IllustrationTHE DRIVER SIDE DOOR WILL NOT OPEN FROM THE INSIDE OR OUTSIDE, WITH OR WITHOUT THE KEY. I'VE TRIED EVERYTHING AND CAN'T GET IT TO OPEN. I HAD TO CRAWL TO THE PASSENGER SIDE AFTER GETTING HOME TO GET OUT.
2004 Kia Optima
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2004 Kia Optima do not stand out strongly from the model-year median of 186.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all Optima years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
220–25K
2225–50K
3550–75K
4375–100K
56100–150K
9150K+
187 reports with mileage · 38 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Latches/locks/linkages. Review the 81 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 45 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Structure. Review the 42 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
8 crash reports3 fire reports7 injury reports
Structure complaints
42 reportsSUB FRAME ROT LEADING TO POOR HANDLING , TIRE WEAR, BAD ENGINE PERFORMANCE. THE ROTTED SUPFRAME IS SEPARATING FROM BODY, CAUSING POOR PERFORMANCE. THE CAR IS PERFORMING POORLY AT ALL SPEEDS. NOT SAFE...
TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE DOOR LOCK FAILED. IN ADDITION, THE DOORS WOULD AUTOMATICALLY LOCK ONCE OPENED WITH THE KEY FOB. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 125,000.
POWER DOOR LOCK LOCKS WHEN UNLOCKING FROM OUTSIDE WITH KEY. REPLACED THE DOOR LATCH. BUT IT STILL DOES IT. ALSO THE HEADLIGHTS STAY ON WHEN TURNING OFF THE CAR. HAVE TO MANUALLY TURN OFF HEADLIGHT SWITCH. *TR
TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE DRIVER SIDE DOOR FAILED TO UNLOCK OR OPEN. THE CONTACT HAD TO GET IN AND OUT OF THE VEHICLE BY USING THE PASSENGER SIDE DOOR. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 138,000.
TL* THE CONTACT OWNS A 2004 KIA OPTIMA. WHILE DRIVING AT APPROXIMATELY 20 MPH, THE POWER STEERING SEIZED. ALSO, THE SUBFRAME WAS FRACTURED. THE VEHICLE WAS NOT TAKEN TO A DEALER AND WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE CONTACT BELIEVED THAT THE FAILURE WAS RELATED TO NHTSA CAMPAIGN NUM…
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TL* THE CONTACT OWNS A 2004 KIA OPTIMA. WHILE DRIVING AT APPROXIMATELY 20 MPH, THE POWER STEERING SEIZED. ALSO, THE SUBFRAME WAS FRACTURED. THE VEHICLE WAS NOT TAKEN TO A DEALER AND WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE CONTACT BELIEVED THAT THE FAILURE WAS RELATED TO NHTSA CAMPAIGN NUMBER: 09V183000 (SUSPENSION). THE APPROXIMATE FAILURE MILEAGE WAS 91,700.
I WAS DRIVING ON I-10 WESTBOUND, KATY TX FREEWAY, TRAVELLING ABOUT 65 MILES PER HOUR. THE PASSENGER'S SIDE FRONT TIRE BLEW OUT CAUSING THE CAR TO GO BACK AND FOURTH BETWEEN TWO LANES OF TRAFFIC. IN THE PROCESS, I WAS HITTING THE RUBBER DIVIDERS, DAMAGING THE HOOD OF THE CAR AND THE WINDSHIELD. THE BLOWN TIRE CAUSED DAMAGE TO TH…
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I WAS DRIVING ON I-10 WESTBOUND, KATY TX FREEWAY, TRAVELLING ABOUT 65 MILES PER HOUR. THE PASSENGER'S SIDE FRONT TIRE BLEW OUT CAUSING THE CAR TO GO BACK AND FOURTH BETWEEN TWO LANES OF TRAFFIC. IN THE PROCESS, I WAS HITTING THE RUBBER DIVIDERS, DAMAGING THE HOOD OF THE CAR AND THE WINDSHIELD. THE BLOWN TIRE CAUSED DAMAGE TO THE OIL PAN, THE RADIATOR, AND EVENTUALLY THE TRANSMISSION. I GOT THE CAR TO THE EMERGENCY LANE. THE CAR WAS TOWED OFF THE FREEWAY AND EVENTUALLY PICKED UP AND TRANSPORTED TO A CAR REPAIR SHOP. A FEW DAYS LATER, THE INSURANCE ADJUSTER AND THE REPAIR SHOP OWNER BOTH AGREED THE CAR WAS A TOTAL LOSS. I HAD TO BUY A NEW CAR. *TR
