2004 Kia Optima Suspension Problems

Had some noise coming from the front of the car, had my mechanic look at it, he said we needed a control arm. When he took off the cover to replace the control arm, he found the sub frame had rotten and was cracking. As I looked online, I saw that KIA had a recall for this issue. When I contacted KIA, their response was "as my car is not under warranty, they are not required to repair the car" The car in question has 70, 558 miles on it. We are the 2nd owner.

NHTSA ID

11642022

Incident

Dec 10, 2024

I WAS REPAIRING BRAKELINES, WHILE OBSERVING UNDER CARRIAGE I NOTICED SUSPENSION RUST, FRAME. LOOKED UP RECALLS AND THIS IS ONE. I INCLUDED SCREENSHOT OF PROOG

NHTSA ID

11405889

Incident

Mar 29, 2021

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE VEHICLE FAILED INSPECTION DUE TO SEVERE CORROSION OF THE SUBFRAME. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 09V183000 (SUSPENSION) AS A POSSIBLE SOLUTION TO THE FAILURE; HOWEVER, THE VIN WAS NOT INCLUDED. THE FAILURE MILEAGE WAS APPROXIMATELY 57,000. ..UPDATED 05/05/17 *BF *CN

NHTSA ID

10956326

Incident

Feb 21, 2017

Mileage

57,000 mi

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. WHILE DRIVING 30 MPH, THERE WAS AN ABNORMAL NOISE COMING FROM THE FRONT OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FRAME WAS RUSTED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE AND THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V183000 (SUSPENSION). THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

10775927

Incident

Nov 4, 2014

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 45 MPH, THE VEHICLE VEERED TO THE RIGHT. THE FAILURE RECURRED MULTIPLE TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE SUSPENSION FRAME ON THE PASSENGER SIDE TIRE WAS RUSTED AND THE TIRE WAS DISCONNECTING FROM THE VEHICLE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INFORMED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V183000 (SUSPENSION). THE APPROXIMATE FAILURE MILEAGE WAS 68,000. UPDATED 2/24/15*CN UPDATED 03/02/15*JB

NHTSA ID

10669605

Incident

Dec 17, 2014

Mileage

68,000 mi

THE NHTSA CAMPAIGN NUMBER IS 09V183000 AND THE COMPONENT IS SUSPENSION. I WAS TOLD THAT THE RECALL PORTION FOR MY VEHICLE WAS PERFORMED BUT ONLY AS AN INSPECTION BY GLASSMAN KIA, SOUTHFIELD MICHIGAN, IN JULY 2009. I EXPERIENCED THE ACTUAL CORROSION OF THE FRONT SUB-FRAME BUT THANK GOD I DID NOT HAVE A CRASH. I AM TOLD BY KMC THAT THERE IS A POSSIBILITY THEY MAY NOT FIX THE CAR. I HAVE AN APPOINTMENT AT GLASSMAN TOMORROW, JULY 17, 2014. *TR

NHTSA ID

10611056

Incident

Jul 15, 2014

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE VEHICLE WOULD DRIFT WHEN DRIVING VARIOUS SPEEDS. THE MECHANIC DISCOVERED THERE WAS SEVERE CORROSION ON THE SUB FRAM WHICH WOULD NEED TO BE REPLACED. THE CONTACT WAS INFORMED BY THE DEALER THAT THE REMEDY FOR NHTSA CAMPAIGN NUMBER 09V183000 (SUSPENSION) HAD ALREADY BEEN PERFORMED ON THE VEHICLE PRIOR TO THE CONTACT'S PURCHASE. THE REMEDY INCLUDED AN INSPECTION OF THE SUB FRAME, DRILLING HOLES INTO THE SUB FRAME AND APPLYING A SEALANT COATING. THE CONTACT INDICATED THAT THE REMEDY WAS INSUFFICIENT AND DID NOT PREVENT THE DEFECT FROM OCCURRING. THE MANUFACTURER WAS NOTIFIED AND NO SOLUTION WAS OFFERED. THE FAILURE MILEAGE WAS 78,603.

