Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
370–25K
2525–50K
1950–75K
1075–100K
23100–150K
8150K+
122 reports with mileage · 41 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 29 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Air Bags. Review the 25 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Engine And Engine Cooling. Review the 20 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
13 crash reports21 fire reports14 injury reports
What owners actually said
163 reports
Mileage unknown · Sep 29, 2005
Electrical SystemFire
DT: THE CONTACT OWNS A 2003 KIA SEDONA. THE VEHICLE WAS TRYING TO START BY ITSELF . THE WINDSHIELD WIPERS WERE ON AND THERE WAS SMOKE IN THE VEHICLE AND FLAMES ON THE DRIVER'S SIDE EMERGENCY BRAKE. THE CONTACT'S HUSBAND PUT THE FLAMES OUT BEFORE THE FIRE DEPARTMENT RESPONDED. THE FIRE WAS FIRST NOTICED FROM THE DRIVERS SIDE …
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DT: THE CONTACT OWNS A 2003 KIA SEDONA. THE VEHICLE WAS TRYING TO START BY ITSELF . THE WINDSHIELD WIPERS WERE ON AND THERE WAS SMOKE IN THE VEHICLE AND FLAMES ON THE DRIVER'S SIDE EMERGENCY BRAKE. THE CONTACT'S HUSBAND PUT THE FLAMES OUT BEFORE THE FIRE DEPARTMENT RESPONDED. THE FIRE WAS FIRST NOTICED FROM THE DRIVERS SIDE WHERE THE EMERGENCY BRAKE WAS LOCATED. THE VEHICLE WAS NOT OPERATING UNUSUALLY BEFORE. THE VEHICLE HAD BEEN PARKED FOR ABOUT TWO HOURS BEFORE THE FIRE WAS NOTICED. THE DEALERSHIP TOLD HER HUSBAND AT THIS POINT THEY BELIEVED THIS WAS STARTED FROM THE LOW JACK INSTALLATION WHICH WAS INSTALLED BY THE DEALERSHIP. THE POLICE REPORTED TO THE SCENE, AND AFTER ARSON WAS RULED OUT THEY HANDED THE SITUATION OVER TO THE FIRE DEPARTMENT. THE CONTACT GOING THERE TONIGHT TO PICK UP THE FIRE DEPARTMENT'S REPORT. *AK THE HORN DID NOT WORK.
NHTSA ODI #10135432
26,000 miles · Sep 29, 2005
Air Bags
DT: WHILE DRIVING THE AIR BAG LIGHT CAME ON. CONSUMER TOOK CAR TO DEALER WHO PERFORMED A DIAGNOSTIC TEST WHICH SHOWED A FAULTY SENSOR WITHIN THE AIR BAG. DEALER ORDERED A NEW AIR BAG SENSOR. CONSUMER WAITED 3 WEEKS FOR THIS TO BE DELIVERED. DEALER SAID THERE WAS NO CHANCE THE AIR BAG COULD DEPLOY AS IT WAS SIMPLY INACTIVE. …
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DT: WHILE DRIVING THE AIR BAG LIGHT CAME ON. CONSUMER TOOK CAR TO DEALER WHO PERFORMED A DIAGNOSTIC TEST WHICH SHOWED A FAULTY SENSOR WITHIN THE AIR BAG. DEALER ORDERED A NEW AIR BAG SENSOR. CONSUMER WAITED 3 WEEKS FOR THIS TO BE DELIVERED. DEALER SAID THERE WAS NO CHANCE THE AIR BAG COULD DEPLOY AS IT WAS SIMPLY INACTIVE. ON JUNE 17, 2005 THE BUCKLE WAS REPLACED, AND THE AIR BAG LIGHT WENT OFF AND NO LONGER ILLUMINATED. ON AUGUST 13, 2005, THE AIR BAG LIGHT CAME ON AGAIN. TOOK VEHICLE BACK TO DEALER ,WHO NOTED THE AIR BAG SENSOR WAS NOT WORKING AND AGAIN HAD TO WAIT FOR THE PART TO COME IN. *AK *JB
