2002 Kia Spectra

THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED THIS PRELIMINARY EVALUATION TO INVESTIGATE ALLEGATIONS OF REAR DRUM BRAKE WHEEL CYLINDER LEAKAGE IN 2002 KIA SPECTRA VEHICLES.THIS INVESTIGATION WAS PROMPTED BY KIA?S EARLY WARNING REPORT TO THE AGENCY FOR THE FIRST QUARTER OF 2004, WHICH CONTAINED A SINGLE FIELD REPORT THAT IDENTIFIED 13 INCIDENTS OF WHEEL CYLINDER LEAKAGE IN THE SUBJECT VEHICLES.THE SUBJECT VEHICLES ARE AVAILABLE IN BOTH 4-DOOR SEDAN AND 5-DOOR HATCHBACK BODY STYLES.THE SAME PARTS SUPPLIER PROVIDES WHEEL CYLINDERS FOR BOTH VEHICLE TYPES, ALTHOUGH THEIR PART NUMBERS DIFFER.THESE PARTS ARE USED ON ALL MY2002-2004 SPECTRA ?TYPE-I? VEHICLES MANUFACTURED THROUGH 12/30/2003.ADDITIONALLY, MY2001-2005 KIA RIO VEHICLES BUILT THROUGH 11/17/2004 USE THE SAME WHEEL CYLINDERS AS THE SUBJECT SPECTRA ?TYPE-I? 4-DOOR SEDAN.MY2004 SPECTRA ?TYPE-II? VEHICLES, WHICH STARTED PRODUCTION ON 12/8/2003, DO NOT USE THE SUBJECT COMPONENTS AS THEY ARE EQUIPPED WITH REAR DISC BRAKES.THE MANUFACTURER NOTIFIED ODI OF ONE COMPLAINANT WHOM ALLEGED A CRASH CAUSED BY, ?INADEQUATE BRAKE SYSTEM RESPONSE,? RESULTING IN ONE PERSON INJURED.HOWEVER, IT APPEARS THAT MULTIPLE CAUSAL FACTORS MAY HAVE CONTRIBUTED TO THE CRASH INCIDENT AND NO SINGLE FACTOR HAS BEEN IDENTIFIED AS THE PRIMARY CAUSE.IN TOTAL, ODI IS AWARE OF 5 CONSUMER COMPLAINTS, 1 FIELD REPORT, AND 813 WARRANTY CLAIMS RELATED TO THE ALLEGED DEFECT IN 2002 KIA SPECTRA VEHICLES.NONE OF THE COMPLAINANTS ALLEGED DEGRADED STOPPING PERFORMANCE OR LOSS OF BRAKING CAPABILITY CAUSED BY WHEEL CYLINDER LEAKAGE.TO DATE, THE COMPLAINT RATE IS 7.0 PER 100,000 VEHICLES AND THE WARRANTY RATE IS 1.13%.KIA?S ANALYSIS OF WARRANTY RETURN PARTS INDICATES A SLOW RATE OF FLUID LOSS; TESTS SHOWED A MAXIMUM FLUID LOSS RATE OF 1 CC PER 4000 BRAKE APPLICATIONS (THE MASTER CYLINDER RESERVOIR HAS A 134CC FLUID CAPACITY BETWEEN THE ?FULL? AND THE LEVEL AT WHICH THE BRAKE WARNING LAMP IS ILLUMINATED).KIA TESTING OF A VEHICLE EQUIPPED WITH A LEAKING WHEEL CYLINDER SHOWED THAT AFTER 100 STOPS FROM 100 KM/H THE PEDAL STROKE INCREASED 5%, PEDAL FORCE INCREASED 13%, AND THE BRAKING DISTANCE INCREASED 7% (51.7M VS. 48.1M) WHEN COMPARED TO THE SAME VEHICLE WITH A NON-LEAKING WHEEL CYLINDER.A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.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 TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

TL* THE CONTACT OWNS A 2002 KIA SPECTRA. THE CONTACT STATED THAT THE FRONT DRIVER AND PASSENGER SIDE INTERIOR DOOR HANDLE FRACTURED WHILE ATTEMPTING TO EXIT THE VEHICLE. THE FAILURE RECURRED FOUR TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE DOOR HANDLES WAS REPLACED HOWEVER, THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 120,000.

