2005 HYUNDAI SONATA Suspension Problems

My car's engine cradle, cross member or subframe is rusted out and the OEM replacement for my VIN number won't fit it correctly I'm getting really upset because this could be dangerous for me and my two young kids. I've already paid the mechanic $600 for the replacement part when it really only costs $450 at the most and the two he has ordered before have both been either too big and it says that it is the correct replacement part. What is going on?!!! If something isn't fixed soon and something happens to me or my kids there is going to be a lawsuit.

Severely rusted out and corroded front subframe, only noticed it on accident very recently, and my car is the last year of a generation that was recalled for this very issue within the Salt Belt- I live right at the bottom outskirts of the Salt Belt in NKY, and my car is the only year not recalled for subframe corrosion. It's bad and I'm freaked out and can't afford it unless I figure out how to do it myself without prematurely dying due to a dropped engine or something similar (premature because if I don't get it fixed soon I reckon that fate isn't too far off)

The contact owns a 2005 Hyundai Sonata. The contact stated that while her daughter was driving at 45 MPH, the vehicle rode over a pothole which caused a fracture in the subframe. The contact had taken the vehicle to several independent mechanics and was informed that the failure was caused by severe salt corrosion. The dealer and the manufacturer were notified of the failure and informed her that there were no recalls associated with the VIN. The vehicle was not repaired. The failure mileage was approximately 134,000. Consumer stated part# FC112 is used for 2003, 2004 AND 2005. 2003 AND 2004 of the same make and model are already recalled for the same issue with the subframe having rust due to excessive salt exposure, but SOMEHOW the 2005 which is EXACTLY the same part and problem has not been recalled.

My mechanic just took a picture of the subframe of the car which is almost completely rusted through. He said that this is extremely dangerous and that if it was to break while driving the car, I would loose control. I have seen numerous complaints about this on the 2005 Hyundai Sonata on the internet which makes me think this is a common issue.

Upon inspecting the undercarriage of my vehicle found the right side of Front Subframe Cradle Suspension rotted almost completely through. When researching for issues pertaining to this model found a TSA was issued , after a lawsuit in California, for the years prior and after my vehicle. The damage is concurrent with the TSA bulletin but excluded. How does a manufacturer whom obviously is aware of an ongoing issue allow so many people, families and children, drive and risk their lives on our public roadways. Is their a subclass recall that will aid those like myself take corrective action.

The contact owns a 2005 Hyundai Sonata. The contact stated while having a state inspection performed, the inspector informed the contact that the sub-frame was completely rusted. Upon investigation, the contact associated the failure with NHTSA Campaign Number: 09V124000 (Suspension) however, the VIN was not included. The manufacturer was informed of the failure and informed the contact that the vehicle was not included in a recall. The failure mileage was approximately 129,000.

I had taken my 2005 Hundai Sonata to my local mechanic for a tire alignment, and it is then when I was told that the front subframe was rusted from the inside. There was no indicator of this beforehand, and had it been let be, I could have lost control of the car while driving and been in an accident.

BOTH THE REAR AND FRONT SUBFRAME HAVE HOLES FROM RUST WHICH HAS STARTED TO CAUSE NUMEROUS OTHER ISSUES SUCH HAS BALL JOINTS TIE ROD ENDS

2005 HYUNDAI SONATA FRONT SUB-FRAME FAILURE. THE SUB FRAME HAS RUSTED THROUGH AND WHILE DRIVING IT BROKE. THIS COULD HAVE CAUSED A TERRIBLE ACCIDENT. HYUNDAI WAS SUED IN A CLASS ACTION LAWSUIT FOR MODEL YEARS 1999-2004 IN UNITED STATES DISTRICT COURT OF CALIFORNIA. MY MODEL YEAR WAS NOT INCLUDED IN THIS LAWSUIT. HOWEVER, MY SONATA HAS THE SAME ISSUE. I HAVE MADE SEVERAL ATTEMPTS TO CONTACT HYUNDAI ASKING THAT THEY REPAIR MY VEHICLE. LISTED BELOW IS A PARTIAL LIST OF MY CORRESPONDENCE WITH THEM. 1/29/2020 CALLED HYUNDAI TALKED TO DANIELLE TO FILE INITIAL COMPLAINT, SHE INSTRUCTED ME TO TAKE THE VEHICLE TO MY LOCAL DEALER ( MIKE MILLER OF PEORIA, IL ) FOR AND INSPECTION. 2/3/2020 ' P.A. DENIED [XX] FROM HYUNDAI SAID THEY WILL DO A ONE TIME EXTENDED WARRANTY TO FIX THE DEFECT. BUT THEY DID NOT FIX THE VEHICLE. 2/5/2020 ' REQUEST THAT HYUNDAI CONSUMER AFFAIRS CALL...