NHTSA ODI #10132873
40,000 miles · Sep 12, 2005
Electrical SystemFire
DT: THE CONSUMER STATED THAT 2003 KIA SEDONA CAUGHT ON FIRE WHILE PARKED IN THE GARAGE. THE VEHICLE HAD BEEN SITTING FOR AROUND SIX HOURS. THE FIRE STARTED UNDERNEATH THE STEERING WHEEL IN THE DASHBOARD AREA. THE INSIDE OF THE VAN HAD SUBSTANTIAL DAMAGE. THE VAN WAS TOWED TO A BODY SHOP UNTIL THE INSURANCE ADJUSTER LOOKED AT TH…
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DT: THE CONSUMER STATED THAT 2003 KIA SEDONA CAUGHT ON FIRE WHILE PARKED IN THE GARAGE. THE VEHICLE HAD BEEN SITTING FOR AROUND SIX HOURS. THE FIRE STARTED UNDERNEATH THE STEERING WHEEL IN THE DASHBOARD AREA. THE INSIDE OF THE VAN HAD SUBSTANTIAL DAMAGE. THE VAN WAS TOWED TO A BODY SHOP UNTIL THE INSURANCE ADJUSTER LOOKED AT THE VAN. THE VAN WAS DRIVING FINE AND WORKING IN GOOD SHAPE PRIOR TO THE FIRE. THE FIRE DEPARTMENT CAME AND PUT OUT THE FIRE. T A FIRE INVESTIGATOR CAME AND INSPECTED THE SCENE. THE FIRE INVESTIGATOR CONCLUDED IT WAS AN ELECTRICAL FIRE. THE DEALER AND THE MANUFACTURER HAVE BEEN TOLD ABOUT THE FIRE. THE CONSUMER JUST TOLD KIA ABOUT THE FIRE, AND THEY WANTED THE CONSUMER TO GET A COPY OF THE FIRE REPORT ,AND THEN THEY WOULD TALK TO HIM. THE DEALERSHIP TOLD THE CONSUMER THAT THEY DIDN'T KNOW WHAT TO TELL HIM. AN INSURANCE AND FIRE REPORT WAS TAKEN, ALTHOUGH THE CONSUMER DID NOT HAVE A COPY RIGHT NOW OF THE REPORT. THE FIRE DEPARTMENT TOOK PICTURES ON THE NIGHT OF THE FIRE. THERE WERE NO INJURIES AND NO DAMAGE TO THE HOME. THE TRANSMISSION WOULD NOT COME OUT OF GEAR FOR THE WRECKER TO TOW IT.*AK
NHTSA ODI #10136174
20,000 miles · Sep 9, 2005
Engine And Engine Cooling
DAD: A NOISE WAS COMING FROM THE MUFFLER/ENGINE. THIS HAPPENED AT SPEEDS OF 35-45 MPH AND IN HOT WEATHER, AND WHEN THE AIR CONDITIONER WAS ON. THE PROBLEM FIRST STARTED ON SEPTEMBER 24, 2004. WHEN THE CONSUMER TOOK VEHICLE TO A DEALERSHIP FOR REPAIRS THEY COULD NOT FIND THE CAUSE OF THE PROBLEM. *AK
NHTSA ODI #10135997
48,000 miles · Aug 30, 2005
Electrical SystemFire
2003 KIA SEDONA WITH APPROX 48,000 MILES, PARKED AND UNOCCUPIED IN THE PARKING AREA OF MY TOWNHOUSE COMMUNITY. WENT TO OPEN THE DOOR REMOTELY USING THE KEY RING AND THERE WAS NO RESPONSE. EVENTUALLY HAD TO MANUALLY OPEN THE CAR AND NOTICED THE ENTIRE LEFT HAND SIDE OF THE INSTRUMENT PANEL AND DASHBOARD AREA HAD LITERALLY MELT…
