2002 Kia Sedona

ODIS ANALYSIS OF WARRANTY DATA SHOWS THAT THE ALLEGED DEFECT HAS OCCURRED AT A RELATIVELY HIGH FREQUENCY IN SALT-BELT STATES (5.9 PERCENT).HOWEVER, THE TESTS CONDUCTED BY ODI AND KIA HAVE SHOWN THAT THE ALLEGED DEFECT HAS A MINIMAL EFFECT ON STEERING EFFORTS.IN ADDITION, ODI INTERVIEWS OF OWNERS WHO EXPERIENCED THE ALLEGED DEFECT SHOWED THAT IN MOST CASES THE PROBLEM WAS PRECEDED BY MONTHS OR YEARS OF NOISE OR A GRADUAL INCREASE IN STEERING EFFORTS AND WAS MORE OF A NUISANCE CONCERN. THERE HAS BEEN ONE ALLEGATION OF A MINOR CRASH RELATED TO THE ALLEGED DEFECT, INVOLVING A MY 2003 KIA SEDONA WITH 59,900 MILES.THE VEHICLE HAD BEEN CHECKED TWICE IN THE PREVIOUS NINE MONTHS BY A DEALER FOR COMPLAINTS OF STIFF STEERING AND THAT THE VEHICLE FELT LIKE IT WAS INTERMITTENTLY LOSING POWER ASSIST.THE CRASH OCCURRED AS THE DRIVER WAS ATTEMPTING TO MAKE A LEFT TURN WHILE TRAVELING AT APPROXIMATELY 20 MILES PER HOUR AND STRUCK A VEHICLE PARKED ON THE RIGHT SIDE OF THE STREET THAT THE VEHICLE WAS TURNING INTO. THE CRASH RESULTED IN MINOR INJURIES TO THE DRIVER. AFTER THE CRASH, IT WAS DETERMINED THAT THE INTERMEDIATE SHAFT WAS EXHIBITING SOME BINDING OF THE STEERING INTERMEDIATE SHAFT BEARINGS.WHILE THE ABSENCE OF ADDITIONAL CRASHES OR INJURIES DOES NOT MEAN THAT THERE IS NOT A SAFETY-RELATED DEFECT, THERE HAVE BEEN NO REPORTED ADDITIONAL CRASHES CAUSED BY THE ALLEGED DEFECT IN THE PAST THREE YEARS. THE RELEASE OF THE TECHNICAL SERVICE BULLETIN SHOULD ASSIST SERVICE PERSONAL IN DIAGNOSING THIS POTENTIAL PROBLEM LONG BEFORE IT BECOMES POTENTIALLY DANGEROUS.ACCORDINGLY, THIS INVESTIGATION IS CLOSED. THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.FOR ADDITIONAL INFORMATION REGARDING THIS ENGINEERING ANALYSIS REFER TO THE EA08-017 CLOSING REPORT.

