Summary
The Hyundai Sonata has 108 recalls spanning 1989 through 2024, with the most serious recent issue affecting 2020–2023 models where a damaged check valve lets the fuel tank expand, contact hot exhaust components, melt through, and leak fuel in a way that can cause a fire.
On 2021–2022 models with the 2.5L turbocharged engine, fuel can also leak at the connection between the high-pressure fuel pump and the fuel rail, creating a separate fire risk. The 2021 model with the 8-speed dual-clutch transmission has a transmission oil pump fault that can trigger fail-safe mode and cut drive power to the wheels without warning roughly 20–30 seconds after the fault appears. Also on the 2021 model, the high-pressure fuel pipe connection at the fuel pump can leak. The 2020 Remote Smart Parking Assist feature has a software error that can cause the car to keep moving in its last commanded direction even when the system detects a fault, raising the risk to bystanders. A 2020 model tire pressure label recall covers vehicles with incorrect tire size information printed inside the door jamb.
On 2017 models, connecting rod bearings in the Sonata Hybrid can wear prematurely, leading to engine damage, stalling, or fire. A software update intended to fix an engine control module issue on 2017 models was found to be insufficient, and a second repair campaign followed. The 2017 model also has a driver frontal airbag that may not inflate fully in a crash.
The 2015–2017 model years share a turn signal software defect where the signal activates in the opposite direction from what the driver intends. On 2015–2016 models with the panoramic sunroof, the wind deflector panel can detach at highway speeds and become a road hazard. The 2016 Sonata Hybrid has a voltage protection device that can inadvertently cut power to the electric motor, and certain 2016 models have a driver airbag that may not adequately protect against neck injury in a crash. The 2015 model has multiple issues: front brake calipers that can fracture and extend stopping distances, a passenger seat belt buckle that may not latch, an incorrect left front axle shaft on 1.6L vehicles that can separate from the transaxle and stop the car, front suspension coil springs that can corrode and fracture into a tire, a wiring harness fault that can reduce power steering assist or lock the shifter in Park, and a seat belt anchor pretensioner attachment problem affecting 2011–2015 models where the front belt linkage can detach in a crash. An airbag control module problem covering 2011–2013 models can disable frontal airbags, side airbags, and seatbelt pretensioners simultaneously.
The 2011–2014 era carries one of the heaviest concentrations of issues. The transmission shift cable can detach from the shift lever, leaving the selected gear indicator wrong and possibly allowing unintended movement. Steering column intermediate shaft universal joint connections on 2011 models may have been improperly assembled and can separate, causing partial or complete loss of steering. The 2011–2012 models have crankshaft debris that can restrict oil flow to connecting rod bearings, leading to engine seizure and stall. The 2011 model also has a brake line defect that can cause fluid loss and longer stopping distances, a front door latch that can stay unlatched and allow the door to open
