2010 Kia Rondo

The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.

The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing.  There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

FIRST PROBLEM, WHEN THE CAR IS IN MOTION THE ECS LIGHT TURNS ON AND WHEN WHILE DRIVING MY KIA RONDO FEELS UNSTABLE LIKE I AM GOING TO LOOSE CONTROL OF THE STIRRING WHEEL. SECOND PROBLEM, WHEN EVER IT RAINS MY KIA WILL STALL WHILE IN MOTION, LOOSE POWER, ENGINE LIGHTS COME ON AND STOPS IN THE MIDDLE OF ANY STREETS, HIGHWAYS OR FREEWAYS AND THE STEERING WHEEL GET SO HARD TO TURN THE CAR TO A SAFETY PLACE.

NHTSA ID

11290187

Incident

Dec 19, 2019

TL* THE CONTACT OWNS A 2010 KIA RONDO. WHILE DRIVING ON WET ROADS, THE BATTERY, ESC, AND EMERGENCY BRAKE INDICATORS ILLUMINATED SIMULTANEOUSLY AND THE STEERING LOST POWER. ALSO, THE VEHICLE OCCASIONALLY SHUT DOWN. THE VEHICLE WAS ABLE TO RESTART, BUT THE FAILURE RECURRED SEVERAL TIMES. THE DEALER AND MANUFACTURER WERE NOT NOTIFIED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 85,900.

NHTSA ID

11256715

Incident

Aug 20, 2019

Mileage

85,900 mi

LOCKS WORK VERY SPORADICALLY WITH BOTH THE REMOTE AND LOCK BUTTON IN THE CAR. IT AFFECTS ALL DOORS EXCEPT THE TAILGATE. DRIVER WINDOW ALSO HAS DIFFICULTY GOING DOWN SPORADICALLY.

NHTSA ID

11016302

Incident

Dec 1, 2016

Mileage

100,000 mi

DURING RAIN, I WAS DRIVING SLOWLY UP TO A STOP LIGHT. THE BRAKE AND BATTERY LIGHTS STARTED FLASHING ON THE DASHBOARD. ABOUT A MINUTE LATER, A LOUD SCREECHING SOUND STARTED FROM UNDER THE HOOD, AND THEN THE STEERING AND BRAKES LOCKED UP FOR A FEW SECONDS. I REGAINED THE ABILITY TO TURN THE CAR, PULLED IT OFF THE ROAD AND THE SCREECHING CONTINUED FOR ANOTHER MINUTE OR TWO. IT STOPPED WHEN I PARKED MY CAR. IT IS CURRENTLY IN THE SHOP AFTER I HAD IT TOWED.

NHTSA ID

11016301

Incident

Aug 18, 2017

Mileage

110,000 mi

WE CANNOT MOVE THE SHIFTER FROM PARK TO DRIVE. AND WE HAVE NO BRAKE LIGHTS ! THE MANUFACTURER RECALL NUMBER: SC098UN THE RECALL # 13V114000 RECALL CAMPAIGN # SC098 THEY SAYS ITS A STOP LAMP SWITCH ?

NHTSA ID

10924687

Incident

Oct 28, 2016

TL* THE CONTACT OWNS A 2010 KIA RONDO. WHILE DRIVING AT APPROXIMATELY 25 MPH, THE CRUISE CONTROL FAILED TO DISENGAGE WHEN THE BRAKES WERE DEPRESSED. THE CONTACT SLIGHTLY CRASHED INTO THE FRONT DRIVER SIDE OF ANOTHER VEHICLE. THE AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED AND NO INJURIES WERE SUSTAINED. THE VEHICLE WAS DRIVEN TO THE CONTACT'S RESIDENCE AND IT WAS NOT DIAGNOSED OR REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 13V114000 (EXTERIOR LIGHTING, SERVICE BRAKES, HYDRAULIC). THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 30,312.

