2004 Kia Optima Body & structure Problems

Door lock/unlock mechanism has failed. Unable to unlock and open door from outside or inside. This defect causes the door to stay locked and unable to open. This can trap people inside of the car if they are unable to crawl out a window or exit from another door. There are many reports of this on Kia forums and general Google search. There was no warning that this part was wearing out until it became impossible to open the door.

NHTSA ID

11480899

Incident

Aug 8, 2022

WHILE STATIONARY - DRIVER'S SIDE DOOR WILL NOT OPEN FROM INSIDE OR OUTSIDE WITH KEY, MANUAL LOCK OR ELECTRONIC LOCK CONTROLS (STUCK CLOSED). UNABLE TO EVACUATE CAR FROM DRIVER'S SIDE. SAFETY CONCERN - LACK OF EGRESS

NHTSA ID

11081243

Incident

Mar 23, 2018

Mileage

121,000 mi

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. WHEN THE VEHICLE WAS TAKEN TO BILL DORATY KIA (2925 MEDINA RD, MEDINA, OH 44256, (330) 721-9500) FOR ROUTINE BRAKE SERVICE, THE TECHNICIAN FOUND A CRACK IN THE FRONT FRAME. THE DEALER STATED THAT THE VEHICLE WAS SAFE TO DRIVE AT THAT TIME. THE CONTACT WAS INFORMED THAT THE FRAME WOULD NEED TO BE REPLACED, BUT NO REPAIRS WERE MADE. SINCE WINTER WAS APPROACHING, THE CONTACT WAS CONCERNED THAT THE FRAME WOULD COMPLETELY CRACK DUE TO THE WEATHER AND SALTED ROADWAYS IN HER STATE. THE CONTACT RECEIVED A MANUFACTURER RECALL AND EXTENDED WARRANTY NOTICES IN 2009. THE VEHICLE WAS TAKEN TO THE DEALER, BUT NO ISSUES WERE FOUND. THE DEALER SENT PICTURES OF THE CRACKED FRAME TO THE MANUFACTURER. THE MANUFACTURER WAS NOTIFIED AND ISSUED CASE NUMBER: 2560103. THE MANUFACTURER STATED THAT THEY WOULD CONTACT THE LOCAL DEALER. THE CONTACT WAS AWAITING A CALL BACK FROM THE MANUFACTURER AND DEALER. THE FAILURE MILEAGE WAS APPROXIMATELY 48,000.

NHTSA ID

11051307

Incident

May 1, 2017

Mileage

48,000 mi

DRIVER DOOR DOES NOT OPEN FROM INSIDE NOR FROM OUTSIDE. WHEN UNLOCKING THE DOORS, ALL DOORS WILL OPEN EXCEPT THE DRIVER'S DOOR. CENTER LOCK MECHANISM OR MANUAL USE OF KEYS DOES NOT HELP. THIS IS WITHOUT A DOUBT A SAFETY PROBLEM WHERE DRIVER CAN BE TRAPPED IN THE CAR IN CASE OF EMERGENCY. THIS IS VERY COMMON IN KIA OPTIMA MODELS.

NHTSA ID

10981452

Incident

Apr 29, 2017

Mileage

120,000 mi

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT HEARD AN ABNORMAL LOUD SOUND FROM THE VEHICLE WITHOUT WARNING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT DEALER WHERE IT WAS DIAGNOSED THAT THE FRAME FAILED. THE VEHICLE WAS SERVICED PER AN UNKNOWN RECALL; HOWEVER, THE REMEDY FAILED TO REPAIR THE VEHICLE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 178,000.

NHTSA ID

10943813

Incident

Jan 2, 2017

Mileage

178,000 mi

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE DRIVER'S SIDE DOOR FAILED TO UNLOCK. THE CONTACT WAS ABLE TO GAIN ACCESS AFTER SEVERAL ATTEMPTS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 101,000.

