12,725 miles reported. Look up ODI 10008327 at NHTSA ↗

RIGHT FRONT SPEAKER POPS ON AND OFF AT A STOP OR MOVING. WHEN YOU USE THE AC BUTTON, WINDSHIELD WIPER, WINDOWS, AND TURN SIGNALS THE SPEAKER EITHER SHUTS OFF OR TURNS ON. THE RADIO WAS REPLACED THREE TIMES, THE SPEAKER TWICE AND THE WIRING AND WIRING HARNESSES WERE REPLACED. THE CAR HAS BEEN IN AND OUT OF THE SHOP WITH AND WITHOUT REPAIRS FOR THE SAME PROBLEM AT LEAST 12 TIMES. THE PROBLEM STARTED THE FIRST NIGHT WHEN I BOUGHT THE VEHICLE IN OCTOBER OF 2001. THE CAR HAS HAD OTHER PROBLEMS WITH THE POWER WINDOW MOTORS, BATTERY, AND REMOTE DOOR …

Owner-reported narrative. 5 miles reported. Look up ODI 10014352 at NHTSA ↗

ON COLD MORNINGS WHERE THE TEMPERATURE WOULD DROP BELOW 30, I WAS EXPERIENCING A LOSS OF BRAKE ABILITY. THIS WOULD ONLY HAPPEN THE FIRST TIME I DROVE THE CAR IN THE MORNING AND ALWAYS ON THE SECOND OR THIRD TAP OF THE BRAKE PEDAL. I WENT TO MY DEALERSHIP IN NOVEMBER/DECEMBER 2002 AND THEY DRAINED THE BRAKE LINE AND TOLD ME IT WAS FIXED. IT WAS NOT AND I HAD TO GO BACK. THIS LAST TIME I COULD NOT STOP IN TRAFFIC AND HAD TO ROLL THRU A BUSY INTERSECTION. THE BRAKE PEDAL WOULD ACTUALLY FREEZE UP OR LOCK IN THE "UP" POSITION IN THE CAR, THEREFORE N…

Owner-reported narrative. 5,918 miles reported. Look up ODI 10016836 at NHTSA ↗

VEHICLE WAS HIT ON DRIVER SIDE DOOR(S) - VEHICLE WAS ROTATED 180 DEGREES FROM THE FORCE OF THE IMPACT. NECK AND BACK INJURIES. BOTH FRONT AIR BAGS DEPLOYED, SIDE AIR BAG DID NOT DEPLOY. *AK

Owner-reported narrative. 14,000 miles reported. Look up ODI 10023806 at NHTSA ↗

CHECK ENGINE LIGHT CONTINUES TO COME ON. WE HAVE BEEN TOLD THAT HYUNDAI IS HAVING A LARGE PROBLEM WITH O2 SENSORS, ESPECIALLY IN WARM CLIMATES. DEALER WORKED ON THE PROBLEM ONCE ALREADY, BUT THE PROBLEM SEEMS TO HAVE RETURNED. THE CAR IS CURRENTLY AT THE DEALERSHIP BEING WORKED ON. THE SERVICE PERSON SAID THERE HAVE BEEN SO MANY PROBLEMS HE IS SUPRISED THEY HAVE NOT HAD A RECALL JUST FOR THE O2 SENSOR. *AK

Owner-reported narrative. 11,650 miles reported. Look up ODI 10026128 at NHTSA ↗

WHILE TRAVELING ON THE HIGHWAY AIR BAG LIGHT WILL APPEAR ON THE DASHBOARD.*AK

Owner-reported narrative. Look up ODI 10029478 at NHTSA ↗

WHILE TRAVELING ABOUT 65MPH ON THE HIGHWAY AND WITHOUT PRIOR WARNING DRIVER SIDE TIRE THREAD SEPARATED FROM THE WHEEL.*AK

Owner-reported narrative. Look up ODI 10029479 at NHTSA ↗

Reported: 2002-05-24 (May 24, 2002)

ON CERTAIN PASSENGER VEHICLES, THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SIDE IMPACT AIR BAG SATELLITE SENSORS MAY BE TOO SENSITIVE TO SOME LATERAL ACCELERATIONS THAT ARE NOT CAUSED BY SIDE IMPACTS TO THE VEHICLE, SUCH AS FORCEFULLY SLAMMING A DOOR CLOSED.

Consequence: INADVERTENT DEPLOYMENT OF A SRS SIDE IMPACT AIR BAG WHEN A SIDE IMPACT CRASH HAS NOT OCCURRED COULD INCREASE THE RISK OF INJURY TO THE SEAT OCCUPANT.

Remedy: DEALERS WILL REPLACE THE SIDE IMPACT AIR BAG SATELLITE SENSORS. OWNER NOTIFICATION BEGAN JULY 8, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HYUNDAI AT 1-800-633-5151.

Reported: 2003-03-17 (March 17, 2003)

ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH A TRACTION CONTROL SYSTEM (TCS), IF THE T125/70D-15 COMPACT SPARE TIRE IS INSTALLED ON A FRONT WHEEL POSITION, THE TCS MAY INADVERTENTLY ACTIVATE BEGINNING AT SPEEDS OF 20 MPH.

