2004 Kia Sorento Suspension Problems

2004 KIA SORRENTO 97,000 MILES. THE LEFT AND RIGHT SIDE REAR CONTROL ARM BRACKETS RUSTED OFF.

2004 KIA SORENTO EX WITH EXTENSIVE RUST DAMAGE TO REAR CROSS-MEMBERS #2 AND #3. DISCOVERED DURING TIRE ROTATION IN NOV 2018, BUT IS OBVIOUS THE DAMAGE HAS EXISTED FOR A SUBSTANTIAL AMOUNT OF TIME. CROSS-MEMBER #2 IS JUST IN FRONT AND ABOVE THE REAR AXLE AND HAS THE MOUNTING BRACKETS FOR THE AXLE STRUTS, WHICH KEEP THE AXLE IN PLACE, IT ALSO HAS A MOUNTING BRACKET FOR THE FUEL TANK, AS WELL AS A PASS THROUGH BRACKET FOR THE REAR BRAKE LINES, AND A MUFFLER HANGER. THE CAR IS NOT SAFE TO BE DRIVEN DUE TO THE IMMINENT DANGER OF A FULL FAILURE. CROSS-MEMBER #2 IS ABOUT 70% RUSTED THROUGH ON THE FUEL TANK SIDE AND PERFORATED IN SEVERAL OTHER PLACES AS WELL. CROSSMEMBER #3 WHICH IS BEHIND THE REAR AXLE CONTAINS NO MOUNTS, BUT A TORSION BAR DOES CONNECT WHERE THE CROSS-MEMBER PASSES THROUGH THE LEFT FRAME RAIL. STRUT MOUNT CONNECTORS ON AXLE ARE ALSO SEVERELY RUSTED. BACKING PLATE FOR REAR DISC BRAKES ON BOTH SIDES IS RUSTED SO SEVERELY THEY CRUMBLE LIKE AN EGGSHELL. CONTACTED KIA AND THEY SAID THEY WILL NOT COVER REPAIR OF THE DEFECT, CASE #12944853 OPENED. IT ONLY TAKES A QUICK SEARCH ONLINE TO FIND THERE ARE MANY CASES OF THIS WITH PARTICULARLY 2004 MODELS.

TOOK MY CAR IN FOR NYS INSPECTION AND WAS ALERTED TO AN ISSUE WITH MY REAR SUSPENSION. THE REAR CROSS MEMBER IS COMPLETED ROTTED OUT AND THE UPPER TRAILING ARM HAVE BECOME SEPARATED FROM THE CROSS MEMBER DUE TO RUST AND CORROSION. THIS IS A 2004 KIA SORENTO EX THAT I PURCHASED NEW AND NOW HAS 103,000 MILES. THIS CORROSION IS AN EXTREMELY HAZARDOUS SITUATION AND THE VEHICLE CANNOT BE REPAIRED. NEEDLESS TO SAY IT CANNOT BE DRIVEN.

WAS DRIVING WIFE TO WORK , STOPPED AT LIGHT WHEN LIGHT TURNED GREEN I PUSHED THE GAS PEDAL AND I HEARD A BANG SO LOUD I THOUGHT SOMEONE HIT US FROM BEHIND. I DROVE CAR HOME AND LOOKED UNDER IT AND I COULDN'T BELIEVE IT ! THE RUST ON THE REAR END BRACKETS AND THE TWO BARS CONNECTED TO THEM WERE TOTALLY RUSTED THROUGH AND HANGING OFF. I WENT TO THE KIA DEALER WHERE I ORIGINALLY BOUGHT THE CAR AND ASKED THEM ABOUT IT THEY SAID THEY NEVER HEARD OF THAT PROBLEM. I TOLD THEM THERE ARE HUNDREDS OF COMPLAINTS ON THE INTERNET ABOUT IT ,THEY TOLD ME DON'T BELIEVE EVERYTHING YOU SEE ON THE INTERNET. THEN THEY SAID THAT IT'S NOT A KIA PROBLEM IT'S A ROAD SALT PROBLEM. I TOLD THEM NOTHING ELSE UNDER THE CAR WAS RUSTED THAT BAD , AND I BELIEVE IT'S A DESIGN PROBLEM. THEY SAID THERE IS NOTHING THEY CAN DO, SO NOW I HAVE A CAR WITH ONLY 83,000 MILES ON IT THAT IS TOO DANGEROUS TO DRIVE. THIS PROBLEM HAD TO HAVE STARTED WAY WAY BEFORE 83,000 MILES TO HAVE GOTTEN THIS BAD.