NHTSA ID

10559096

Incident

Jan 8, 2014

Mileage

78,603 mi

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THEY NOTICED RUST ON THE PASSENGER'S SIDE SUBFRAME RAIL. THE VEHICLE WAS PREVIOUSLY INSPECTED UNDER NHTSA CAMPAIGN ID NUMBER 09V183000 (SUSPENSION) BUT NO REPAIR WAS REQUIRED. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 73,615. ..UPDATED 12-30-13 *BF

NHTSA ID

10550923

Incident

Oct 21, 2013

Mileage

73,615 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 THE VEHICLE WOULD MAKE A LOUD NOISE AND THE STEERING WHEEL WOULD VIBRATE VIOLENTLY. A LOCAL MECHANIC INFORMED THE CONTACT OF THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 09V183000 (SUSPENSION:FRONT). AN AUTHORIZED DEALER WAS THEN NOTIFIED AND INFORMED THE CONTACT THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 67,000.

NHTSA ID

10419661

Incident

Aug 1, 2011

Mileage

67,000 mi

TL*THE CONTACT OWNS A 2004 KIA OPTIMA. WHILE DRIVING APPROXIMATELY 10 MPH, AN EXTREMELY LOUD SOUND OF METAL TO METAL EMITTED OUTSIDE OF THE VEHICLE. THE CONTACT DROVE ONTO THE EMERGENCY LANE AND NOTICED THE FRONT DRIVER'S SIDE SUSPENSION AND FRAME COMPLETELY FRACTURED DUE TO RUST CORROSION. THE VEHICLE WAS TOWED TO THE RESIDENCE. THE FAILURE WAS ASSOCIATED WITH RECALL NHTSA CAMPAIGN ID NUMBER 09V183000 (SUSPENSION: FRONT); HOWEVER, THE VIN WAS NOT INCLUDED. THE VEHICLE WAS NOT REPAIRED. THE CONTACT PLANNED TO NOTIFY THE MANUFACTURER REGARDING THE DEFECT. THE FAILURE MILEAGE WAS 85,854. I WAS LESS THAN TEN MINUTES REMOVED FOR HIGHWAY, I COULD HAVE BEEN KILLED, WHEEL FRONT PASSANGER COMPLETELY BROKE OFF! UPDATED 09/14/2011 *LN UPDATED 12/19/11

NHTSA ID

10407497

Incident

Jun 19, 2011

Mileage

85,854 mi

AS DESCRIBED BY OTHERS DRIVER SIDE LOWER BALL JOINT ON '04 KIA OPTIMA BROKE WITH 1 SHEARED BOLT AND 1 BOLT JUST FALLING OUT (RUSTED WITH NO CLEAN AREAS) THE BALL JOINT HAD 1 PART OF THE SHEARED BOLT REMAINING AND 1 RUSTED THREADED HOLE. DEALER OFFERED NO HELP OTHER THAN TO INDICATE THAT THIS WAS NOT RELATED TO THE SUBFRAME RECALL OF LAST AUGUST ('09). *TR

NHTSA ID

10360722

Incident

Oct 8, 2010

Mileage

86,500 mi

I HAVE BEEN REFUSED THE REPAIR ON MY 2004 KIA BY NO LESS THAN 3 DEALERSHIPS ABOUT THE RUSTING FRONT END BECAUSE OF LACK OF RUST PROOFING. IT MADE THE CAR UNDRIVABLE 4 MONTHS AGO AND I HAVE HAD NO SATISFACTION. YOU ARE GOING AFTER TOYOTA WITH BOTH BARRELS YET YOU ARE LEAVING KIA ALONE AND I HAVE HAD NOTHING BUT SERIOUS EXPENSES AND PROBLEMS WITH THIS CAR SINCE IT WAS PURCHASED BRAND NEW IN 2004. I HAVE MADE SEVERAL ATTEMPTS AT CONTACTING YOUR OFFICE WITH NEGATIVE REPLIES. IF I DO NOT HERE FROM THIS AGENCY IN THE NEAR FUTURE CONCERNING MY ISSUES I WILL CONTACT THE MEDIA AND SEEK MY RESTITUTION THROUGH THE SQUEAKY WHEEL GETTING THE GREASE METHOD AND MY ATTEMPTS TO HAVE THE GOVERNMENT ASSIST WILL BE PART OF THAT DISCUSSION. PLEASE PUT HEAT ON KIA TO GET AGGRESSIVE WITH THE RECALL REPAIRS. *TR

NHTSA ID

10311430

Incident

Oct 31, 2009

Mileage

30,000 mi

WHEEL MISALIGNMENT AND OTHER NOTICEABLE STRESS IN STEERING, OR ACCELERATED ABNORMAL TIRE WEAR. RATTLING NOISE COMING FROM LEFT FRONT END AREA, NOT CV AXLE OR STRUT. *TR