NHTSA ID

10759520

Incident

Aug 25, 2015

Mileage

30,312 mi

DURING WET WEATHER CONDITIONS THE VEHICLE SUDDENLY LOST POWER STEERING, BRAKING ABILITY AND THE BATTERY INDICATOR LAMP ILLUMINATED. THIS HAS HAPPENED ABOUT A DOZEN TIMES. MY WIFE, SON, AND DAUGHTER HAVE EXPERIENCED THE SAME PROBLEM IN THE SAME TYPE OF WEATHER CONDITIONS WITH THIS VEHICLE. THE LAST TIME IT HAPPENED TO ME WHILE I WAS IN THE PROCESS OF MAKING A LEFT TURN, GOOD THING I THOUGHT QUICK AND GRABBED THE EMERGENCY BRAKE OR I WOULD HAVE HAD A HEAD ON COLLISION CAUSE OF THE LOSS OF (POWER STEERING AND BRAKING ABILITY). EVERYONE IN THE FAMILY IS AFRAID TO USE THE VEHICLE IN ANY WEATHER CONDITION SINCE THEY EXPERIENCED THIS PROBLEM. *TR

NHTSA ID

10714319

Incident

Sep 8, 2013

Mileage

53,238 mi

WHILE DRIVING IN WET CONDITIONS, THE BATTERY INDICATOR LIGHT AND THE BRAKE INDICATOR LIGHT ILLUMINATED IN THE DISPLAY. POWER STEERING FAILED, AND THE VEHICLE WAS DIFFICULT TO MANEUVER TO SAFETY. THE HEADLIGHTS AND DASHLIGHT POWER WAS SIGNIFICANTLY REDUCED. AFTER COMING TO A STOP WITHOUT STEERING POWER, THE EMERGENCY BRAKE WAS ENGAGED AND DISENGAGED WITHOUT A CHANGE IN THE ILLUMINATOR LIGHT. THE CAR WAS HESITANT TO MOVE - GRINDING NOISE AND MAJOR DIFFICULTY TURNING THE STEERING WHEEL. THIS HAPPENED ON TWO DIFFERENT OCCASIONS DURING SIMILAR WEATHER/ROAD CONDITIONS. *TR

NHTSA ID

10667529

Incident

Nov 17, 2014

TECHNICAL SERVICE BULLETIN: INFORMATION FOR HEADLAMP CONDENSATION AND MOISTURE - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information relating to some Kia models that may exhibit fogging, condensation, and/or moisture inside a headlamp assembly. Generally, a fogging condition is considered normal and can be eliminated by turning on the headlamps with the engine running for up to 30 minutes or during normal driving conditions. Headlamp assembly replacement WILL NOT be necessary in most cases.

PITSTOP - BRAKE CALIPER LEAK INSPECTION - This PITSTOP provides information related to a brake caliper fluid/oil substance found on some Kia vehicles, due to possible excess assembly oil applied during assembly.

PITSTOP - ENGINE COMPONENT RE-USE GUIDELINES - In general, parts and components removed during engine repairs should be considered serviceable, and should be thoroughly cleaned and transferred to the new engine.

TSB: DEFOGGING LOGIC ? NORMAL OPERATION, DISABLING, AND ENABLING - Starting with 2010MY, all Kia vehicles, except Rio (JB), incorporate a defogging logic to prevent the interior windows from becoming excessively fogged. Depending on the specific model, the HVAC control head monitors ambient temperature and/or cabin humidity to determine which settings will best prevent the windows from fogging. If the system detects lower ambient temperature or higher cabin humidity, the defogging logic may automatically switch ON the A/C, and/or set the air intake mode to Fresh Air. If the user changes these settings, the defogging logic will take control again after 3 to 5 minutes, depending on the procedure in this publication.

TSB: MANDATORY REPLACEMENT OF LOCKING/SECURITY HARDWARE - By design, certain fasteners, which are designed to lock into place once fully attached, are utilized in various Kia models and are strictly intended for ?one time use.? Some examples are: axle shaft nuts with stake collar, cotter pins, washers with locking tabs and other similar hardware, including threaded fasteners with pre-applied ?thread-locking adhesives.? It is critical for technicians to be aware that ALL such locking fasteners, regardless of type, are for ?one time use? only.

TSB: MANDATORY REPLACEMENT OF LOCKING/SECURITY HARDWARE - By design, certain fasteners utilized in various Kia models are strictly intended for ?one time use?. Though not limited to the following, some examples are: axle shaft nuts with stake collar, cotter pins, washers with locking tabs and other similar hardware, including threaded fasteners with pre-applied ?thread-locking adhesives.?