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2002 Kia Sedona

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2002 Kia Sedona do not stand out strongly from the model-year median of 120.

About this comparison →

When problems were reported

Mileage at the reported incident

109 reports with mileage · 89 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.

  • Electrical System. Review the 50 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Seat Belts. Review the 28 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 27 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

17 crash reports13 fire reports11 injury reports

Equipment complaints

10 reports
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72,000 miles · Dec 12, 2007
Electrical SystemEquipmentSeatsFire

TL*THE CONTACT OWNS A 2002 KIA SEDONA. THE VEHICLE HAD BEEN PARKED FOR APPROXIMATELY 8-10 HOURS WHEN IT SUDDENLY CAUGHT FIRE. THE WIRING FUSE BOX CAUSED THE ENGINE, RADIO, AND WIPER/WASHER TO ACTIVATE. THE FIRE ORIGINATED IN THE INSTRUMENT PANEL. THE CONTACT WAS ABLE TO DOUSE THE FIRE WITH A FIRE EXTINGUISHER. THE VEHICLE W…

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TL*THE CONTACT OWNS A 2002 KIA SEDONA. THE VEHICLE HAD BEEN PARKED FOR APPROXIMATELY 8-10 HOURS WHEN IT SUDDENLY CAUGHT FIRE. THE WIRING FUSE BOX CAUSED THE ENGINE, RADIO, AND WIPER/WASHER TO ACTIVATE. THE FIRE ORIGINATED IN THE INSTRUMENT PANEL. THE CONTACT WAS ABLE TO DOUSE THE FIRE WITH A FIRE EXTINGUISHER. THE VEHICLE WAS LATER TOWED TO A DEALER AND THEY DID NOT PROVIDE A REASON AS TO WHY IT CAUGHT FIRE. THE CONTACT FOUND NUMEROUS COMPLAINTS ON THE SAME TYPE OF VEHICLE WITH IDENTICAL FAILURES. THE CURRENT AND FAILURE MILEAGES WERE 72,000. UPDATED 03/06/08. *LJ THE CONSUMER STATED THE RECALL WAS DONE, HOWEVER EVER SINCE THE REPAIR, THE SEATS NEVER WORKED CORRECTLY. THE CONSUMER HAD WORKED DONE ON THE AIR CONDITIONER. UPDATED

NHTSA ODI #10211579

Mileage unknown · Dec 14, 2005
Air BagsElectrical SystemEquipment

IN 11/04 MY ABS LIGHTS WENT ON IN MY 02 KIA SEDONA. I TOOK THE VAN TO GET NEW BRAKES AND WAS TOLD THAT I NEEDED TO TAKE IT TO THE DEALERSHIP BECAUSE THE ABS SENSOR WAS BROKEN IN PIECES ON THE DRIVER SIDE WHEELS. IN 8/05 MY AIR BAG LIGHT CAME ON IN THE DASH AND STAYED ON. BEFORE I COULD GET MY CAR IN TO DEALERSHIP, I WAS DRIVING…

