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Woes of an aging Hyundai #5135711 06/16/19 12:08 PM
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Fifth87 Offline OP
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Vehicle in question is my fiancée's '05 Sonata
She has owned since new, maintained either by an independent or myself.
130K, runs and drives fine, (surprisingly) body and interior in good shape
Replacement is not an option at this point.

First issue is an electrical issue that has gotten progressively worse.
Power locks intermittently lock/unlock on their own, worse in cold weather. Sometimes closing the door hard triggers it, sometimes not. Makes for a real challenge at times as you can unlock it, and it will lock you out instantly. Clock also has become intermittent, but does not lose time. Battery is a 3yr old dealer replacement battery installed by someone other than myself.

Second issue, and one that I am more worried about.
Due to her complete refusal to wash the car, the front subframe is getting tender. I have been keeping an eye on it and have been surprised twice now that it had not been caught in the State Inspection process.
Doing an oil change yesterday, I tapped on a portion of the subframe and the end of my ratchet went right through, creating a clean hole.
Foolish me, I tapped on another portion and created another hole. I did not think to take pictures and the car is not here at the moment.

Any thoughts or suggestions would be greatly appreciated.


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Re: Woes of an aging Hyundai [Re: Fifth87] #5135716 06/16/19 12:18 PM
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eljefino Offline
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Subframes can be changed-- I used to do this all the time with saturn s-series.

The door locks are probably a pinched wire in the door hinge, or a grimy switch. I'd pull the fuse if you don't want to put the work in.

Re: Woes of an aging Hyundai [Re: Fifth87] #5135717 06/16/19 12:19 PM
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Danno Offline
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Replacement needs to be an option.
That subframe issue is telling me the car is on borrowed time, or past time.
One big pothole and its done, never mind what that corrosion does to crashworthiness.


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Re: Woes of an aging Hyundai [Re: Fifth87] #5135722 06/16/19 12:22 PM
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We replaced a few subframe/engine cradles in the garages I've worked at. It's $1000 repair but cheaper than a new vehicle. If he rest of it isn't rusted out it may be worth doing.


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Re: Woes of an aging Hyundai [Re: caprice_2nv] #5135728 06/16/19 12:31 PM
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atikovi Offline
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Originally Posted by caprice_2nv
We replaced a few subframe/engine cradles in the garages I've worked at. It's $1000 repair but cheaper than a new vehicle. If he rest of it isn't rusted out it may be worth doing.


If the subframe is so rusted out that it requires replacement, isn't the body it's attached to going to be just as bad?

Re: Woes of an aging Hyundai [Re: atikovi] #5135764 06/16/19 01:23 PM
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Mad_Hatter Offline
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Originally Posted by atikovi
Originally Posted by caprice_2nv
We replaced a few subframe/engine cradles in the garages I've worked at. It's $1000 repair but cheaper than a new vehicle. If he rest of it isn't rusted out it may be worth doing.


If the subframe is so rusted out that it requires replacement, isn't the body it's attached to going to be just as bad?


At minimum the drivetrain and suspension should be inspected, front and rear. A rusted out subframe as is being described, can be a safety problem. But before deciding to replace it i would inspect everything else, including the rear end.

Replacing a subframe is not particularly hard. You just have to be sure to properly support everything. It's something you can do if you have/have access to the necessary tools.

Last edited by Mad_Hatter; 06/16/19 01:26 PM.
Re: Woes of an aging Hyundai [Re: Fifth87] #5135781 06/16/19 01:44 PM
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eljefino Offline
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The worst issue I have with switching subframes is getting the exhaust apart in a way that it can be put back together later.

That, and the captive nuts inside the unibody frame rails get bent if one uses a rattle gun. Start the old bolts out nice and easy, by hand.

There are plenty of cars with good floorboards and bad subframes. IDK about your hyundai, but the way they seal up and zinc-coat car bodies vs black-painted subframes is sometimes not comparable.

Re: Woes of an aging Hyundai [Re: Fifth87] #5135797 06/16/19 02:03 PM
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Nitronoise Offline
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My Sons 03 Santa FE had the subframe replaced by Hyundai up in Minnon a recall /TSB you might want to check into it with the dealership


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Re: Woes of an aging Hyundai [Re: atikovi] #5135801 06/16/19 02:06 PM
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Linctex Offline
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Originally Posted by eljefino
That, and the captive nuts inside the unibody frame rails get bent if one uses a rattle gun. Start the old bolts out nice and easy, by hand.


Even doing that, I have never had good luck getting them out.


Originally Posted by atikovi
If the subframe is so rusted out that it requires replacement, isn't the body it's attached to going to be just as bad?


Sometimes it is just as bad, yes


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Re: Woes of an aging Hyundai [Re: Nitronoise] #5135815 06/16/19 02:17 PM
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Mad_Hatter Offline
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Originally Posted by Nitronoise
My Sons 03 Santa FE had the subframe replaced by Hyundai up in Minnon a recall /TSB you might want to check into it with the dealership


The recall didn't effect '05 Sonata's.

Re: Woes of an aging Hyundai [Re: Fifth87] #5135820 06/16/19 02:22 PM
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I'm in the rust belt and have an '05 Elantra bought years ago from the original local owner. At purchase the mechanical maintenance was up to date or early done by the selling dealer. There was just a tad of light rust started in a few spots, so each spring I spend a couple hours with a wire brush and the Rustoleum rust converter. So far, so good and the mechanicals are also doing well at 138k miles. A little time with preventative can be well worth it. Lots of cars up here can look pretty good until you get underneath.

Re: Woes of an aging Hyundai [Re: Danno] #5135840 06/16/19 02:42 PM
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Mad_Hatter Offline
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Originally Posted by Danno
Replacement needs to be an option.
That subframe issue is telling me the car is on borrowed time, or past time.
One big pothole and its done, never mind what that corrosion does to crashworthiness.


If he's able to punch a hole just by tapping on it, it's not a question of if but when. Pray it gives out while parked in the garage and not on the highway.

Re: Woes of an aging Hyundai [Re: Fifth87] #5135858 06/16/19 03:10 PM
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maxdustington Offline
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If you can get the SF from a upic yard and install it yourself, do it. Otherwise that car ain't worth it with the problems it has.


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Re: Woes of an aging Hyundai [Re: Fifth87] #5135944 06/16/19 04:36 PM
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Fifth87 Offline OP
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Thanks to all that have replied so far.
After some research Hyundai still sells the subframe. Anything from a yard is likely to be junk. I intend on farming out this job, as this is beyond the scope of my skills having limited time to do it. Even with the cost, still cheaper than a decent used car that she would agree to drive.


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Re: Woes of an aging Hyundai [Re: Fifth87] #5136005 06/16/19 05:51 PM
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eljefino Offline
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Good idea! Almost always cheaper to keep it, and you'll be happy you got through this vehicular midlife crisis a year from now.

This sort of job is a 7/10 on the frustration factor.

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