2004 Hyundai SONATA Power Train Clutch Assembly Problems, Complaints and Defects, Recalls and Failures

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2004 Hyundai SONATA Power Train Clutch Assembly Problems, Complaints and Defects

 Issue ID663721
 Internal NHTSA #10218575
 Model Year2004
 File date15/02/08
Product type codeVEHICLE
 Description of the problemHyundai sonata, 5 speed, 2005, 4 cylinder, 47,500 miles, approximately 4 years old. There was a lot of play in the clutch, but it still engaged. Once engaged however, the vehicle was slow to build up speed. Took it to key hyundai, the dealer where it was purchased. Was immediately told that their 5 year, 60,000 mile bumper-to-bumper warranty would not be in effect because this was due to normal wear-and-tear. They never dropped the transmission to look at the internals. They gave me the choice of $1,100 for repairs, and $2,500 if a new flywheel was needed. Since it wasn't covered by a warranty, i took it to my mechanic. He dropped the transmission and noted that the flywheel came loose from the shaft it was attached to and caused wear to the clutch assembly housing. The flywheel and other parts would have to be replaced. The flywheel alone will cost $1050, and the entire job about $2300. No after market flywheels are available for this vehicle. Hyundai should have honored their warranty. I spoke with several people at key hyundai plus hyundai usa customer service. Key said that it was not going to be warranted and customer service would only refer me back to the dealership. No one could give me information about an average life for the clutch.
 Vehicle Mileage at Failure47500
Number of Occurences1
Source of the issueNHTSA WEB SITE
 Was vehicle invloved in a crash?N
 Was vehicle involved in a fire?N
 Was incedent reported to police?N
 Was medical attention required?
 Was part original equipment?
No. of injured persons0
No. of fatalities0
 Date of purchase19/01/21
Was original owner?Y
Anti-lock brakesN
Cruise controlY
Number of cylinders4
Drive train type
Transmission typeMAN
 Vehicle speed0
 DoT tire identifier
 Tire size
 Location of tire code
 Type of tire failure code
 Was defective tire repaired?
 Date of manufacture
Type of child seat code
Type of restraint
 Dealer's telephone number
 Dealer's cityJACKSONVILLE
 Dealer's state codeFL
 Dealer's ZIP code
  • What is Recall?

    A recall is when a product is removed from the market or a correction is made to the product because it is either defective or potentially harmful.
  • What is Failure?

    Failure is the state or condition of not meeting a desirable or intended objective, and may be viewed as the opposite of success. Product failure ranges from failure to sell the product to fracture of the product, in the worst cases leading to personal injury, the province of forensic engineering.
  • What is Defect?

    Non-conformance of a car component with the specified requirements, or non-fulfillment of user expectations, including the safety aspects.
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