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IN 11/04 MY ABS LIGHTS WENT ON IN MY 02 KIA SEDONA. I TOOK THE VAN TO GET NEW BRAKES AND WAS TOLD THAT I NEEDED TO TAKE IT TO THE DEALERSHIP BECAUSE THE ABS SENSOR WAS BROKEN IN PIECES ON THE DRIVER SIDE WHEELS. IN 8/05 MY AIR BAG LIGHT CAME ON IN THE DASH AND STAYED ON. BEFORE I COULD GET MY CAR IN TO DEALERSHIP, I WAS DRIVING HOME FROM WORK IN EARLY 9/05 GOING OVE AN OVERPASS WHEN MY CAR JUST DIED AND LOST ALL POWER. I WAS TOLD THAT MY MASTER FLOW SENSOR WENT BAD AND NEEDED A NEW ONE (WARRANTY). THEY ALSO REPLACED THE SEAT BELT SENSOR IN THE DRIVERS SIDE TO TAKE CARE OF THE AIR BAG LIGHT.2 DAYS LATER MY AIRBAG LIGHT CAME BACK ON. IN 12/05 MY ABS LIGHT CAME ON AGAIN ALONG WITH THE WARNING BEEP. I CALLED MY DEALERSHIP AND GOT APPT. FOLLOWING TUESDAY. I WAS TOLD IT SHOULD BE SAFE TO DRIVE UNTIL THEN. BOTH HEADLIGHTS ALSO WENT OUT. NOW WHEN APPLYING BRAKE MY BRAKE GOES DOWN GRINDS, ADJUST THEN GOES ALL THE WAY DOWN . GOT CAR TO DEALERSHIP TUES AM. IN THE AFTERNOON RECEIVED CALL 1 YR OLD BATTERY IS LEAKING ACID DUE TO FAULTY ALTERNATOR (SENDING TOO MUCH POWER OUT. WAS TOLD MUST REPLACE BATTERY SO THAT DEALERSHIP MAY COMPLETE DIAGNOSIS. WAS TOLD BY DEALERSHIP KIA ONLY WARRANTIES MAIN ISSUE NOT ANY ADDITIONAL ITEMS DAMAGED BY MAIN ISSUE. RECEIVED CALL A LITTLE WHILE AGO, TOLD BAD ALTINATOR NEEDS BATTERY FAULTY SEAT BELT SENSOR NOW IN PASSENGER SEAT BELT (3 MONTHS AGO WAS DRIVERS SIDE ALSO MY HEADLIGHTS ARE BOTH BLOWN - YES FAULTY ALTENATOR MOST LIKELY CAUSED THIS. I WAS ALSO TOLD THAT MY NEW BRAKES (REPLACED IN AUG 05 AT LESS THAN 3000 MI AGO) ARE WORE THIN AND NEED RELACEMENT ALONG WITH ROTORS WHICH NOW HAVE GROOVES IN THEM AND THEY ARE ALSO TO THIN. I HAVE NOW REPLACED THE BRAKES 4 TIMES ON A VEHICLE THAT IS 4 YRS OLD AND BEING TOLD MUST REPLACE ONCE AGAIN. *NM

NHTSA ODI #10145225

46,876 miles · Nov 10, 2005
Electrical SystemEngine And Engine CoolingEquipment

CONSUMER BELTS SQUEAL, SLIDDING DOOR DRAGS, PULLEY WAS REPLACED AT 7744 MILES. *TS ***NO ANSWER REQUIRED*** THE PULLEY AND BELT HAVE BEEN REPLACED 10 TIMES. THE ALTERNATOR SEIZED WHILE THE VEHICLE WAS BEING DRIVEN. THE A/C FAN MADE LOUD NOISES. THE SLIDING DOOR DRAGGED. THE EMERGENCY BRAKE WOULD NOT HOLD, THE DEALER ADJUST…

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CONSUMER BELTS SQUEAL, SLIDDING DOOR DRAGS, PULLEY WAS REPLACED AT 7744 MILES. *TS ***NO ANSWER REQUIRED*** THE PULLEY AND BELT HAVE BEEN REPLACED 10 TIMES. THE ALTERNATOR SEIZED WHILE THE VEHICLE WAS BEING DRIVEN. THE A/C FAN MADE LOUD NOISES. THE SLIDING DOOR DRAGGED. THE EMERGENCY BRAKE WOULD NOT HOLD, THE DEALER ADJUSTED IT THREE TIMES THEN FINALLY REPLACED. AN INTERNAL SHORT IN THE FUSE CLOCK CAUSED THE VEHICLE NOT TO START. THE VEHICLE STALLED INTERMITTENLTY BUT THE DEALER WAS UNABLE TO DUPLICATE THE STALLING. THE POWER WINDOWS WOULD STICK AND MAKE NOISE, THE DEALER LUBED IT AND REPLACED THE REGULATOR. THE REAR HATCH RUSTED AROUND HANDLE AND HAD TO BE REPAIRED/REFINISHED TWICE. THE EXHAUST MANIFOLD RACKED. OIL LEAKED FROM OIL FILTER. THE FRONT AND REAR WIPERS FAILED. THE SLIDING DOOR HANDLE BROKE. THE DASH LIGHTS ILLUMINATED DUE TO BROKEN BAD SWITCH CONTACTS. THE ROTORS WARPED. THE A/C WAS BLOWING WHEN IT WASN'T ON AND SOMETIMES IT BLEW OUT WARM AIR. THE REAR SEAT ARM REST WILL NOT STAY DOWN. THE THRESHOLD ON THE LEFT SIDE IS CRACKED. *NM