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2003 KIA SEDONA WITH APPROX 48,000 MILES, PARKED AND UNOCCUPIED IN THE PARKING AREA OF MY TOWNHOUSE COMMUNITY. WENT TO OPEN THE DOOR REMOTELY USING THE KEY RING AND THERE WAS NO RESPONSE. EVENTUALLY HAD TO MANUALLY OPEN THE CAR AND NOTICED THE ENTIRE LEFT HAND SIDE OF THE INSTRUMENT PANEL AND DASHBOARD AREA HAD LITERALLY MELTED INTO THE FLOORBOARD. APPEARS AS IF THERE WAS SOME KIND OF ELECTRICAL SHORT. VEHICLE WAS TOWED TO BONNEVILLE KIA AND DUE TO MY EXTENDED SERVICE CONTRACT IMMEDIATELY SET UP A RENTAL. THE SERVICE REP AT BONNEVILLE SAID HE HAD NOT SEEN "ANYTHING LIKE IT" AND WAS TO CALL HIS FACTORY REP AND RECOMMENDED I CONTACT MY AUTO INSURANCE CARRIER TO BEGIN THE CLAIMS PROCESS. THE CIRCUMSTANCES OF THIS INCIDENT SEEM WAY TO CLOSE TO OTHER COMPLAINTS FOUND ON OUR WEBPAGE. CLEARLY THERE IS SOME KIND OF DEFECT THAT KIA NEEDS TO ADDRESS. OTHER THAN SERVICE FOR OIL CHANGES AND TIRE ROTATION, ONLY KIA BONNEVILLE HAS PERFORMED MAINTENANCE ON THIS VEHICLE. PURCHASE DATE WAS DEC 2003. *JB
NHTSA ODI #10126073
45,000 miles · Aug 29, 2005
Vehicle Speed Control
DT: THE CONSUMER STATED THAT 2003 KIA SEDONA ACCELERATED BY ITSELF WHILE SITTING AT A STOP SIGN. THE ENGINE ACCELERATED WHEN THE CONSUMER HAD FOOT ON THE BRAKE. THE CAR HAD NEVER DONE THIS BEFORE. THE CAR TRAVELED A COUPLE OF FEET AND THERE WAS A NEAR MISS BY OTHER VEHICLES. THE CONSUMER CONTACTED THE DEALER AND WAS WAITING …
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DT: THE CONSUMER STATED THAT 2003 KIA SEDONA ACCELERATED BY ITSELF WHILE SITTING AT A STOP SIGN. THE ENGINE ACCELERATED WHEN THE CONSUMER HAD FOOT ON THE BRAKE. THE CAR HAD NEVER DONE THIS BEFORE. THE CAR TRAVELED A COUPLE OF FEET AND THERE WAS A NEAR MISS BY OTHER VEHICLES. THE CONSUMER CONTACTED THE DEALER AND WAS WAITING FOR ON AN APPOINTMENT TO TAKE THE VEHICLE IN FOR SERVICE. THE CONSUMER HAS NOT CONTACTED KIA AT THIS POINT. HE SUGGESTED THAT ON ONE KNEW WHAT WOULD MAKE THE VEHICLE DO THIS. THE CAR ACCELERATED BY ITSELF 6 TIMES IN THE SAME DAY, AND THE CONSUMER HAD FOOT ON THE BRAKE ALL 6 TIMES. THE CONSUMER CONSULTED THE OWNER'S MANUAL AND LOOKED AT THE ENGINE ,AND THE ENGINE SIZE WAS DESCRIBED AS 3500.*AK
NHTSA ODI #10134469
Mileage unknown · Aug 27, 2005
Air BagsCrash
A FRONT END IMPACT AT 45 MPH AND THE AIRBAG DID NOT DEPLOY. *JB
NHTSA ODI #10134390
Mileage unknown · Aug 24, 2005
Seat Belts
I HAVE HAD MY 2003 KIA SEDONA A LITTLE OVER 2 YEARS. I BOUGHT IT NEW FROM A DEALER. SINCE 2002, I HAVE HAD PROBLEMS WITH THE FRONT SEAT BELT SENSORS, TO THE POINT BOTH HAVE HAD TO BE REPLACED. WHEN THIS SENSOR DOES NOT OPERATE PROPERLY, THE "AIRBAG NEEDS SERVICING" LIGHT COMES ON. WITH THAT LIGHT ON, THE VAN WILL NOT PASS IN…