NHTSA ID

10286191

Incident

Jun 1, 2009

Mileage

89,250 mi

TL*THE CONTACT OWNS A 2004 KIA OPTIMA. WHILE DRIVING 20 MPH OUT OF A PARKING LOT, THE FRONT PASSENGER SIDE LOWER BALL JOINT AND AXLE DETACHED FROM THE VEHICLE. THE CONTACT CONTROLLED THE VEHICLE UNTIL IT CAME TO A STOP TWELVE FEET FROM THE INCIDENT. HER INSURANCE COMPANY PROVIDED ROADSIDE ASSISTANCE AND THE VEHICLE WAS TOWED TO A COLLISION SHOP. PRIOR TO THE FAILURE, THE CONTACT INFORMED THE DEALER OF A GRINDING NOISE SHE HEARD. THEY STATED THAT THEY WERE TOO BUSY TO CHECK THE VEHICLE, BUT THREE HOURS LATER THE AXLE AND LOWER BALL JOINTS FAILED. THE FAILURE MILEAGE WAS 68,954.

NHTSA ID

10249111

Incident

Oct 10, 2008

Mileage

68,954 mi

RT BALL JOINT/AXLE BROKE WHILE DRIVING ON 10 OCT 08. MY VEHICLE IS A 2004 KIA OPTIMA. *TR

NHTSA ID

10247756

Incident

Oct 10, 2008

Mileage

68,592 mi

VEHICLE WAS INVOLVED IN A SINGLE CAR ACCIDENT IMPACTING A FIXED MEDIAN CURB. THE CAR WAS TOWED TO A REPAIR SHOP IDENTIFIED BY MY INSURANCE COMPANY. THE TOW TRUCK DRIVER REMARKED THAT THE FRONT SUSPENSION APPEARED TO HAVE BOLTS MISSING. THIS WAS INDEPENDENTLY VERIFIED BY THE BODY SHOP. IN THEIR DAMAGE ASSESSMENT, THEY FOUND THAT THE LOWER CONTROL ARM TO BALL JOINT BOLTS WERE MISSING AND THE 2 HOLES WERE ROUNDED OUT IN A WAY THAT WOULD BE CONSISTENT WITH THE BOLTS FALLING OUT. THE BOLTS FALLING OUT CAUSED THE LEFT FRONT SUSPENSION TO COLLAPSE THEREBY CAUSING THE ACCIDENT. A COMPLAINT WAS FILED WITH KIA MOTORS AMERICA. THEY REQUIRED THE INSURANCE COMPANY OR MYSELF TO PROVIDE ALL OF THE EVIDENCE TO SHOW THAT THEIR CAR WAS AT FAULT. AFTER SUBMITTING THE REPAIR ESTIMATE AND PICTURES FROM BOTH THE SCENE AND FROM THE REPAIR SHOP, KIA MOTORS AMERICA AND THEIR LEGAL DEPARTMENT DETERMINED THAT THEY ARE NOT AT FAULT. THE REPAIR SHOP MANAGER COULD NOT BELIEVE THAT THEY WOULD MAKE A DETERMINATION WITHOUT EVER LOOKING AT THE CAR. ACCORDING TO JENNIFER AT KIA, THE COMPLAINT IS CLOSED AND I HAVE NO FURTHER RECOURSE OTHER THAT TO CONTACT A LAWYER. THE VEHICLE HAS NOT BEEN REPAIRED AS IT WILL BE SHOWN AS A CLAIM AGAINST MY INSURANCE POLICY AND THEN CAUSE MY RATES TO INCREASE. I FEAR THAT THIS PROBLEM MAY BE PRESENT ON OTHER 2004 KIA OPTIMAS OR OTHER MODELS THAT BOTH KIA AND HYUNDAI MAKES. *JB UPDATED 01/11/06. *JB

NHTSA ID

10135721

Incident

Aug 4, 2005

Mileage

10,700 mi

MY 2004 KIA OPTIMA PULLS TO THE LEFT. IT WILL PULL YOU INTO ONCOMING TRAFFIC. YOUR WEB PAGE DOESNOT HAVE KIA LISTED AS A VEHICLE CHOICE. *AK

NHTSA ID

10049492

Incident

Oct 20, 2003

Mileage

30 mi