ON APRIL 28, 2008, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED PRELIMINARY EVALUATION PE08-033 TO INVESTIGATE COMPLAINTS ALLEGING STEERING BINDING IN MODEL YEAR 2002 THROUGH 2004 KIA SEDONA MINIVANS.KIA'S RESPONSE TO ODI'S REQUEST FOR INFORMATION IN PE08-033 INDICATED THAT CONCERNS WITH BINDING OF THE STEERING INTERMEDIATE SHAFT WERE FIRST IDENTIFIED AND INVESTIGATED IN AUGUST 2002, IN VEHICLES SOLD IN INDONESIA.THIS INVESTIGATION RESULTED IN THE ADDITION OF A STIFFENING RIB TO THE BEARING CAP SEAL.IN JUNE 2003, KIA AGAIN INVESTIGATED OWNER COMPLAINTS OF STEERING NOISE AND HIGHER THAN NORMAL STEERING RESISTANCE AND IN OCTOBER AND NOVEMBER OF 2003 DESIGN CHANGES TO THE SHAFT UNIVERSAL JOINT BEARINGS WERE MADE TO IMPROVE LUBRICANT RETENTION AND ELIMINATE WATER INTRUSION THAT COULD LEAD TO EARLY BEARING FAILURE.ACCORDING TO KIA, THE ALLEGED DEFECT RESULTS IN A PROGRESSIVE CHANGE IN STEERING EFFORT THAT SHOULD BE APPARENT TO THE DRIVER THROUGH NOISE AND GRADUAL CHANGES IN STEERING STIFFNESS LONG BEFORE THE CONDITION COULD BECOME DANGEROUS. ODI'S ANALYSES OF COMPLAINT AND WARRANTY DATA RELATING TO THE ALLEGED DEFECT SHOW THAT THE CONDITION IS OCCURRING AT SIGNIFICANTLY HIGHER RATES IN SALT-BELT STATES (NOTE:FOR PURPOSES OF THIS INVESTIGATION THE SALT BELT INCLUDES CONNECTICUT, DELAWARE, THE DISTRICT OF COLUMBIA, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA AND WISCONSIN).THE WARRANTY RATE FOR REPLACEMENT OF THE STEERING INTERMEDIATE SHAFT IS 5.5% FOR VEHICLES SOLD IN THE SALT BELT AND 0.5% FOR THE REST OF THE UNITED STATES.THE COMPLAINT RATE FOR THE ALLEGED DEFECT IS 186.8 PER 100,000 VEHICLES IN THE SALT BELT AND 29.4 PER 1000,000 VEHICLES FOR THE REST OF THE UNITED STATES.THERE IS ONE ALLEGATION OF A CRASH RELATED TO THE ALLEGED DEFECT.A SUBJECT VEHICLE STRUCK TWO PARKED CARS WHILE ATTEMPTING TO MAKE A LEFT TURN, ALLEGEDLY RESULTING IN MINOR INJURIES TO THE DRIVER. ODI HAS UPGRADED THIS INVESTIGATION TO AN ENGINEERING ANALYSIS (EA08-017) COVERING MY 2002 THROUGH 2004 KIA SEDONA VEHICLES SOLD OR CURRENTLY REGISTERED IN SALT BELT STATES TO ASSESS THE FREQUENCY AND TREND OF THE ALLEGED DEFECT AND ITS EFFECT ON STEERING EFFORT.

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

THE DOOR HANDLES ARE PLASTIC AND EVENTUALLY BROKE OFF ON THE OUTSIDE SO THAT OPENING THE DOORS -ALL 4- IS TRICKY SINCE ONLY ONE SIDE OF THE HANDLE REMAINS IN PLACE. THE INSIDE DOOR HANDLES HAVE A PLASTIC CHROME-LOOKING COATING THAT PEELS OFF AND HAS CUT OUR HANDS SEVERAL TIMES CAUSING US TO NEED BANDAGES AS SOON AS WE RUN IN THE FRONT DOOR.

NHTSA ID

11016451

Incident

Sep 9, 2010

DRIVER DOOR WILL NOT OPEN FROM THE INSIDE OR OUTSIDE.

NHTSA ID

10966519

Incident

Mar 16, 2017

IT IS NEARLY IMPOSSIBLE TO PUMP GAS INTO THE VAN. THE PUMP KEEPS SHUTTING OFF NO MATTER HOW SLOW I PUMP OR HOW FAR I PUT THE NOZZLE INTO THE TANK.

NHTSA ID

10929784

Incident

Dec 1, 2015

Mileage

150,000 mi

I WAS DRIVING NO LESS THEN THAN BLOCK FROM MY HOUSE - WHEN I NOTICE SMOKE FROM THE DRIVER SIDE FUSE PANEL AND NEXT THING YOU KNOW THE WHOLE PANEL BECAME ENGULF IN FLAMES. I CALLED THE FIRE DEPARTMENT AND ABLE TO PUT FIRE OUT- BUT UNFORTUNATELY, THE CAR BECOME TOTAL IN THE DAMAGE.

NHTSA ID

10862700

Incident

May 2, 2016

Mileage

1,800,000 mi

DROVE HOME FROM WORK AT 35 MPH. THE NEXT MORNING NOTICED TIRE TREAD HAD SEPARATED FROM THE SIDEWALL AROUND MUCH OF THE PERIMETER OF THE TIRE. TIRE WAS FLAT.