Consequence: INADVERTENT ACTIVATION OF THE TCS WILL CAUSE AUTOMATIC APPLICATION OF THE BRAKE AT THE WHEEL WHERE THE COMPACT SPARE TIRE IS INSTALLED. INADVERTENT BRAKE APPLICATION COULD CAUSE OVERHEATING AND DAMAGE TO THE BRAKE, AND MAY PREVENT THE VEHICLE FROM BEING DRIVEN AT SPEEDS ABOVE 20 MPH, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL REPLACE THE SPARE TIRE WITH A NEW LARGER DIAMETER T125/80R-15 COMPACT SPARE TIRE AND A NEW TIRE PRESSURE LABEL WILL BE INSTALLED ON THE DRIVER'S DOOR TO PROVIDE INFORMATION APPLICABLE TO THE T125/80R-15 COMPACT SPARE TIRE. VEHICLES PRODUCED FROM NOVEMBER 15, 2002 THROUGH DECEMBER 16 2002, ALREADY CONTAIN T125/80R-15 COMPACT SPARE TIRES, WILL ONLY REQUIRE NEW TIRE PRESSURE LABELS. OWNER NOTIFICATION BEGAN JUNE 30, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HYUNDAI AT 1-800-633-5151.

Reported: 2004-04-09 (April 9, 2004)

SOME PASSENGER VEHICLES CONTAIN A FUEL TANK ASSEMBLY VALVE THAT MAY NOT CLOSE PROPERLY. IF A VEHICLE WITH A FUEL TANK ASSEMBLY VALVE THAT IS NOT PROPERLY CLOSED WERE TO ROLL OVER, FUEL SPILLAGE MAY OCCUR.

Consequence: FUEL SPILLAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.

Remedy: DEALERS WILL INSTALL AN ADDITIONAL FUEL TANK ASSEMBLY VALVE. OWNER NOTIFICATION BEGAN ON JUNE 30, 2004. OWNERS SHOULD CONTACT HYUNDAI AT 1-800-633-5151.

Reported: 2004-07-26 (July 26, 2004)

CERTAIN PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 301, "FUEL SYSTEM INTEGRITY" A VALVE ON THE FUEL TANK ASSEMBLY MAY NOT CLOSE PROPERLY. IF A VEHICLE ROLLS OVER AND THE FUEL TANK ASSEMBLY VALVE IS NOT PROPERLY CLOSED, FUEL SPILLAGE MAY OCCUR.

Consequence: FUEL SPILLAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.

Remedy: DEALERS WILL INSTALL AN ADDITIONAL FUEL TANK ASSEMBLY VALVE. THE RECALL BEGAN ON OCTOBER 5, 2004. OWNERS SHOULD CONTACT HYUNDAI DE PUERTO RICO AT 1-800-981-0188.

Reported: 2009-04-16 (April 16, 2009)

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.

Consequence: IF THAT HAPPENS, THE VEHICLE MAY LOSE DRIVE POWER TO THE WHEELS, AND THE FRONT WHEEL MAY MAKE CONTACT WITH THE FENDER OR WHEEL WELL, THEREBY INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL MEASURE THE THICKNESS OF THE FRONT SUB-FRAME AND INSPECT THE FRONT SUB-FRAME FOR CORROSION DAMAGE AND, IF NECESSARY, THE FRONT SUB-FRAME WILL BE REPLACED WITH A NEW SUB-FRAME THAT INCORPORATES ADDITIONAL HOLES IN THE UPPER AND LOWER PANELS. IF THE FRONT SUB-FRAME DOES NOT REQUIRE REPLACEMENT, THE DEALER WILL ADD DRAINAGE HOLES TO THE SUB-FRAME AND WILL TREAT THE SUB-FRAME WITH RUST-PROOFING MATERIAL TO STOP THE CORROSION PROCESS. THIS PROCEDURE WILL BE PERFORMED FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING APRIL 2009. OWNERS MAY CONTACT THE HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.

Reported: 2009-05-21 (May 21, 2009)

HYUNDAI IS RECALLING 91,350 MY 2002-2003 HYUNDAI SONATA VEHICLES. REPEATED USE OF THE INTERIOR DOOR HANDLE MAY CAUSE WEAR OF THE CHROME PLATE. IF THE TOP EDGE OF THE HANDLE HAS VERY THIN CHROME PLATING, THAT PORTION OF THE PLATING MAY WEAR AWAY MORE EASILY THAN MORE THICKLY PLATED AREAS AS THE DOOR HANDLE IS USED. THE WORN CHROME PLATING ON THE UPPER EDGE OF THE HANDLE MAY RESULT IN A CRACK OR SEPARATION BETWEEN THE CHROME PLATING ON THE INBOARD AND OUTBOARD SURFACES OF THE HANDLE, WHICH MAY FORM A SHARP EDGE.

Consequence: THIS MAY INFLICT LACERATION INJURIES TO ANYONE USING THE DOOR HANDLE.

Remedy: DEALERS WILL REPAIR THE CHROME PLATED INTERIOR DOOR HANDLE FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JUNE 2009. OWNERS MAY CONTACT HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.

Reported: 2009-08-07 (August 7, 2009)

HYUNDAI IS RECALLING 82 MODEL YEAR 2002-2003 SONATA VEHICLES. REPEATED USE OF THE INTERIOR DOOR HANDLE MAY CAUSE WEAR OF THE CHROME PLATING. IF THE TOP EDGE OF THE HANDLE HAS VERY THIN CHROME PLATING THAT PORTION OF THE PLATING MAY WEAR AWAY MORE EASILY THAN MORE THICKLY PLATED AREAS AS THE DOOR HANDLE IS USED. THE WORN CHROME PLATING ON THE UPPER EDGE OF THE HANDLE MAY RESULT IN A CRACK OR SEPARATION BETWEEN THE CHROME PLATING ON THE INBOARD AND OUTBOARD SURFACES OF THE HANDLE, WHICH MAY FORM A SHARP EDGE.

Consequence: A SHARP EDGE COULD LACERATE OR OTHERWISE INJURE A VEHICLE OCCUPANT.

Remedy: DEALERS WILL REPAIR THE CHROME PLATED INTERIOR DOOR HANDLE FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 16, 2009. OWNERS MAY CONTACT HYUNDAI OF PUERTO RICO AT 1-787-999-3333.