RUST HOLES THROUGH ENGINE CRADLE OR SUB FRAME. THIS CAR HAS ONLY 39,900 MILES ON IT AND WAS WELL MAINTAINED. WHILE GETTING OIL CHANGED THE MECHANIC SHOWED ME THE PROBLEM AND TOLD ME TO CONTACT THE HYUNDAI DEALER AND TELL THEM ABOUT IT. I CALLED AND THEY TOLD ME THERE WAS NOTHING THEY WOULD DO, I HAD TO PAY FOR THE REPAIRS.

WHILE CHANGING MY OIL ON THE WEEKEND, I NOTICED SEVERE CORROSION FAILURES WITH THE FRONT SUBFRAME ON THE RIGHT SIDE OF MY CAR. (SEE ATTACHED PHOTOS). ONE AREA WAS IN FRONT OF THE LOWER CONTROL ARM AND ANOTHER AREA IS BEHIND THE CONTROL ARM. IT LOOKS LIKE THE SUBFRAME WILL FAIL AT ANY MOMENT AND THE CONTROL ARM WOULD BE FREE TO MOVE ANYWHERE. THIS WOULD SIGNIFICANTLY AFFECT CONTROL OF THE VEHICLE AND BE A SERIOUS SAFETY CONCERN. I SEE THIS PART HAS ALREADY HAD A RECALL FOR 2001 TO 2004 HYUNDAI SONATAS WHICH IS THE SAME BODY AND FRAME STYLE AS THE 2005 VEHICLE. RECALL #09V124000.

MY HYUNDAI SONATA 2005 IS VERY UNSAFE! THE WHOLE FRAME OF THE CAR IS ROTTED OUT. I WAS DRIVING ON THE EXPRESSWAY WITH MY CHILDREN IN THE CAR AND MY TIRE BLEW! A NICE MAN DRIVE OFF FROM THE OTHER SIDE OF HIGHWAY CAME AROUND TO PUT A SPARE ON. I TOOK THE CAR GOT A NEW TIRE AND ALIGNMENT. THEN A FEW MONTHS LATER MY WHOLE STERLING WHEEL IS TURNED TO LEFT AND CAR IS PULLING HORRIBLY TO RIGHT AND MY RIGHT TIRE IS BENT IN. I TOOK IT IN TO GET CHECKED ASAP. THEY LOOKED AT IT AND TO MY UTTER BELIEF MY CAR IS ROTTED OUT! UNSAFE ! I FEEL THIS IS A REAL ISSUE FOR HYUNDAI! THERE ARE MANY DRIVERS OUT THERE WITH THE SAME ISSUE AND HYUNDAI IS DOING NOTHING TO HELP! YOU MADE THESE VEHICLES. NOW PLEASE HELP US DRIVE SAFELY WITH OUR FAMILIES!...

FRONT SUBFRAME SEVERE RUST THROUGHOUT THE FRAME

THE ENGINE CRADLE AND BOTH REAR UPPER STRUT MOUNTS ARE CORRODED TO THE POINT THAT THE CAR IS UNSAFE TO DRIVE AND PRESENTS A SAFETY HAZARD TO ITS DRIVER, OCCUPANTS, AND OTHERS ON THE ROAD. IT WILL NOT PASS THE ANNUAL PENNSYLVANIA SAFETY INSPECTION. THE MECHANIC SHOWED ME (THE OWNER) AT LEAST ONE LARGE HOLE IN THE CRADLE (SILVER-DOLLAR SIZED) AS WELL AS LONG THREE-FINGER WIDE HOLES IN THE UPPER REAR STRUT MOUNTS. (THIS IS SIMILAR TO A PROBLEM THAT I ENCOUNTERED IN 2010 IN MY HYUNDAI ELANTRA (REAR SUSPENSION ONLY IN THAT CAR), REPORTED TO THE NTHSB AND SUBSEQUENTLY RECTIFIED BY HYUNDAI USA.) MOREOVER, THIS IS SIMILAR TO PROBLEMS CITED IN ROBERT D'ELIA V. HYUNDAI MOTOR COMPANY AND HYUNDAI MOTOR AMERICA AND RECTIFIED IN A SUBSEQUENT SETTLEMENT AND RECALL. THIS CONCERNS A CAR WITH 100XXX MILES ON THE ODOMETER. CAR WAS UNDERCOATED BY DEALERSHIP AT POS. DRIVEN EXCLUSIVELY IN...