NHTSA ID

10934627

Incident

Dec 9, 2016

Mileage

101,000 mi

PASSENGER AND DRIVER DOOR LOCKS WILL NOT UNLOCK 85% OF THE TIME, PREVENTING NORMAL ENTRY TO / EXIT FROM THE VEHICLE. MULTIPLE ATTEMPTS USING THE KEY IN THE DOOR LATCH ARE REQUIRED TO GAIN ENTRY THE OTHER 15% OF THE TIME. THIS IS A HUGE SAFETY ISSUE IN CASE OF CRASH, FIRE, OR CARJACKING. INTERNET RESEARCH SHOWS THIS TO BE A COMMON ISSUE AROUND 100K MILES. THIS SHOULD BE A RECALL EVENT...

NHTSA ID

10913613

Incident

Oct 1, 2015

Mileage

105,000 mi

DRIVER DOOR WOULD NOT OPEN FROM INSIDE OR OUT. POWER DOOR LOCK WOULD AUTOMATICALLY RE-LOCK ALL DOORS WHEN ATTEMPTING TO OPEN OR UNLOCK WITH KEY OR INSIDE LOCK LEVER. HAD TO CRAWL OVER CONSOLE TO GET IN OR OUT WHEN FINALLY ABLE TO GET PASSENGER FRONT DOOR TO OPEN. FINALLY ABLE TO GET DOOR OPEN BY HOLDING KEY CYLINDER IN UNLOCK POSITION AND FORCING HANDLE TO OPEN. UNHOOKED DOOR LOCK ACTUATOR. AS LONG AS LOCKED OR UNLOCKED DOOR WITH KEY ONLY, DOOR WOULD OPEN. IF LOCKED DOOR WITH INSIDE LOCK LEVER, DOOR WOULD NOT OPEN AGAIN. MECHANIC REPLACING THE DRIVER FRONT DOOR LATCH ASSEMBLY REPAIRED VEHICLE. VERY DANGEROUS SITUATION IF IN ACCIDENT OR VEHICLE FIRE.

NHTSA ID

10893697

Incident

Aug 4, 2016

Mileage

173,000 mi

BOTH DRIVER AND PASSENGER DOORS WON'T OPEN, EVEN THOUGH THEY ARE UNLOCKED. THE CAR COULD BE ON OR OFF WITH THIS PROBLEM.

NHTSA ID

10837709

Incident

Feb 23, 2016

OUT OF NOWHERE MY DAUGHTER'S CAR DOOR WOULD NOT OPEN, TRAPPING HER INSIDE. IT WON'T OPEN WITH THE KEY OR REMOTE. I CALLED KIA AND THEY SAID MY WARRANTY RAN OUT AND THERE IS NO RECALL DESPITE THIS BEING A COMMON ISSUE-- A VERY DANGEROUS SAFETY ISSUE I MUST SAY, SINCE THE DRIVER AND PASSENGERS COULD POSSIBLY BE TRAPPED AND DIE IN AN EMERGENCY.

NHTSA ID

10807653

Incident

Nov 29, 2015

Mileage

64,200 mi

THE DRIVER SIDE DOOR WILL NOT OPEN FROM THE INSIDE OR OUTSIDE, WITH OR WITHOUT THE KEY. I'VE TRIED EVERYTHING AND CAN'T GET IT TO OPEN. I HAD TO CRAWL TO THE PASSENGER SIDE AFTER GETTING HOME TO GET OUT.

NHTSA ID

10790123

Incident

Nov 1, 2015

SUB FRAME ROT LEADING TO POOR HANDLING , TIRE WEAR, BAD ENGINE PERFORMANCE. THE ROTTED SUPFRAME IS SEPARATING FROM BODY, CAUSING POOR PERFORMANCE. THE CAR IS PERFORMING POORLY AT ALL SPEEDS. NOT SAFE...

NHTSA ID

10785782

Incident

Oct 18, 2015

Mileage

124,000 mi

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE DOOR LOCK FAILED. IN ADDITION, THE DOORS WOULD AUTOMATICALLY LOCK ONCE OPENED WITH THE KEY FOB. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 125,000.