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I HAVE HAD MY 2003 KIA SEDONA A LITTLE OVER 2 YEARS. I BOUGHT IT NEW FROM A DEALER. SINCE 2002, I HAVE HAD PROBLEMS WITH THE FRONT SEAT BELT SENSORS, TO THE POINT BOTH HAVE HAD TO BE REPLACED. WHEN THIS SENSOR DOES NOT OPERATE PROPERLY, THE "AIRBAG NEEDS SERVICING" LIGHT COMES ON. WITH THAT LIGHT ON, THE VAN WILL NOT PASS INSPECTION (VA STATE INSPECTION). THE FIRST TIME THIS HAPPENED, THE DEALERSHIP WAS OUT OR STOCK OF THE REPLACEMENT SEATBELT ASSEMBLY, BUT THEY GAVE ME ONE FROM ANOTHER CAR WHILE WE WAITED FOR MY PARTS TO COME IN. THEY NEVER CAME IN. NOW, THE 2ND ONE HAS GONE BAD, AND I AM STILL WAITING FOR A PART. EVIDENTLY, WHERE THE DEARLERSHIP ORDERS PARTS FROM KIA IS OUT OF STOCK OF THESE ITEMS DUE TO HIGH VOLUME OF REPLACEMENT. I AM (1) CONCERNED THAT SO MANY OF THESE ARE GOING BAD THAT THE COMPANY HAS RUN OUT OF STOCK, AND (2) WORRIED THAT FAILURE OF THIS SENSOR COULD RESULT IN MY AIRBAG NOT WORKING PROPERLY. I HAVE NOW BEEN WAITING OVER 4 MONTHS FOR THE REPLACEMENT PARTS, AND THEY ARE STILL NOT AVAILABLE FROM THE DEALER. THIS ITEM IS NOT COVERED BY WARRANTY, AND IT DOES NOT APPEAR TO BE A RECALL ITEM. BUT SHOULDN'T A SAFETY ITEM LIKE THAT CAUSE A RECALL SINCE IT INVOLVES PERSONAL SAFETY AND THE PASSIVE RESTRAINT OPERATION? AND IF THAT MANY ARE FAILING, DOESN'T THAT CAUSE CONCERN FROM THE NHTSB?
NHTSA ODI #10134141
28,750 miles · Aug 20, 2005
EquipmentSeat Belts
THIRD TIME I AM HAVING MY SEAT BELT BUCKLE REPLACED DUE TO AIRBAG LAMP BEING ON. THEY JUST KEEP REPLACING FAULTY PART WITH ANOTHER FAULTY PART, THIS THIRD TIME, ONLY TOOK TWO DAYS FOR LIGHT TO COME BACK ON. I HAVE ALSO BEEN TOLD IN THE MEANTIME MY AIRBAGS ARE INACTIVE. THIS PROBLEM NEEDS TO BE ADDRESSED AND RECALLED, NOT JUST R…
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THIRD TIME I AM HAVING MY SEAT BELT BUCKLE REPLACED DUE TO AIRBAG LAMP BEING ON. THEY JUST KEEP REPLACING FAULTY PART WITH ANOTHER FAULTY PART, THIS THIRD TIME, ONLY TOOK TWO DAYS FOR LIGHT TO COME BACK ON. I HAVE ALSO BEEN TOLD IN THE MEANTIME MY AIRBAGS ARE INACTIVE. THIS PROBLEM NEEDS TO BE ADDRESSED AND RECALLED, NOT JUST REPLACED. I DO NOT FEEL SAFE.
NHTSA ODI #10133618
Mileage unknown · Jul 27, 2005
Electrical SystemFire
DROVE 2003 KIA SEDONA 4 OR 5 MILES. GOT OUT TO EAT AND IN ABOUT 5 MINUTES OR LESS THE INSIDE WAS FULL OF SMOKE AND THE DASHBOARD WAS IN FLAMES BEHIND THE STEERING WHEEL. USED FIRE ESTINGISHER BUT DID NOT GET THE FIRE OUT COMPLETELY AND FIRE DEPARTMENT CAME AND PUT THE FIRE OUT. I HAD HEARD THERE COULD BE A PROBLEM WITH THIS HAPP…
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DROVE 2003 KIA SEDONA 4 OR 5 MILES. GOT OUT TO EAT AND IN ABOUT 5 MINUTES OR LESS THE INSIDE WAS FULL OF SMOKE AND THE DASHBOARD WAS IN FLAMES BEHIND THE STEERING WHEEL. USED FIRE ESTINGISHER BUT DID NOT GET THE FIRE OUT COMPLETELY AND FIRE DEPARTMENT CAME AND PUT THE FIRE OUT. I HAD HEARD THERE COULD BE A PROBLEM WITH THIS HAPPENING ON OTHER 2003 KIA SEDONA'S. HAVE CONTACTED KIA AND THEY WILL NOT DO ANYTHING UNTIL INSURANCE COMPANY CONTACTS THEM.