NHTSA ID

10855307

Incident

Mar 13, 2016

Mileage

120,000 mi

A FRONT TIE ROD BROKE, SOMETHING IN THE STEERING COLUMN BROKE, AND THE AIR BAG INDICATOR LIT UP BUT NO AIR BAGS DEPLOYED. THE TWO FRONT TIRES WERE NOT POINTING IN THE SAME DIRECTION. I HAD IT TOWED TO A MECHANIC, AND THEY SAID THAT THE STEERING COLUMN ISSUE LIKELY CAUSED A DISCONNECT IN A CIRCUIT, WHICH CAN PREVENT ALL AIR BAGS FROM DEPLOYING.

NHTSA ID

10733967

Incident

Jun 19, 2015

Mileage

195,000 mi

TL* THE CONTACT OWNS A 2002 KIA SPECTRA. AFTER OPENING THE FRONT DRIVER AND PASSENGER SIDE WINDOWS, THEY FAILED TO CLOSE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FRONT DRIVER SIDE WINDOW NEEDED A NEW MOTOR. THE VEHICLE WAS REPAIRED. THE TECHNICIAN CONFIRMED THAT THE FRONT PASSENGER SIDE NEEDED TO BE LUBRICATED. THE VEHICLE WAS REPAIRED HOWEVER, THE FAILURE RECURRED. IN ADDITION, THE CONTACT STATED THAT AFTER THE VEHICLE WAS INSPECTED, THE TECHNICIAN STATED THAT THE LOWER CONTROL ARM NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE CONTACT ALSO STATED THAT WHEN THE BRAKE PEDAL WAS DEPRESSED AND THERE WAS AN ABNORMAL NOISE COMING FROM THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE REAR BRAKE DRUMS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURES. THE FAILURE MILEAGE WAS 72,896.

NHTSA ID

10693083

Incident

May 15, 2014

Mileage

72,896 mi

THE PAINT JUST FADED AWAY. ALOT ON THE HOOD OF THE CAR. LOOKS BAD WITH PART OF THE PAINT FADING AWAY. WAS THERE A RECALL FOR THE FACTORY PAINT JOB ON THE CAR/ *TR

NHTSA ID

10658989

Incident

Jun 1, 2007

Mileage

90,000 mi

TL* THE CONTACT OWNS A 2002 KIA SPECTRUM. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE STALLED. THE VEHICLE FAILED TO RESTART AND IT WAS COASTED TO THE SIDE OF THE ROAD. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO STATED THAT THE FAILURE WAS CONTRIBUTED TO A FAULTY FUEL PUMP. THE VEHICLE WAS REPAIRED. THE FAILURE RECURRED AND THE MECHANIC REPLACED THE FUEL PUMP CONNECTOR AND A BLOWN FUSE . THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 165,000.

NHTSA ID

10621946

Incident

Aug 6, 2014

Mileage

165,000 mi

HEAT HAS WARPED DASHBOARD SO VENTS NO LONGER STAY SEATED. *TR

NHTSA ID

10598543

Incident

Jun 30, 2009

DRIVING AT 35 MPH, SLOWING DOWN APPROACHING TRAFFIC LIGHT, PRESSED ON BRAKES AND HAD ALMOST NO TENSION. NEARLY SMASHED DIRECTLY INTO THE PERSON IN FRONT OF ME. USED BOTH FEET WITH ALL THE PRESSURE I COULD GIVE TO STOP THE CAR. FOUND OUT THAT THE BRAKE PROPORTIONING VALVE IS LEAKING BRAKE FLUID LEAVING ME WITH NO BRAKE FLUID WHATSOEVER. VERY DANGEROUS. THE PROPORTIONING VALVE NEEDS REPLACING. I HAVE BEEN FILLING UP THE BRAKE FLUID RESERVOIR AT LEAST ONCE A WEEK. THIS IS AN INCREDIBLY DANGEROUS SITUATION TO BE IN. THOUSANDS OF PEOPLE HAVE HAD THIS SAME PROBLEM, WHY HAS THIS NOT BEEN ASSESSED? *JS

NHTSA ID

10545547

Incident

Aug 13, 2013

Mileage

122,800 mi

AS I WAS ABOUT TO STOP DOWN A STEEP HILL MY BRAKES GAVE AWAY AND JESUS TOOK THE WHEEL IS ALL I CAN SAY.BRAKE CAME ON NO BRAKE FLUID .I GET MY OIL CHANGED EVERY 3,000 MILES IT JUST LEAKS OUT AS SOON AS I REPLACE IT. MECHANIC FOR 40 YEARS SAID NEVER SEEN THIS HAPPEN ON A CAR. THE CONNECTOR WERE THE VALVES OR CONNECTING IS LEAKING ALL THE BRAKE FLUID OUT . *TR

NHTSA ID

10510333

Incident

Apr 1, 2013

Mileage

186,000 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.