WHILE DRIVING APPROXIMATELY 35 MPH, THE REAR OF THE VEHICLE SHOOK VIOLENTLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO NOTICED THAT THE CROSSMEMBER BARS WERE SEVERELY CORRODED THROUGH AND WERE NOT ABLE TO BE REPAIRED. THE VEHICLE WAS NOT REPAIRED. MAJOR SAFETY HAZARD. THE ENTIRE BRACKET HOLDING THE DIFFERENTIAL RUSTED THROUGH. THE FRAME REAR CROSS MEMBER ALSO RUSTED THROUGH CAUSING THE CONTROL ARMS IS DETACHED FROM THE REAR END ALSO CREATING A SAFETY HAZARD.

MY DAUGHTER TOOK MY CAR A 2004 KIA SORENTO IN FOR A NYSI AND THE SHOP DEAD LINED THE CAR AND MADE ME FLATBED IT HOME DUE TO THE FACT THAT THE REAR END WAS FALLING OUT DUE TO EXCESSIVE ROT ON THE BRACKETS AND THEY DEEMED THE CAR UNSAFE TO DRIVE. THE WOMEN THAT RUNS THE SHOP TOLD MY DAUGHTER AND SON THAT THIS ISN'T THE FIRST TIME THAT SHE HAS SEEN THIS ON A KIA. IN FACT ITS A PREVALENT ISSUE! UPON COMING HOME I DID SOME RESEARCH ON THE INTERNET AND FOUND THAT THIS IS A MAJOR ISSUE THAT THE FEDERAL GOVERNMENT SHOULD BE LOOKING INTO ORDERING KIA TO DO A RECALL,MY DAUGHTER COULD HAVE BEEN KILLED DRIVING THIS VEHICLE.I ALSO SAW ON THE INTERNET THAT IN THE UK KIA HAD TAKEN CARE OF THIS ISSUE WITH CONSUMERS. I WOULD LIKE CONSIDERATION IN HAVING KIA REPAIR THIS CAR FREE OR PURCHACE THE VEHICLE BACK AT BLUE BOOK PRICING. THIS IS AN EXTREMELY DANGEROUS ISSUE THAT COULD HAVE KILLED MY DAUGHTER OR ANYONE ELSE ON THE ROAD WHERE MY DAUGHTER WAS DRIVING THE KIA SORENTO.

THE REAR AXLE IS FALLING APART AND IT'S RUSTED WHERE I CAN'T EVEN WELD A BRACKET FOR THE REAR SUSPENSION IT'S SO RUSTED THAT I WAS TOLD BY A MECHANIC THAT THE REAR AXLE CAN ACTUALLY FALL OFF THE VEHICLE I WOULD HAVE TO REPLACE THE ENTIRE REAR AXLE SO I CAN PUT A BRACKET OR IT WILL COME WITH A BRACKET IT WILL COST ME $4000 AND I THINK A KIA SHOULD BE RESPONSIBLE BECAUSE THE WHOLE ENTIRE CAR UNDERNEATH IT RUSTED BUCKET FULL OF RUST

TL* THE CONTACT OWNS A 2004 KIA SORENTO. WHILE DRIVING APPROXIMATELY 50 MPH, THE REAR OF THE VEHICLE SHOOK VIOLENTLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO NOTICED THAT THE CROSSMEMBER BARS WERE CORRODED THROUGH AND WERE NOT ABLE TO BE REPAIRED. THE VEHICLE WAS NOT REPAIRED. THE DEALER AND MANUFACTURER WERE NOT CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 150,000. THE VIN WAS NOT AVAILABLE.