NHTSA ID

10764062

Incident

Sep 15, 2015

BEFORE THE INCIDENT THERE WERE ISSUES WITH THE REAR CAPTAIN CHAIRS SEAT BELT LATCH WHEN TRYING TO BUCKLE THEM. I HAVE THREE SMALL CHILDREN UNDER THE AGE OF 3 YEARS OF AGE AND IT IS VERY IMPORTANT AND CRUCIAL THAT SEAT BELTS ARE IN WORKING ORDER WITHOUT ISSUES FOR THE SAFETY OF THEIR WELL BEING. BEFORE THE INCIDENT THE SEATS THEMSELVES IN THE REAR ROWS HAD ISSUES LATCHING AS WELL WHEN BEING INSTALLED. ON AUGUST 18, 2015 MYSELF AND THREE SMALL CHILDREN WERE IN A SEVERE HIGH IMPACT ACCIDENT AND NONE OF THE AIRBAGS HAD GONE OFF LIKE THEY NEVER EXISTED. MY KIDS AND I SUFFER FROM SEAT BELT ABRASIONS AND I SUFFER FROM BRUISING IN MULTIPLE PLACES FROM MY HEAD DOWN, SHOULDER PAIN AND BACK ISSUES. POLICE, PARAMEDIC'S, COLLISION CENTER, WITNESSES, AND MY INSURANCE COMPANY WERE ALL NOTIFIED OR HAD NOTIFIED ABOUT THE AIRBAGS. APPARENTLY, MY SEAT WHICH WAS THE DRIVER SEAT WAS ALSO COMPLETELY SNAPPED OFF AS WELL. UPDATED 08/26/15*BF

NHTSA ID

10750433

Incident

Aug 18, 2015

I HAD MY CAMSHAFT REAR PLUG REPLACED AFTER IN CAME OUT AND LEAKED OIL EVERYWHERE IN 2014. NOW IT'S COME OUT AGAIN DOING THE SAME THING. WHAT CAN I DO TO KEEP IT FROM HAPPENING AGAIN AND AGAIN. IS IT THE PLUG OR THE CAMSHAFT THAT'S BLOWING IT OUT. I CAN'T FIND ANY SCHEMATIC TO SHOW ME WHY OR WHAT TO DO. *TR

NHTSA ID

10689862

Incident

Feb 22, 2015

GOING DOWN 251 AND THEY WERE BUSH HOGING AND WE SLOWED DOWN AND THE LAST ONE WE WENT BY BROKE THE PASSENGER SIDE BACK WINDOW. *TR

NHTSA ID

10605647

Incident

Jun 18, 2014

Mileage

180,000 mi

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 - 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: 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.?

TSB - USE OF AFTERMARKET USB CHARGING CABLES IN USB/12V PORTS - This article provides information regarding the use of USB ports and 12V power outlets to connect/charge mobile phones. Customers may experience issues with their head units that may be related to the use of aftermarket USB charging cables, including; * Electrical interference and limited or no functionality when attempting to play music, or when charging a device through the USB port * Excessive static or noise when listening to the audio source * Malfunctions and screen freeze of the head unit screen * Slow down of the system response while device is plugged in * Music will not play from iPhone 5 or 6 with Kia iPod cable and aftermarket adapter * No or limited functionality when trying to play music from an Apple device

TSB: AUTOMATIC TRANSMISSION FLUID APPLICATION GUIDE - THIS BULLETIN PROVIDES INFORMATION RELATING TO THE CORRECT AUTOMATIC TRANSMISSION FLUIDS THAT ARE REQUIRED FOR EACH KIA MODEL. REFER TO THE SHOP MANUAL ON KGIS FOR THE SPECIFIC KIA MODEL, THEN REFERENCE THE AUTOMATIC TRANSAXLE SYSTEM/ REPAIR PROCEDURES/ INSPECTION AND ADJUSTMENT SECTION FOR THE CORRECT ATF CHECK/FILL PROCEDURES.