At approximately 15,000 miles brakes began pulsating and squeaking very bad, by 19,803 I had the brake rotors resurfaced by a Midas mechanic after the dealer told me this was normal maintenance and not covered under warranty. Again at 25,598 I had them resurfaced after pulsation developed for the second time. Then with 33,204 miles they had gotten so bad that I replaced front rotors and pads. Well this did work either by 44,688 they were pulsating again. I replaced pads under Advance Auto Parts manufactures warranty, but rotors not covered so I had them resurfaced. By this time the rear squeaking drum brakes had become unbearable so I replaced them as well. I could talk all day about what problems I have encountered with this car so I am going to list them by approximate mileage.
Problems:
1. 16,500 miles some type of sensor caused the car not to idle when I put gas into the tank (when this problem happened I was 1,100 miles from home and on vacation)
2. 19,803 Front brake rotors resurfaced
3. 25,598 Front brake rotors resurfaced
4. 33,204 Front brake rotors replaced, pads replaced
5. 44,688 Front brake rotors resurfaced, pads replaced again
6. 44,688 Rear shoes replaced
7. 45,000 door speaker stopped working
8. 48,000 Driver widow cable came off track and stopped working (took door panel of and fixed it my self)
9. 53,000 Passenger widow stopped going up all the way (took door panel of and fixed it my self)
10. 55,00 Driver window now making popping noise when I role it up (this ones going back to the dealer)
11. 56,000 The hood has rusted from the inside out (dealer called Hyundai Representative to look at this problem and I still haven't resolved it)
Not a bad car for the money (Paid 15,600 with Tax and 0.9 finance option) but probably would not buy another Hyundai made product due to the brake problems I have experienced with It. I also know someone who has a 2002 Hyundai sonata and they have also experienced some brake problems as well.
I have a Hyundai XG 350L and I'm under 30k miles. I too have felt the car shimmy under braking conditions due to uneven rotors. The dealership has told me that Hyundai will not cover this because it was caused by heat, however, the brake pads are fine. I have never had a rotor go bad in less than 30k miles, especially if the brake pad is still in great shape. Hyundai has a defect in their brake system and what gives them the right to drop this off of their warranty just because it has become a real problem. I'm very unhappy with this type of customer service.
This is an update on the car with now approximately 85,000 miles I have paid out a grand total of over $3,800 in parts, and labor with myself doing the majority of labor. Problem areas lately are major engine work, front-end work and a variety of electrical problems. Hyundai refused to repair the rust problem on the hood giving me no clear reason as to why they felt it was not a defect. I could have upgraded and bought a Toyota Camry with the money I have spent on repairs with this car. POOR QUALITY.
I have a 2001 XG 300 with approximately 61000 miles on it. I took it to the dealer about it pulling to the left hand side. After telling me they examined it by taking the tires off the front they could find nothing wrong, everything looked OK. About 3 weeks later, I was backing up in my driveway and the brake pad on the left side broke into 3 pieces and fell off of my car resulting in me going over a hill and hitting a tree. I called my road side assistance and had it hauled to the dealer who again checked my brake pads and told me they were still in good shape (had plenty of wear still on them),they had only broke because of heating an cooling down due to normal driving. These brake pads were Hyundai parts and they still will not back their products. So now I have to pay to replace the brake pads and rotors, along with all the damages done on my car by the accident. Please be careful with your brakes so the same thing does not happen to you.
How did you take the passenger door panel off of the Sonata? I have the same problem you had.