NHTSA ODI #10143219

Mileage unknown · Jan 15, 2004
Engine And Engine CoolingEquipmentService Brakes, Hydraulic

I REALLY NEED HELP AND DON?T KNOW WHAT TO DO. ALSO WITH MY CAR MY ENGINE LIGHT WAS CONSTANTLY ON AND TO THIS DAY THE LIGHT IS PROBABLY STILL ON AND KIA HAVE NOT CONTACTED ME YET AND EVEN THOUGH I HAVE A RENTAL FROM ENTERPRISE THROUGH KIA PAYING THAT IS NOT THE ISSUE I WANT MY CAR SO THAT CAN SELL IT SO THAT I DON?T LOSE MY HOME…

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I REALLY NEED HELP AND DON?T KNOW WHAT TO DO. ALSO WITH MY CAR MY ENGINE LIGHT WAS CONSTANTLY ON AND TO THIS DAY THE LIGHT IS PROBABLY STILL ON AND KIA HAVE NOT CONTACTED ME YET AND EVEN THOUGH I HAVE A RENTAL FROM ENTERPRISE THROUGH KIA PAYING THAT IS NOT THE ISSUE I WANT MY CAR SO THAT CAN SELL IT SO THAT I DON?T LOSE MY HOME BECAUSE I AM UNEMPLOYED DUE TO THIS BUCKET OF BOLTS. AND ALSO THE KIA REPAIR MAN STEVE JOHNSON AT KIRKLAND KIA STATED TO ME THAT MY ODOMETER READING WAS INCORRECT AND THE KIA MANUFACTURER TOOK MY CAR TO ANOTHER DEALER BECAUSE I WAD BEING SEEN AT THEIR AUTO SHOP TOO MUCH AND IS BIZARRE OR WHAT? I SPOKE TO A PAUL STAPLETON AT KIA MOTORS AMERICA BECAUSE THEY HAVE HAD MY VEHICLE FOR 30 DAYS STRAIGHT. ON OCT 8 I PICKED MY CAR UP AND 20 MIN LATER MY ENGINE LIGHT WAS BACK ON. THE DAY BEFORE I WAS OFFERED $1000 FOR A GOOD WILL GESTURE FROM KIA. WHEN THE ENGINE LIGHT CAME BACK ON THE NEXT DAY MR. STAPLETON OFFERED TO BUY MY VEHICLE BACK FOR 11,300 AND THAT WAS WITHOUT THE $1000 GOOD WILL. TODAY IS OCT 12TH AND BY THIS AFTERNOON I WILL BE HEARING FROM THIS COMPANY. THIS IS NOT SATISFYING TO ME BECAUSE I STILL HAD A FULL WARRANTY ON MY CAR AND FOR 11,300 I WILL HAVE TO PURCHASE USED AND NO WARRANTY BECAUSE I HAD A 2002 THAT WAS PAID IN FULL AND A FULL WARRANTY.

NHTSA ODI #10070909

Mileage unknown · Jul 22, 2003
Electrical SystemEngine And Engine CoolingEquipment

MY 2002 KIA SEDONA HAS EXPERIENCED MULTIPLE PROBLEMS SINCE I BOUGHT IT IN MARCH, 2002. MAJOR ELECTRICAL PROBLEMS, BATTERY REPLACEMENT, SLIDING DOOR FAILING TO CLOSE, ENGINE NOISE, AIR CONDITIONER PROBLEMS. HAVE CONTACTED MANUFACTURER AND DEALER. SOME ISSUES RESOLVED - - OTHERS UNABLE TO BE DIAGNOSED OR REPLICATED. FEAR THAT …

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MY 2002 KIA SEDONA HAS EXPERIENCED MULTIPLE PROBLEMS SINCE I BOUGHT IT IN MARCH, 2002. MAJOR ELECTRICAL PROBLEMS, BATTERY REPLACEMENT, SLIDING DOOR FAILING TO CLOSE, ENGINE NOISE, AIR CONDITIONER PROBLEMS. HAVE CONTACTED MANUFACTURER AND DEALER. SOME ISSUES RESOLVED - - OTHERS UNABLE TO BE DIAGNOSED OR REPLICATED. FEAR THAT ENGINE, ELECTRICAL SYSTEM IS STILL NOT WORKING PROPERLY AND WILL FAIL AND CAUSE AN ACCIDENT.*AK