RUSTED BRACKETS POSING A DANGEROUS SAFETY RISK, 2004 KIA SORENTO WITH 162,000 MILES. THE ENTIRE BRACKET HOLDING THE DIFFERENTIAL RUSTED THROUGH. THE FRAME REAR CROSS MEMBER ALSO RUSTED THROUGH CAUSING THE CONTROL ARMS IS DETACHED FROM THE REAR END ALSO CREATING A SAFETY HAZARD. THERE IS A DESIGN FLAW THAT ALLOWS WATER TO STAY INSIDE THE HOLLOW CROSS MEMBER THAT CAUSED THE CORROSION. DRAIN OR WEEP HOLES IN THE CROSS MEMBER AND AN ANTI-CORROSION COATING WOULD HAVE PREVENTED THIS. WHEN THE BRACKET(S) BREAKS THE REAR AXLE IS NO LONGER HELD IN PLACE THERE ARE REPORTS ON NHTSA WHERE THESE BRACKETS HAVE ROTTED AWAY AND FAILED CAUSING LOSS OF CONTROL OF THE VEHICLE. THIS IS A KNOWN DESIGN FLAW THAT HAS BEEN APPEARING ON THE OLDER CARS WHERE THE ENTIRE FRAME AND REAR END WOULD HAVE TO BE REPLACED. THERE WILL EVENTUALLY BE MORE OF THESE FAILURES AND THERE IS A POTENTIAL FOR FATAL ACCIDENTS FROM LOSS OF VEHICLE CONTROL. I AM AWARE THAT IN EUROPE KIA HAS BEEN REPAIRING SORENTOS.

PURCHASED USED, WAS DRIVING TO GRANDSON'S BALL GAME, WHEN CAR STARTED MAKING FUNNY NOISE AND ACTED AS THE THE REAR END WAS GOING TO FALL OUT, WE PULLED OVER IN GROCERY STORE PARKING LOT, GOT OUT AND LOOKED, COULD NOT SEE ANYTHING, HAD DAUGHTER FOLLOW US HOME, JUST IN CASE, TOOK IT TO FRIEND WHO NOTICED THE REAR BRACKET ARMS ARE COMPLETELY RUSTED OUT , LOOKS LIKE IT IS WHAT HOLDS THE REAR END IN PLACE. I'M NOT SURE WHAT TO DO, I PAID OVER $5000 USED AND I CAN'T JUST PARK IT, I THINK KIA SHOULD BE RESPONSIBLE FOR THIS MISHAP, IT IS NOT LIKE IT CAN JUST BE FIXED, IT NEEDS REPLACED, SO I'M THINKING IT WOULD BE A MAJOR JOB, I'VE READ MANY MANY OTHER FORUMS AFTER FINDING THIS OUT ABOUT MINE AND RESEARCHING, I"M SURE THIS COULD POTENTIALLY BE A SERIOUS OR EVEN LIFE THREATENING PROBLEM, I'M NOT SURE I WOULD WANT TO SELL IT TO SOMEONE ELSE, IF IT IS DANGEROUS, I WOULD REALLY LIKE TO KNOW THE SERIOUSNESS OF THIS PROBLEM, IS THIS A MINOR OR MAJOR PROBLEM, IS THERE MORE HOLDING THAT REAR END IN PLACE THEN JUST THOSE RUSTED OUT ARMS OR BRACKETS? WOULD YOU WANT YOUR DAUGHTER DRIVING THIS?, I DON'T KNOW IF THE PREVIOUS OWNER WAS AWARE OF NOT, IF SO WE WERE NOT NOTIFIED, I WOULD HATE TO THINK I COULD BE DRIVING DOWN THE ROAD WITH MYSELF AND GRANDBABIES AND SOMETHING HORRIBLE HAPPEN. PLEASE HELP, I"M REALLY CONCERNED ABOUT THIS, ESPECIALLY AFTER ALL THE TROUBLE WITH THE CRANKSHAFT BOLT I" READING ABOUT. I'M SCARED TO DEATH TO DRIVE THIS THING, IF IT HAD NEVER WENT UP ON A RACK WE WOULD BE NONE THE WISER AND WOULD STILL BE DRIVING DAILY JUST AS IF WE DID NOT KNOW, BUT NOW THAT I KNOW, I DON'T KNOW WHAT TO DO.. THIS IS A REAL SAFETY ISSUE, THERE IS TO MUCH NONSENSE CAR DEALERS GET AWAY WITH ANYWAY FOR US CONSUMERS TO WORRY ABOUT OUR LIVES OR SOMEONE ELSE'S WHILE DRIVING. WILL THE REAR END FALL OUT? IS IT SAFE TO DRIVE? YOU TELL ME? WOULD YOU DRIVE IT?