NHTSA ID

10723224

Incident

Jul 18, 2012

Mileage

125,000 mi

POWER DOOR LOCK LOCKS WHEN UNLOCKING FROM OUTSIDE WITH KEY. REPLACED THE DOOR LATCH. BUT IT STILL DOES IT. ALSO THE HEADLIGHTS STAY ON WHEN TURNING OFF THE CAR. HAVE TO MANUALLY TURN OFF HEADLIGHT SWITCH. *TR

NHTSA ID

10714185

Incident

Mar 19, 2015

Mileage

146,680 mi

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE DRIVER SIDE DOOR FAILED TO UNLOCK OR OPEN. THE CONTACT HAD TO GET IN AND OUT OF THE VEHICLE BY USING THE PASSENGER SIDE DOOR. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 138,000.

NHTSA ID

10691649

Incident

Feb 20, 2015

Mileage

138,000 mi

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. WHILE DRIVING AT APPROXIMATELY 20 MPH, THE POWER STEERING SEIZED. ALSO, THE SUBFRAME WAS FRACTURED. THE VEHICLE WAS NOT TAKEN TO A DEALER AND WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE CONTACT BELIEVED THAT THE FAILURE WAS RELATED TO NHTSA CAMPAIGN NUMBER: 09V183000 (SUSPENSION). THE APPROXIMATE FAILURE MILEAGE WAS 91,700.

NHTSA ID

10681555

Incident

Feb 1, 2015

Mileage

91,700 mi

I WAS DRIVING ON I-10 WESTBOUND, KATY TX FREEWAY, TRAVELLING ABOUT 65 MILES PER HOUR. THE PASSENGER'S SIDE FRONT TIRE BLEW OUT CAUSING THE CAR TO GO BACK AND FOURTH BETWEEN TWO LANES OF TRAFFIC. IN THE PROCESS, I WAS HITTING THE RUBBER DIVIDERS, DAMAGING THE HOOD OF THE CAR AND THE WINDSHIELD. THE BLOWN TIRE CAUSED DAMAGE TO THE OIL PAN, THE RADIATOR, AND EVENTUALLY THE TRANSMISSION. I GOT THE CAR TO THE EMERGENCY LANE. THE CAR WAS TOWED OFF THE FREEWAY AND EVENTUALLY PICKED UP AND TRANSPORTED TO A CAR REPAIR SHOP. A FEW DAYS LATER, THE INSURANCE ADJUSTER AND THE REPAIR SHOP OWNER BOTH AGREED THE CAR WAS A TOTAL LOSS. I HAD TO BUY A NEW CAR. *TR

NHTSA ID

10680973

Incident

Jan 26, 2015

Mileage

62,000 mi

DRIVER'S DOOR LOCKS AND CANNOT BE OPENED WITH A KEY AND DOES NOT OPEN ONCE INSIDE OF THE CAR. THE OPERATOR ESSENTIALLY IS LOCKED IN THE CAR. IN THE EVENT OF A CRASH OR FIRE, THE OCCUPANT MAY NOT BE ABLE TO EASILY VACATE THE VEHICLE; THE ONLY WAY WOULD BE TO CLIMB OVER THE CONSOLE TO THE PASSENGER COMPARTMENT OR THE REAR TO EXIT THE PASSENGER DOORS. THERE HAVE BEEN NUMEROUS COMPLAINTS WITH NO ACTION TAKEN BY THE MANUFACTURER TO REMEDY THE DEFECT AND AFFECTS MULTIPLE MANUFACTURING YEARS. IN MY OPINION IT CLEARLY IS A SAFETY ISSUE. *TR

NHTSA ID

10652810

Incident

Apr 1, 2014

Mileage

150,000 mi

DRIVER SIDE DOOR DOES NOT OPEN FROM INSIDE, EVEN WHEN IN 'UNLOCK' POSITION. I DROVE TO WORK, HAVING NO PROBLEMS OPENING THE DOOR TO GET INTO THE CAR, NOTHING UNUSUAL HAPPENED DURING MY 15 MINUTE COMMUTE. I ARRIVED AT WORK, AND WAS FORCED TO EXIT THE CAR THROUGH THE PASSENGER SIDE DOOR. THE DRIVER SIDE DOOR WILL NOW ONLY OPEN IF YOU USE THE KEY AND CAN RANDOMLY FIND THE PERFECT TIMING OF TURNING THE KEY AND PULLING THE DOOR HANDLE. IT IS NEARLY IMPOSSIBLE TO PERFORM THIS MANEUVER FROM INSIDE THE VEHICLE. HAVING NO EASE OF ACCESS FROM THE DRIVER SIDE FRONT SEAT OF THE VEHICLE POSES AN EXTREME SAFETY CONCERN TO ALL THOSE DRIVING SIMILAR VEHICLES. HAVING PERFORMED JUST CURSORY RESEARCH OVER THE PAST TWO DAYS, I HAVE COME ACROSS HUNDREDS OF SIMILAR ACCOUNTS FROM OTHER KIA OWNERS. THIS IS OBVIOUSLY A MANUFACTURING DEFECT, AND SHOULD BE HANDLED AS A RECALL. *TR