NHTSA ODI #10028851

Mileage unknown · Jul 16, 2003
EquipmentVisibility

THE WINDSHIELD CRACKS TOO EASILY. I WILL BE REPLACING THE WINDSHIELD FOR THE 2ND TIME IN 18 MONTHS. THEY TELL ME IT IS A ROCK CHIP, HOWEVER, THE LAST WINDSHIELD (FACTORY INSTALLED HAD 2 CRACKS IN IT. THIS WINDSHIELD HAS 5 CRACKS. ALL START IN THE BLACK AREA OF THE WINDSHIELD. I TRULY AM WORRIED THAT THIS IS AN ONGOING PROBLE…

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THE WINDSHIELD CRACKS TOO EASILY. I WILL BE REPLACING THE WINDSHIELD FOR THE 2ND TIME IN 18 MONTHS. THEY TELL ME IT IS A ROCK CHIP, HOWEVER, THE LAST WINDSHIELD (FACTORY INSTALLED HAD 2 CRACKS IN IT. THIS WINDSHIELD HAS 5 CRACKS. ALL START IN THE BLACK AREA OF THE WINDSHIELD. I TRULY AM WORRIED THAT THIS IS AN ONGOING PROBLEM AND I WILL BE REPLACING THE WINDOW AGAIN. *AK

NHTSA ODI #10028428

7,600 miles · Jun 2, 2003
Electrical SystemEquipment

BATTERY KEEPS ON DYING, NEEDING BOOST. RECEIVED RUARY JANUARY 2003. THAT ONE DIED IN FEB. THEY REPLACED RADIO, SAYING IT HAD A SHORT. BUT BATTERY DIED AGAIN. THEN THEY SAID AN ALTERNATOR WIRE WAS LOOSE. THEY RECONNECTED IT. BUT BATTERY DIED AGAIN, THE FOLLOWING MONTH. BACK FOR SERVICE ON 6/2/03. AFRAID ELECTRICAL SYSTEM MAY FAIL…

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BATTERY KEEPS ON DYING, NEEDING BOOST. RECEIVED RUARY JANUARY 2003. THAT ONE DIED IN FEB. THEY REPLACED RADIO, SAYING IT HAD A SHORT. BUT BATTERY DIED AGAIN. THEN THEY SAID AN ALTERNATOR WIRE WAS LOOSE. THEY RECONNECTED IT. BUT BATTERY DIED AGAIN, THE FOLLOWING MONTH. BACK FOR SERVICE ON 6/2/03. AFRAID ELECTRICAL SYSTEM MAY FAIL WHILE VEHICLE IS BEING OPERATED. KNOW OF 2 OTHER INDIVIDUALS WITH SAME KIA SEDONA EX THAT THIS HAS HAPPENED TO (BATTERY FAILURE). *AK

NHTSA ODI #10020924

7,600 miles · Jun 2, 2003
Electrical SystemEquipment

BATTERY KEEPS ON DYING, NEEDING BOOST. RECIEVED NEW ONE IN JANUARY 2003. THAT ONE DIED IN FEB. THEY REPLACED RADIO, SAYING IT HAD A SHORT. BUT BATTERY DIED AGAIN. THEN THEY SAID AN ALTERNATOR WIRE WAS LOOSE. THEY RECONNECTED IT. BUT BATTERY DIED AGAIN, THE FOLLOWING MONTH. BACK FOR SERVICE ON 6/2/03. AFRAID ELECTRICAL SYSTEM MAY…

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BATTERY KEEPS ON DYING, NEEDING BOOST. RECIEVED NEW ONE IN JANUARY 2003. THAT ONE DIED IN FEB. THEY REPLACED RADIO, SAYING IT HAD A SHORT. BUT BATTERY DIED AGAIN. THEN THEY SAID AN ALTERNATOR WIRE WAS LOOSE. THEY RECONNECTED IT. BUT BATTERY DIED AGAIN, THE FOLLOWING MONTH. BACK FOR SERVICE ON 6/2/03. AFRAID ELECTRICAL SYSTEM MAY FAIL WHILE VEHICLE IS BEING OPERATED. KNOW OF 2 OTHER INDIVIDUALS WITH SAME KIA SEDONA EX THAT THIS HAS HAPPENED TO (BATTERY FAILURE).*AK