THIS IS A FOLLOW UP TO NHTSA ID #10852665. I CONTACTED MANUFACTURER REGARDING THE RUSTED FRAME. SUGGESTED TOWING TO DEALER FOR DIAGNOSIS. TOWED TO DEALER, WHO CALLED SAYING IT WAS BAD AND TO CALL KIA BACK. CALLED KIA AND A CASE WAS OPENED #K3156514. WAS TOLD I WOULD HEAR BACK BY WEDNESDAY THE 6TH OF APRIL HAVE NOT RECEIVED ANY RETURN CALLS, LEFT 2 VOICEMAILS CAR IS STILL AT DEALER, ITS BEEN 8 DAYS AND NO INFO..KIA NEEDS TO STEP UP AND RECALL THESE VEHICLES BEFORE SOMEONE GETS KILLED! THIS COMPLAINT STARTS AT 2003 AND SO FAR HAVE READ UP TO 2005 FOR THI ISSUE. EUROPE RECALLED IT BUT NOT HERE? MILEAGE WAS 92000 NOT 82000.

MECHANIC AT A GAS STATION TOLD MY MIL SHE NEEDED A NEW REAR AXLE. WHEN I CHECKED THE AXLE I FOUND THE TOP LEFT STABILIZER BRACKET WAS BADLY RUSTED. I TOOK THE CAR TO THE LOCAL KIA DEALER TO GET A RECALL REPAIR. THIS SHOULD NEVER HAPPEN TO A CAR WITH ONLY 60K MILES. THE DEALER HAS NOT COMPLETED THE ESTIMATE. THE CAR IS NOT DRIVE-ABLE. THERE SHOULD BE A RECALL

TL* THE CONTACT OWNS A 2004 KIA SORENTO. THE CONTACT STATED THAT THE STABILITY BAR/TORQUE BAR THAT SUPPORTS THE REAR SUSPENSION FOR THE TIRE WAS NOT STRUCTURALLY SOUND AND HAD EXTENSIVE RUST AND CORROSION ON THE PIPING. THE PARTS NEEDED TO BE REPLACED. THE MECHANIC INDICATED THAT THE MANUFACTURER NEEDED TO PROVIDE A PERMANENT REPAIR OR SOLUTION TO REPAIR THE VEHICLE, AND RECOMMENDED THAT THE VEHICLE BE INSPECTED AND DIAGNOSED BY A DEALER. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 150,000. UPDATED 10/13/16*LJ *TR

TL* THE CONTACT OWNS A 2004 KIA SORENTO. THE VEHICLE WAS DIAGNOSED BY AN INDEPENDENT MECHANIC WHO STATED THAT THE REAR CONTROL ARM BRACKET WAS CORRODED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 112,000. UPDATED 02/26/16*LJ THE CONSUMER STATED THE CONTROL ARM BRACKET COMPLETELY DETACHED FROM THE AXLE. UPDATED 03/01/16.*JB