NHTSA ID

10598494

Incident

Jun 13, 2014

Mileage

107,000 mi

DRIVER DOOR WILL NOT OPEN EVEN THOUGH IT INDICATES THE DOOR IS UNLOCKED. DESPITE MULTIPLE TRIES THE DOOR WILL NOT UNLOCK OR OPEN TRAPPING THE DRIVER IN THE CAR. *TR

NHTSA ID

10595400

Incident

Jun 1, 2014

Mileage

57,000 mi

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE FRONT DRIVER'S SIDE DOOR WOULD NOT UNLOCK. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSIS OR REPAIRS. THE MANUFACTURER WAS NOT MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 105,000.

NHTSA ID

10566354

Incident

Feb 27, 2012

Mileage

105,000 mi

I WAS ON A WEEKEND TRIP AND WHEN I GOT TO MY DESTINATION I WAS UNABLE TO UNLOCK OR OPEN THE DRIVER'S SIDE DOOR. I HAD TO CRAWL OUT THE PASSENGER SIDE DOOR. I AM BACK HOME NOW. I HAVE TRIED SPRAYING SOME LUBRICANT ON DOOR LATCH BUT I STILL CAN NOT GET IT TO OPEN. *JS

NHTSA ID

10538400

Incident

Aug 30, 2013

Mileage

100,529 mi

THE PASSENGER WHEEL CAME OFF THE CAR AS MY SON WAS BACKING OUT OF A PARKING SPACE AT A GROCERY STORE. I BOUGHT THIS CAR NEW. THAT PART OF THE CAR HAD NEVER BEEN WORKED ON. THE CAR HAD TO BE TOWED TO A GARAGE FOR REPAIR. KIA USED GLUE ON LIFE A SUPPORT NUT ON A BALL JOINT, WHERE THEY SHOULD HAVE USED A COTTER PIN. I HAVE BOUGHT FOUR (4) KIAS. THESE CARS ARE STILL IN THE FAMILY. THE KIA I DRIVE DAILY IS IDENTICAL (EXCEPT BEING AUTOMATIC) TO THE ONE THAT THE WHEEL CAME OFF. *TR

NHTSA ID

10534657

Incident

Jul 30, 2012

Mileage

102,800 mi

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT WHILE TRAVELING APPROXIMATELY 5 MPH, THE VEHICLE EMITTED A LOUD POP. UPON INSPECTION, IT WAS FOUND THAT THE SUB FRAME HAD FAILED. THE CONTACT WAS INFORMED BY THE DEALER THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER 09V183000 (SUSPENSION). THE MANUFACTURER WAS NOT CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 110,000.

NHTSA ID

10532663

Incident

Jul 29, 2013

Mileage

110,000 mi

ON MY 2004 KIA OPTIMA WHEN I UNLOCK THE DOORS WITH THE KEY ALL DOORS UNLOCK EXCEPT THE DRIVERS DOOR REAL BIG SAFETY CONCERN, IF I GET STUCK IN MY CAR DURING AN ACCIDENT AN CANNOT GET OUT I WILL SUE KIA MOTOR COMPANY FOR NOT ISSUING A SAFETY RECALL, I HAVE ALSO NOTICE A LOT OF POSTINGS BASED UPON THIS ISSUE ON FIXYA.COM FOR THE 2003-2006 KIA OPTIMA NEED ATTENTION ASAP. *TR

NHTSA ID

10507295

Incident

Oct 28, 2011

Mileage

160,000 mi