NHTSA ODI #10020923

Mileage unknown · May 24, 2003
EquipmentService Brakes, Hydraulic

FALLAS SISTEMA AIRE ACONDICIONADO DESDE 8-28-2002, TODAVIA SIGUE DANDIO PROBLEMAS EN ESTOS MOMENTOS SE ENCUENTRA EN TALLER DE KIA PARA REPARACION. FRENOS REPARADOS EN 2 OCASIONES LOS ROTORES Y PADS. CRISTAL DELANTERO SE QUEBRO SIN RAZON. RADIO DEJO DE FUNCIONAR. *NLM

NHTSA ODI #10019238

Mileage unknown · Nov 27, 2002
EquipmentPower TrainSteering

CONSUMER COMPLAINS OF A LOUD WHISLTE WHEN DRIVING OVER 40 MPH. THE FACTORY REP TEST DROVE THE VEHICLE AND DETERMINED IT TO BE THE ROOF RACK. THEIR SOLUTION WAS POSSIBLY A REDESIGN OF THE CROSS MEMBERS. NOTHING HAS BEEN DONE. *JG

NHTSA ODI #568446

Official recalls

3

05V013000 · Vehicle Speed Control:cables

Jan 19, 2005

ON CERTAIN MINI VANS, DURING ASSEMBLY, THE THROTTLE CABLE WOULD TWIST ITSELF OUT OF POSITION.

Consequence & remedy

Consequence: THIS CAN PERMIT THE CABLE TO BE HUNG UP, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL REPLACE THE THROTTLE CABLE FREE OF CHARGE. VEHICLES PRODUCED FROM MARCH 20, 2001 THROUGH NOVEMBER 7, 2001 WILL HAVE A GUIDE CLIP INSTALLED ON THE THROTTLE BODY ASSEMBLY IN ORDER TO ENSURE THAT THE TENSION FORCE CABLE DOES NOT MOVE OUT OF POSITION. VEHICLES MANUFACTURED BEGINNING ON NOVEMBER 8, 2001, ALREADY HAVE THE EXTENDED GUIDE, WHICH ACCOMPLISHES THE SAME OBJECTIVE. THE RECALL BEGAN MARCH 21, 2005. OWNERS MAY CONTACT KIA AT 1-800-333-4542.

03V135000 · Seats:mid/rear Assembly

Apr 3, 2003

ON CERTAIN PASSENGER VEHICLES, SOME OF THE SECOND AND THIRD ROW SEAT STRIKERS INSTALLED ON THE VEHICLE FLOOR PAN HAVE BEEN IMPROPERLY HEAT TREATED AND COULD BREAK IN A CRASH.

Consequence & remedy

Consequence: THIS COULD RESULT IN INJURIES TO OCCUPANTS OF THESE SEATS.

Remedy: DEALERS WILL REPLACE THE SEAT STRIKERS. OWNER NOTIFICATION BEGAN APRIL 25, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT KIA AT 1-800-333-4542

03V017000 · Seat Belts:rear/other

Jan 22, 2003

CERTAIN MINI VANS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 209, "SEAT BELT ASSEMBLIES." THE SECOND AND THIRD SEAT BELT BUCKLE ANCHOR BOLTS DO NOT COMPLY WITH THE STANDARDS.

Consequence & remedy

Consequence: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED.

Remedy: DEALERS WILL REPLACE THE SEAT BELT BUCKLE ANCHOR BOLTS. OWNER NOTIFICATION BEGAN FEBRUARY 24, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT KIA 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

3

EA08017 · Steering Intermediate Shaft Binding

Opened Aug 28, 2008 · Closed Jul 1, 2009

Status: closed (inferred from source dates) · Steering

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.

PE08033 · Steering Binding

Opened Apr 28, 2008 · Closed Aug 28, 2008

Status: closed (inferred from source dates) · Steering

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.

PE04067 · Throttle Cable Binding

Opened Sep 24, 2004 · Closed Jan 27, 2005

Status: closed (inferred from source dates) · Vehicle Speed Control; Vehicle Speed Control:cables; Vehicle Speed Control:linkages

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.

Additional source detail variants (6)

Vehicle Speed Control:cables

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.

Vehicle Speed Control:cables

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.

Vehicle Speed Control

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.

Vehicle Speed Control

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.

Vehicle Speed Control:linkages

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.

Vehicle Speed Control:linkages

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.