I TOOK MY CAR TO MY MECHANIC TO CHANGE OIL ON 1/9/2018 AND HE DISCOVERED A BIG HOLE (BIGGER THAN THE FIST-SIZE) ON THE RIGHT FRONT OF THE SUBFRAME UNDERNEATH THE CAR DUE TO RUSTING AND SEVERE CORROSION (PLEASE SEE THE ATTACHED PICTURE FOR MORE DETAILS). THE MECHANIC TOLD ME THAT THIS IS A SERIOUS SAFETY ISSUE, WHICH IS NOT SUPPOSED TO HAPPEN. HE STRONGLY RECOMMENDED ME TO GO TO THE DEALER AND HAVE THIS FIXED AS SOON AS POSSIBLE. RIGHT AFTER THAT, I CALLED HYUNDAI CUSTOMER SERVICE AND THEY TOLD ME THAT MY CAR DOESN'T HAVE A WARRANTY AND IT IS NOT UNDER RECALL BASED ON THE VIN, SO THEY WILL NOT DO ANYTHING ABOUT IT. I GOT THE SAME ANSWER FROM THE DEALER AT HYUNDAI DAVIS IN NJ. I SEARCHED ONLINE AND FOUND 2 RECALLS ISSUED BY HYUNDAI FOR THE SAME PROBLEM. ONE STARTED IN 2009 WITH THE...

TAKATA RECALL SUBFRAME IS ROTTED. MECHANIC ADVISED NOT TO DRIVE IT AS IT IS VERY UNSAFE. CAR HAS LESS THAN 60,000 MILES ON IT

FRONT CRADLE RUST OUT UNSAFE WILL NOT PASS INSPECTION. THE 2004S WERE RECALLED BUT NOT THE 2005S.

DIRECT REPLY - LETTER FROM SENATOR BROWN INQUIRY ON BEHALF OF CONSTITUENT REGARDING HYUNDAI RECALL. *SMD 2005 HYUNDAI SONATA. THE CONSUMER STATED DURING A MAINTENANCE CHECK, THE MECHANIC FOUND THE SUB-FRAME UNDER THE FRONT END OF THE VEHICLE KNOWN AS THE ENGINE CRADLE WAS BADLY CORRODED TO THE EXTENT THAT SIGNIFICANT METAL IN THE SUB-FRAME WAS GONE; PERHAPS MORE THAN 50% GONE AT ON E LOCATION. APPARENTLY, THERE WAS NO RECALL FOR THE CONSUMERS MODEL YEAR. HOWEVER, A RECALL WAS ISSUED FOR OTHER YEARS. THE CONSUMER REFERENCED RECALL # 09V124000. *JB

LETTER FROM SENATOR PORTMAN ON BEHALF OF CONSTITUENT RE 2005 HYUNDAI SONATA SAFETY RECALL. *LD THE CONSUMER STATED FOR SEVERAL WEEKS, HIS DAUGHTER NOTICED SOME UNUSUAL VIBRATIONS AND NOISE WHILE DRIVING. AN INSPECTION REVEALED THE SUB-FRAME UNDER THE FRONT END ALSO CALLED THE CRADLE, WAS BADLY CORRODED TO THE EXTENT THAT SIGNIFICANT METAL IN THE SUB-FRAME WAS GONE;PERHAPS MORE THAN 50% GONE AT ONE LOCATION. THE CONSUMER WAS INFORMED A RECALL HAD BEEN ISSUED FOR THE VERY PROBLEM. HOWEVER, IT DIDN'T APPLY TO THE 2005 MODEL. HYUNDAI REFUSED TO COVER THE REPAIR, STATING THE MODEL WAS NOT COVERED. THE CONSUMER REFERENCED RECALL # 09V124000. *JB

