2025 Kia EV9 Tires & Wheels Problems

These Hankook iON Evo tires started vibrating wildly at the first service that I took the car to for a rotation. We took it back to the dealership (Ourisman Kia in Fairfax VA) three times where they kept the car for several days to diagnose. After opening the tires up, they state that the inner sound insulating foam on all four tires has separated. The tires were at 7/32 and now 5/32 and the car only has 18,200 miles on it. The tires have a 50k treadwear warranty, but this isn't covered as part of the warranty. The inner foam separation on a Kia EV9 is a known issue and widely discussed on the internet. For an $80k vehicle with OEM tires that cost over $1500 to replace, it's ridiculous that they aren't covered by the dealership or by Hankook.

Vehicle Information: 2025 Kia EV9 GT-Line AWD VIN: [XXX] Mileage: ~16,000 miles Component/Part Affected: Wheel studs / Wheel attachment system Summary: Multiple wheel studs (3 on one wheel, 2 on another) were found stripped/damaged on my [XXX] Kia EV9, making the vehicle unsafe to drive. This is a critical safety issue, as wheels cannot be properly secured and could detach while driving. Details: •The vehicle has been serviced exclusively at Kia dealerships (Winn Kia Fremont and Putnam Kia Burlingame, CA). •Putnam Kia Burlingame visits (7/31/25 and 8/29/25) involved seat motor repairs, multi-point inspections, and tire-pressure checks only. No wheel removal or rotation occurred there as per their confirmation. •Kia Fremont has performed all wheel/tire-related services and recently discovered the damage. •Photos show damage across two wheels (3 studs stripped on one, 2 on another). This suggests a consistent pattern of improper service (over-torquing or cross-threading), not isolated wear. Safety Concern: The vehicle is currently undriveable. Multiple compromised studs across two wheels increase the likelihood of wheel detachment while driving — posing a severe hazard to me, my family, and other motorists. Manufacturer Response So Far: •Kia Fremont has ordered replacement studs but says parts will take ~7 days. •I am seeking Kia’s confirmation that all repairs and a rental vehicle will be covered under warranty. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Took my 4-month old Kia EV9 to a tire shop b/c I heard a rattling on the right side at low speed. Turns out both of the locking lug nuts had popped out of the front and rear hubs on the right side. Seems like someone at the port install facility in West Point Georgia didn't use the correct tools or torque settings. Turns out this is a known issue among a few customers per this Reddit thread: [XXX] I notified Kia CS. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)