I BROUGHT THIS VEHICLE FOR INSPECTION AND WAS TOLD IT WILL NOT PASS BECAUSE ONE OF THE CONTROL ARMS IS DETACHED IN THE REAR END. I WAS TOLD NOT TO DRIVE THE VEHICLE AT ALL BECAUSE IT IS NOT SAFE. ADDITIONALLY THERE IS ROT UNDER THE ENTIRE VEHICLE. THE LEFT SIDE FRAME WAS WELDED AND REPAIRED BY THE PREVIOUS OWNER BUT THE RIGHT SIDE IS NOW RUSTED BADLY AND IN NEED OF REPAIR. AXLES ARE LEAKING DUE TO RUST. BRAKES ARE A PROBLEM BUT I HAVEN'T INVESTIGATED FURTHER TO KNOW IF ITS CAUSED BY ROT. I HAVE BEEN ON MULTIPLE FORUMS FOR THIS ISSUE AND IT SEEMS MANY PEOPLE HAVE SAME ISSUES ESPECIALLY THE CONTROL ARM PROBLEM. I CAN NOT RETURN THIS VEHICLE BECAUSE I WAS SCAMMED AND AM NOW STUCK WITH A DANGEROUSLY ROTTED CAR. I AM TOLD ITS NOT WORTH FIXING. THIS CAR LOOKS FINE AND WITHOUT LOOKING UNDERNEATH A PERSON WOULD NOT KNOW A PROBLEM EXISTED PERHAPS UNTIL AN ACCIDENT.

ON MONDAY, AUGUST 10TH, 2015 I WAS DRIVING MY 2004 KIA SORENTO LX AND HEARD A LOUD BANG AND THEN THE VEHICLE BEGAN TO FISHTAIL. I WAS TRAVELING AT A LOW SPEED OF AROUND 35 MPH. I IMMEDIATELY SLOWED DOWN AND MANAGED TO DRIVE THE VEHICLE TO A NEARBY GARAGE. AT THE GARAGE THE VEHICLE WAS PLACED ON THE LIFT AND IT WAS IDENTIFIED THAT THE DRIVERS SIDE FRAME RAIL HAD COMPLETELY BROKEN IN HALF AND WAS SEVERELY CORRODED. THE PASSENGER SIDE WAS ALSO SEVERELY CORRODED BUT NOT BROKEN ALL THE WAY THROUGH. THE CROSS-MEMBER ABOVE THE REAR AXLE IS ALMOST COMPLETELY GONE. I NOW HAVE AN 11 YEAR OLD VEHICLE WHICH SHOULD HAVE A RETAIL VALUE OF AROUND $5K WHICH IS NOW COMPLETELY WORTHLESS. I DID SOME INTERNET RESEARCH AND FOUND I AM NOT THE ONLY ONE EXPERIENCING THIS SEVERE CORROSION PROBLEM WITH THIS YEAR AND MODEL KIA. I AM SURPRISED THERE HAVE BEEN NO SAFETY RECALLS FOR THIS PROBLEM. HAD MY INCIDENT HAPPENED AT HIGHWAY SPEEDS THE STORY MAY BE A LOT DIFFERENT.