ON CERTAIN MINI VANS, FREEZING CONDITIONS CAN CAUSE WATER ON THE THROTTLE CABLE TO FREEZE DURING NORMAL OPERATION. RESISTANCE TO MOVEMENT OF THE THROTTLE CABLE CAN OCCUR WHEN THE DRIVER LIFTS THEIR FOOT OFF OF THE GAS PEDAL.
Consequence & remedy
Consequence: THIS CAN CAUSE THE CABLE TO STICK, THUS PREVENTING THE ENGINE FROM RETURNING TO IDLE AND CAUSING THE VEHICLE TO MAINTAIN SPEED OR ACCELERATE. SUCH AN EVENT CAN OCCUR WITHOUT WARNING AND COULD CAUSE A CRASH.
Remedy: DEALERS WILL MODIFY A PROTECTIVE SLEEVE AROUND THE THROTTLE CABLE. THE RECALL BEGAN ON AUGUST 15, 2005. OWNERS MAY CONTACT KIA AT 1-800-333-4542.
ON CERTAIN MINI VANS EQUIPPED WITH ALLOY WHEELS, MOISTURE CAN ACCUMULATE AROUND THE REAR HUB CAPS CAUSING DAMAGE TO THE OUTER WHEEL BEARING.
Consequence & remedy
Consequence: WHEEL BEARING FAILURE MAY OCCUR WITHOUT WARNING WHICH COULD RESULT IN A CRASH.
Remedy: DEALERS WILL REPLACE THE REAR HUB CAPS FREE OF CHARGE. UPON INSPECTION, SOME VEHICLES WILL ALSO REQUIRE REPLACEMENT OF THE REAR OUTER BEARINGS AND/OR HUB ASSEMBLY. THE RECALL BEGAN ON JUNE 13, 2005. OWNERS MAY CONTACT KIA AT 1-800-333-4542.
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.
ON CERTAIN PASSENGER VEHICLES, THERE WAS A PROGRAMMING ERROR IN THE ANTI-LOCK BRAKING SYSTEM (ABS) ELECTRONIC CONTROL MODULE LOGIC. THE PROGRAMMING ERROR COULD CAUSE REDUCED BRAKING FORCE AT SPEEDS BELOW 25 MPH, WHICH COULD RESULT IN INCREASED STOPPING DISTANCES.
Consequence & remedy
Consequence: SUCH INCREASED STOPPING DISTANCES COULD RESULT IN A CRASH.
Remedy: DEALERS WILL REPROGRAM THE CONTROL MODULE. OWNER NOTIFICATION BEGAN MAY 19, 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
4
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.
PE05035 · Electrical Fire
Opened Jun 28, 2005 · Closed Oct 19, 2005
Status: closed (inferred from source dates) · Electrical System:wiring:interior/under Dash
BY LETTER DATED OCTOBER 4, 2005, KIA NOTIFIED THE AGENCY THAT IT IS CONDUCTING A SAFETY RECALL (NHTSA RECALL NO. 05V463) INVOLVING ALL MODEL YEAR (MY) 2002, 2003 KIA SEDONA EX VEHICLES AND CERTAIN MY 2004 KIA SEDONA EX VEHICLES.KIA?S RECALL COVERS 74,276 VEHICLES.KIA REPORTS THAT FIRES WERE CAUSED BY WIRING UNDER FRONT SEATS BEING MISROUTED; THIS ALLOWED THE WIRE TO BE PINCHED BY METAL SEAT COMPONENTS.OVER TIME, THE SHORT IN THE WIRING UNDER THE SEAT CAUSES OVERHEATING OF COMPONENTS IN THE FUSE BOX (LOCATED UNDER THE DRIVER SIDE INSTRUMENT PANEL).SPECIFICALLY, THE CIRCUIT BREAKER DIODES CYCLE ON-OFF-ON ETC. AND OVERHEAT.KIA WILL INSPECT VEHICLES FOR PROPER WIRE ROUTING AND INSTALL PROTECTIVE COVERING OVER CERTAIN METAL PARTS UNDER FRONT SEATS.DEALERS WILL ALSO APPLY A LABEL WARNING TECHNICIANS NOT TO REMOVE THE CIRCUIT BREAKER DIODES WHICH CANNOT BE SERVICED BUT CAN BE DAMAGED BY REMOVAL ATTEMPTS.BASED ON KIA?S SAFETY RECALL ACTION, THIS INVESTIGATION IS CLOSED.
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.
2003 Kia Sedona Problems, Complaints & Recalls | Skip That Year
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