2004 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.

Everything appears normal driving down road bout 45 to 50 mph. Slowed down for car n front was turning when I noticed smoke coming from under hood around headlights both sides. Then we pulled into a storage unit place. When even more smoke . I got out popped hood it was all on fire. I turned off van and a friend and I got a couple cups and dipped in water puddle and put fire out , while we were watching to make sure it restarted 2 more times. After half hour goes by and no more smoke . Closed van up found a ride home after contacting insurance company.

NHTSA ID

11436117

Incident

Oct 7, 2021

I HAVE A 2004 KIA SENDONA LX VAN AND THE WHEEL BARRINGS ARE BAD I FIXED IT ONCE ALREADY A MONTH AGO AND IT IS ALREADY BROKEN AGAIN BOTH TIMES IT COMPLETELY FELL APART IN TO LITTLE PEICES WHEN I TOOK THE WHEEL OFF.

NHTSA ID

11319611

Incident

Mar 28, 2020

Mileage

18,000 mi

TL* THE CONTACT OWNED A 2004 KIA SEDONA. THE CONTACT STATED THAT THE VEHICLE CAUGHT FIRE. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE. THE VEHICLE WAS DESTROYED AND TOWED TO A TOW YARD. THE CONTACT MENTIONED THAT THE CAUSE OF THE FIRE WAS UNKNOWN. THE DEALER AND MANUFACTURER WERE NOT CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 100,100.

NHTSA ID

11193363

Incident

Mar 30, 2019

Mileage

100,100 mi

MY 2004 KIA SEDONA WAS SITTING STATIONARY IN MY DRIVEWAY ENGINE WAS OFF. WHEN SOMETHING IN THE ENGINE COMPARTMENT CAUGHT FIRE CAUSING EXTENSIVE DAMAGE TO ENGINE PARTS ON THE TOP SIDE OF THE ENGINE. SUCH BE AS FLUID RESERVOIRS WIRING, FUSE BOX, AND MORE.

NHTSA ID

11141627

Incident

Sep 1, 2018

Mileage

25,000 mi

ON SATURDAY, DECEMBER 16, AT APPROXIMATELY 11:30 AM, MY WIFE'S 2004 KIA SEDONA SPONTANEOUSLY CAUGHT FIRE IN THE DRIVEWAY OF OUR HOME. I HAD DRIVEN IT THAT MORNING TO RUN A QUICK ERRAND, ACTUAL DRIVE TIME LESS THAN HALF AN HOUR WITHOUT ANYTHING OUT OF THE ORDINARY. I RETURNED HOME, PARKED IN OUR DRIVEWAY BEHIND MY FORD WINDSTAR. BOTH MY WIFE AND MYSELF WERE IN OUR HOUSE WHEN WE HEARD A LOUD BOOM FOLLOWED SHORTLY BY A SECOND BOOM. THAT IS WHEN WE SAW THAT FIRE WAS COMING FROM THE ENGINE COMPARTMENT OF HER VAN AND THE REAR OF MY WINDSTAR WAS ON FIRE. WE IMMEDIATELY CALLED 911 AND SHORTLY THEREAFTER OUR LOCAL FIRE COMPANY ARRIVED AND BEGAN FIGHTING THE BLAZE. BY THAT TIME BOTH VEHICLES WERE ENGULFED IN FLAMES. THE FIRE APPEARS TO HAVE STARTED IN THE ENGINE COMPARTMENT OF THE KIA. BOTH VEHICLES ARE A TOTAL LOSS. UNTIL THIS INCIDENT, NOTWITHSTANDING BASIC MAINTENANCE AND REPAIRS, THE KIA SEDONA WAS A VERY RELIABLE VEHICLE. AS WITH THE WINDSTAR, MAINTENANCE AND REPAIRS WERE DONE ON A REGULAR AND AS NEEDED BASIS BY THE SAME SHOP THAT HAS WORKED ON ALL OUR VEHICLES FOR OVER 10 YEARS. I AM SURE I CAN PRODUCE MAINTENANCE AND REPAIR RECORDS IF NEEDED. THE LAST TIME THE KIA WAS SERVICED WAS LATE OCTOBER OF THIS YEAR TO REPLACE AN ALTERNATOR.

NHTSA ID

11080722

Incident

Dec 16, 2017

Mileage

214,000 mi

WHEN I WENT TO START MY CAR IT IMMEDIATELY SHUT OFF, AS IT OCCASIONALLY DOES. THE RPM'S DROPPED AND THE ENGINE CUT OUT. USUALLY THE PROBLEM IS RESOLVED BY ME REVVING THE ENGINE FOR A MINUTE OR TWO, BUT THE PROBLEM PERSISTED LONGER THAN USUAL. IT EVENTUALLY STAYED ON AND I TRIED TO DRIVE AWAY. AS I CHANGED INTO GEAR EVERYTHING SEEMED OKAY, I REVERSED FROM WHERE I WAS PARKED THEN I PUT IT INTO DRIVE AND WHILE IN THE MIDDLE OF THE ROAD THE ENGINE CUT OUT AND I WAS STUCK THERE FOR ONLY A FEW SECONDS LUCKILY. I DROVE BACK TO WHERE I WAS PARKED AND AS I STOPPED THE ENGINE CUT OUT ON ME. THIS TYPICALLY HAS HAPPENED TO ME WHEN THE GAS TANK WAS BELOW HALF. I MANAGED TO GET TO A GAS STATION AND FILL UP AND THAT STOPPED THE PROBLEM.

NHTSA ID

10993222

Incident

Jun 5, 2017

Mileage

101,294 mi

"TAKATA RECALL" ON TUESDAY MAY 9, 2017 WE WERE INVOLVED IN AN AUTOMOBILE ACCIDENT. TO OUR AMAZEMENT AND HORROR, NOT ONE AIRBAG DEPLOYED . 'WE WERE HIT ON THE PASSENGER SIDE OF THE VAN . THE FRONT PASSENGER DOOR REQUIRED ASSISTANCE FROM THE POLICE/FIRE FIGHTERS ASSISTANCE TO EXIT THE VAN HOWEVER THE SLIDING DOOR COULD NOT BE OPENED REQUIRING REMOVING THE BABY THROUGH THE DRIVER'S SIDE. THE LIGHT TURNED GREEN AND WE BEGAN TO MOVE FORWARD WHEN OUR VAN WAS STRUCK BY THE OTHER CAR EXITING A PARKING LOT. NEITHER ONE OF US SAW THE ADVANCE NOR IMPACT OF THE OTHER CAR. AFTER REALIZING WHAT HAPPENED WE CALL EMERGENCY VEHICLES FOR ASSISTANCE. WE WERE INSTRUCTED TO MOVE OUR VAN TO A SAFE LOCATION AND WAIT FOR H

NHTSA ID

10992708

Incident

May 9, 2017

Mileage

158,000 mi

TL* THE CONTACT OWNS A 2004 KIA SEDONA. WHILE STATIONARY, THE FRONT END OF THE VEHICLE ERUPTED INTO FLAMES. THE CONTACT STATED THAT THE FIRE ORIGINATED FROM THE ENGINE COMPARTMENT. A POLICE REPORT WAS NOT FILED. THE FIRE WAS EXTINGUISHED BY THE FIRE DEPARTMENT. THERE WERE NO INJURIES SUSTAINED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FIRE. THE FAILURE MILEAGE WAS 110,000.

NHTSA ID

10985783

Incident

May 15, 2017

Mileage

110,000 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.