BROUGHT TO GET OIL CHANGED, MECHANIC SHOWED ME THE ENGINE CARRIER WAS ABOUT TO FAIL. IT IS ALMOST RUSTED THRU 2004 HA RECALL BUT NOT 2005 ALSO WHEN IN PARK CAR ROLLS

I OWN A 2005 HYUNDAI SONATA GLS. WHILE DRIVING DOWN THE FREEWAY AT 70 MPH THE CAR SUDDENLY BECAME HARD TO CONTROL, AS IN IT STARTED PULLING EXTREMELY HARD TO THE RIGHT. I HAD TO DRIVE HOME WITH THE STEERING WHEEL COCKED TO THE LEFT IN ORDER TO GO STRAIGHT. I BROUGHT IT INTO THE SHOP THINKING IT NEEDED AN ALIGNMENT - BOTH FRONT TIRES WERE TILTED IN AT THE TOP - WHAT I FOUND OUT WAS THAT THE SUBFRAME WAS RUSTED IN HALF. IT SEEMS VERY SHADY TO ME THAT THERE IS A RECALL FOR THIS EXACT PROBLEM FOR PRETTY MUCH EVERY YEAR EXCEPT 2005. THIS IS THE SAME MODEL AS THE 2004 AND IT WAS MANUFACTURED THAT YEAR AS WELL. *ALSO, THE TRIM ON THE CAR, WHICH IS WHAT MAKES IT MORE EXPENSIVE, IS CONSTANTLY COMING OFF WHILE I'M DRIVING. THE SILVER TRIM AROUND THE PASSENGER WINDOW FLEW...

FAILED INSPECTION IN PART DUE TO FRONT SUBFRAME RUST THROUGH. CALLED HYUNDAI AND SPOKE TO A CLAIMS REP. BY THE NAME OF MIKE EXT.631677. MIKE TOLD ME THERE WERE RECALLS ON SONATAS UP TO 2004 FOR THIS PROBLEM, BUT NOT 2005. THE 2005 MODEL IS THE SAME MODEL AS 2004. THE MODEL YEAR DIDN'T CHANGE TILL 2006 SO WHY WAS 2005 EXCLUDED FROM THE RECALL? MY CAR HAS 115K MILES ON IT AND THE UNDERBODY IS ALWAYS WASHED DURING WINTER SEASONS. MIKE TOLD ME IT WASN'T UNDER WARRANTY, AND THAT HYUNDAI WOULD NOT BE ABLE TO DO ANYTHING FOR ME, TO CONTACT MY DEALERSHIP, MAYBE THEY WOULD DO SOMETHING. I HAVE A 1969 CAMARO AND THE SUBFRAME IS FINE. HOW IS IT THE A CAR 10 YEARS OLD HAS A BAD FRAME? HOPE YOU WILL BE ABLE TO HELP US.

I NOTICE THAT THERE IS A RECALL ON HYUNDAI SONATA'S FROM 2006 -2010 IN REGARDS TO RUST CONCERNS WITH REAR SUSPENSION. THIS WAS JUST DETECTED BY MY MECHANIC THAT THE ATTACHING POINT FOR THE CONTROL ARM HAS RUSTED AND BECAME SEPARATED FROM THE CROSSMEMBER. THE RESULT AND MY IMMEDIATE CONCERN WAS THE SUDDEN CHANGE IN VEHICLE HANDLING, A LOUD NOISE COMING FROM THE REAR TIRE WHEN I HIT A SMALL BUMP. I WAS WONDERING WHY THE 2005 SONATA ISN'T COVERED IN THIS RECALL?

ACCORDING TO MECHANIC THE UPPER CONTROL ARM REAR PASSENGER SIDE IS RUSTED AND DETACHED.

TL* THE CONTACT OWNS A 2005 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING 10 MPH, THE FRONT DRIVER'S SIDE WHEEL PARTIALLY SEPARATED FROM THE SUSPENSION SYSTEM. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS WHERE IT WAS ADVISED THAT THE SUB FRAME WAS RUSTED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED AND MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 135,000. *TR