DRIVER'S DOOR LOCKS AND CANNOT BE OPENED WITH A KEY AND DOES NOT OPEN ONCE INSIDE OF THE CAR. THE OPERATOR ESSENTIALLY IS LOCKED IN THE CAR. IN THE EVENT OF A CRASH OR FIRE, THE OCCUPANT MAY NOT BE ABLE TO EASILY VACATE THE VEHICLE; THE ONLY WAY WOULD BE TO CLIMB OVER THE CONSOLE TO THE PASSENGER COMPARTMENT OR THE REAR TO EXIT …
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DRIVER'S DOOR LOCKS AND CANNOT BE OPENED WITH A KEY AND DOES NOT OPEN ONCE INSIDE OF THE CAR. THE OPERATOR ESSENTIALLY IS LOCKED IN THE CAR. IN THE EVENT OF A CRASH OR FIRE, THE OCCUPANT MAY NOT BE ABLE TO EASILY VACATE THE VEHICLE; THE ONLY WAY WOULD BE TO CLIMB OVER THE CONSOLE TO THE PASSENGER COMPARTMENT OR THE REAR TO EXIT THE PASSENGER DOORS. THERE HAVE BEEN NUMEROUS COMPLAINTS WITH NO ACTION TAKEN BY THE MANUFACTURER TO REMEDY THE DEFECT AND AFFECTS MULTIPLE MANUFACTURING YEARS. IN MY OPINION IT CLEARLY IS A SAFETY ISSUE. *TR
DRIVER SIDE DOOR DOES NOT OPEN FROM INSIDE, EVEN WHEN IN 'UNLOCK' POSITION. I DROVE TO WORK, HAVING NO PROBLEMS OPENING THE DOOR TO GET INTO THE CAR, NOTHING UNUSUAL HAPPENED DURING MY 15 MINUTE COMMUTE. I ARRIVED AT WORK, AND WAS FORCED TO EXIT THE CAR THROUGH THE PASSENGER SIDE DOOR. THE DRIVER SIDE DOOR WILL NOW ONLY OPEN IF …
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DRIVER SIDE DOOR DOES NOT OPEN FROM INSIDE, EVEN WHEN IN 'UNLOCK' POSITION. I DROVE TO WORK, HAVING NO PROBLEMS OPENING THE DOOR TO GET INTO THE CAR, NOTHING UNUSUAL HAPPENED DURING MY 15 MINUTE COMMUTE. I ARRIVED AT WORK, AND WAS FORCED TO EXIT THE CAR THROUGH THE PASSENGER SIDE DOOR. THE DRIVER SIDE DOOR WILL NOW ONLY OPEN IF YOU USE THE KEY AND CAN RANDOMLY FIND THE PERFECT TIMING OF TURNING THE KEY AND PULLING THE DOOR HANDLE. IT IS NEARLY IMPOSSIBLE TO PERFORM THIS MANEUVER FROM INSIDE THE VEHICLE. HAVING NO EASE OF ACCESS FROM THE DRIVER SIDE FRONT SEAT OF THE VEHICLE POSES AN EXTREME SAFETY CONCERN TO ALL THOSE DRIVING SIMILAR VEHICLES. HAVING PERFORMED JUST CURSORY RESEARCH OVER THE PAST TWO DAYS, I HAVE COME ACROSS HUNDREDS OF SIMILAR ACCOUNTS FROM OTHER KIA OWNERS. THIS IS OBVIOUSLY A MANUFACTURING DEFECT, AND SHOULD BE HANDLED AS A RECALL. *TR
DRIVER DOOR WILL NOT OPEN EVEN THOUGH IT INDICATES THE DOOR IS UNLOCKED. DESPITE MULTIPLE TRIES THE DOOR WILL NOT UNLOCK OR OPEN TRAPPING THE DRIVER IN THE CAR. *TR
Official recalls
109V183000 · Suspension:front
May 27, 2009
KIA MOTORS CORPORATION (KMC) IS RECALLING 36,538 MODEL YEAR 2001-2004 OPTIMA VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. ROAD SALT APPLIED IN THESE STATES DURING THE WINTER MONTHS MAY RESULT IN PROGRESSIVE, INTERNAL CORROSION OF THE FRONT SUBFRAME. OVER TIME, SUCH SUBFRAME CORROSION NEAR THE CONNECTION TO THE LOWER CONTROL ARM CAN LEAD TO WHEEL MISALIGNMENT AND/OR OTHER NOTICEABLE STRESS IN STEERING, OR ACCELERATED ABNORMAL TIRE WEAR.
Consequence & remedy
Consequence: CORROSION OF THE FRONT SUBFRAME COULD LEAD TO SEPARATION, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: KMC WILL NOTIFY OWNERS AND DEALERS WILL REPAIR THE VEHICLES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 15, 2009. OWNERS MAY CONTACT KIA'S CONSUMER ASSISTANCE CENTER AT 1-800-333-4542.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
0No exact-year investigations in this snapshot.