MAJOR RUST PROBLEM WITH FRAME AND SUSPENSION KIA SORENTO PURCHASED MARCH 30 2004 2 MONTHS PAST THE WARRANTY 85392 MILES HAVING JUST DRIVEN ON THE HIGHWAY 65MPH VEHICLE WAS ENTERING SCHOOL PARKINGLOT, AT THE ENTRANCE VEHICLE WENT OVER SPEED BUMP AT THIS POINT THERE WAS A LOUD BANG AND THE VEHICLE STARTED SHAKING AND SQUEALING. UPON INSPECTION THE PASSENGER SIDE REAR STABILIZER-TRACTION BAR BROKE COMPLETELY OFF THE FRAME RAIL JUST FORWARD OF THE WHEEL. THIS CAUSES THE REAR AXEL TO MOVE FREELY FORWARD AND BACK. FURTHER INSPECTION BY KIA DEALERSHIP SHOED MORE COMPONENTS ABOVE THE REAR AXEL BROKEN FREE. I FILED A GOOD WILL COMPLAINT WITH KIA WHO RESPONDED WITH A BIG NO REGARDING ANY HELP. FORTUNATELY THIS BREAKDOWN HAPPENED IN A PARKING LOT AND NO INJURIES HAPPENED BUT IF THIS HAD HAPPENED ON THE HIGHWAY IT WOULD HAVE BEEN A MAJOR ACCIDENT WITH POSSIBLE INJURIES OR DEATH IF THE VEHICLE ROLLED OVER . THIS WAS VERY GOOD LOW MAINTENANCE LOW MILEAGE VEHICLE AND WE WERE HOPING FOR A FEW MORE YEARS OF USAGE, NOW WE ARE DISAPPOINTED WITH KIA THAT NO NOTICES OF MAJOR RUST ISSUES WERE MADE AVAILABLE. NOW WHAT WE HAVE IS A CAR THAT WORTHLESS AND DOESN'T LIVE UP TO THE WARRANTY LIMITS. *TR

WAS DRIVING VEHICLE WHEN FRAME BROKE AND ALMOST CRASHED IT FOUND OUT FROM A BODY SHOP THAT THE FRAME HAD CORRODED AND BROKE AND WE OWE MONEY ON THIS PIECE OF JUNK AND THE KIA CORPORATION HAS NEVER HEARD OF THIS HAPPENING. *TR

RUSTED BRACKETS RECALLED IN EUROPE, REFUSED BY KIA TO REPLACE EVEN THO THEY WERE RUSTED UNDER WARRANTY, POSE A DANGEROUS SAFETY RISK TO UNSUSPECTING OWNERS. THE ENTIRE BRACKET HOLDING THE DIFFERENTIAL RUSTED THROUGH CREATING A SAFETY HAZARD. PRESENTED WITH A SMALL SQUEAK IN REAR. I ASKED KIA TO SEND PEOPLE LETTERS WARNING AND THEY WOULD NOT ADDRESS THE REQUEST. HOW KIA IS GETTING AWAY WITH SEVERE RUST, CAUSING SAFETY HAZARDS IN ALL VEHICLES, IS BEYOND ME. I KNOW THEY ARE LESS EXPENSIVE, IS IT WORTH IT? CAN SOMEONE PLEASE ADDRESS THE ISSUE AND AT LEAST LET THE PUBLIC KNOW IT IS HAPPENING BEFORE SOMEONE GETS SEVERELY INJURED OR GOD FORBID DIES. THERE ARE THOUSANDS STILL ON THE ROAD. I PAID FOR THEIR DIAGNOSTIC WORTHLESSNESS TO MAKE SURE IT WAS DOCUMENTED.

BROUGHT VEHICLE TO DEALER FOR OIL/FILTER CHANGE AT 53,000 MILES. DEALER FOUND ONE OF THE TWO BRACKETS ON TOP OF REAR END WAS COMPLETELY RUSTED AND BROKEN OFF AND THE OTHER BRACKET WAS SEVERELY RUSTED. DEALER WOULD NOT ALLOW ME TO DRIVE VEHICLE AND IS NOT REPAIRABLE. THERE ARE NO NEW REPLACEMENT REAR ENDS FOR VEHICLE AND THE BRACKETS ARE NOT AVAILABLE AS A REPLACEMENT PART. I NOTICED OTHER VERY SIMILAR COMPLAINTS ON YOUR SITE: NHTSA ID #'S - 10452414, 10439449, 10427559, AND 10403443. THERE MAY BE OTHER ID'S THAT HAVE BEEN RETIRED (MICROFILM, ETC.). AS SUCH, THE VEHICLE IS A TOTAL LOSS. DON'T KNOW WHY NHTSA HASN'T ISSUED A RECALL. *TR