2004 Kia Optima Structure

Door lock/unlock mechanism has failed. Unable to unlock and open door from outside or inside. This defect causes the door to stay locked and unable to open. This can trap people inside of the car if they are unable to crawl out a window or exit from another door. There are many reports of this on Kia forums and general Google search. There was no warning that this part was wearing out until it became impossible to open the door.

WHILE STATIONARY - DRIVER'S SIDE DOOR WILL NOT OPEN FROM INSIDE OR OUTSIDE WITH KEY, MANUAL LOCK OR ELECTRONIC LOCK CONTROLS (STUCK CLOSED). UNABLE TO EVACUATE CAR FROM DRIVER'S SIDE. SAFETY CONCERN - LACK OF EGRESS

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. WHEN THE VEHICLE WAS TAKEN TO BILL DORATY KIA (2925 MEDINA RD, MEDINA, OH 44256, (330) 721-9500) FOR ROUTINE BRAKE SERVICE, THE TECHNICIAN FOUND A CRACK IN THE FRONT FRAME. THE DEALER STATED THAT THE VEHICLE WAS SAFE TO DRIVE AT THAT TIME. THE CONTACT WAS INFORMED THAT THE FRAME WOULD NEED TO BE REPLACED, BUT NO REPAIRS WERE MADE. SINCE WINTER WAS APPROACHING, THE CONTACT WAS CONCERNED THAT THE FRAME WOULD COMPLETELY CRACK DUE TO THE WEATHER AND SALTED ROADWAYS IN HER STATE. THE CONTACT RECEIVED A MANUFACTURER RECALL AND EXTENDED WARRANTY NOTICES IN 2009. THE VEHICLE WAS TAKEN TO THE DEALER, BUT NO ISSUES WERE FOUND. THE DEALER SENT PICTURES OF THE CRACKED FRAME TO THE MANUFACTURER. THE MANUFACTURER WAS NOTIFIED AND ISSUED CASE NUMBER: 2560103. THE MANUFACTURER STATED THAT THEY WOULD CONTACT THE LOCAL DEALER. THE CONTACT WAS AWAITING A CALL BACK FROM THE MANUFACTURER AND DEALER. THE FAILURE MILEAGE WAS APPROXIMATELY 48,000.

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT HEARD AN ABNORMAL LOUD SOUND FROM THE VEHICLE WITHOUT WARNING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT DEALER WHERE IT WAS DIAGNOSED THAT THE FRAME FAILED. THE VEHICLE WAS SERVICED PER AN UNKNOWN RECALL; HOWEVER, THE REMEDY FAILED TO REPAIR THE VEHICLE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 178,000.

DRIVER DOOR DOES NOT OPEN FROM INSIDE NOR FROM OUTSIDE. WHEN UNLOCKING THE DOORS, ALL DOORS WILL OPEN EXCEPT THE DRIVER'S DOOR. CENTER LOCK MECHANISM OR MANUAL USE OF KEYS DOES NOT HELP. THIS IS WITHOUT A DOUBT A SAFETY PROBLEM WHERE DRIVER CAN BE TRAPPED IN THE CAR IN CASE OF EMERGENCY. THIS IS VERY COMMON IN KIA OPTIMA MODELS.

DRIVER DOOR WOULD NOT OPEN FROM INSIDE OR OUT. POWER DOOR LOCK WOULD AUTOMATICALLY RE-LOCK ALL DOORS WHEN ATTEMPTING TO OPEN OR UNLOCK WITH KEY OR INSIDE LOCK LEVER. HAD TO CRAWL OVER CONSOLE TO GET IN OR OUT WHEN FINALLY ABLE TO GET PASSENGER FRONT DOOR TO OPEN. FINALLY ABLE TO GET DOOR OPEN BY HOLDING KEY CYLINDER IN UNLOCK POSITION AND FORCING HANDLE TO OPEN. UNHOOKED DOOR LOCK ACTUATOR. AS LONG AS LOCKED OR UNLOCKED DOOR WITH KEY ONLY, DOOR WOULD OPEN. IF LOCKED DOOR WITH INSIDE LOCK LEVER, DOOR WOULD NOT OPEN AGAIN. MECHANIC REPLACING THE DRIVER FRONT DOOR LATCH ASSEMBLY REPAIRED VEHICLE. VERY DANGEROUS SITUATION IF IN ACCIDENT OR VEHICLE FIRE.

PASSENGER AND DRIVER DOOR LOCKS WILL NOT UNLOCK 85% OF THE TIME, PREVENTING NORMAL ENTRY TO / EXIT FROM THE VEHICLE. MULTIPLE ATTEMPTS USING THE KEY IN THE DOOR LATCH ARE REQUIRED TO GAIN ENTRY THE OTHER 15% OF THE TIME. THIS IS A HUGE SAFETY ISSUE IN CASE OF CRASH, FIRE, OR CARJACKING. INTERNET RESEARCH SHOWS THIS TO BE A COMMON ISSUE AROUND 100K MILES. THIS SHOULD BE A RECALL EVENT...

BOTH DRIVER AND PASSENGER DOORS WON'T OPEN, EVEN THOUGH THEY ARE UNLOCKED. THE CAR COULD BE ON OR OFF WITH THIS PROBLEM.

THE 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.

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE FRONT DRIVER'S SIDE DOOR WOULD NOT UNLOCK. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSIS OR REPAIRS. THE MANUFACTURER WAS NOT MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 105,000.

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

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT WHILE TRAVELING APPROXIMATELY 5 MPH, THE VEHICLE EMITTED A LOUD POP. UPON INSPECTION, IT WAS FOUND THAT THE SUB FRAME HAD FAILED. THE CONTACT WAS INFORMED BY THE DEALER THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER 09V183000 (SUSPENSION). THE MANUFACTURER WAS NOT CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 110,000.

I WAS ON A WEEKEND TRIP AND WHEN I GOT TO MY DESTINATION I WAS UNABLE TO UNLOCK OR OPEN THE DRIVER'S SIDE DOOR. I HAD TO CRAWL OUT THE PASSENGER SIDE DOOR. I AM BACK HOME NOW. I HAVE TRIED SPRAYING SOME LUBRICANT ON DOOR LATCH BUT I STILL CAN NOT GET IT TO OPEN. *JS

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE FRONT DRIVER'S SIDE DOOR FAILED TO UNLOCK, WHICH PREVENTED ACCESS IN ENTERING OR EXITING THE VEHICLE. THE CONTACT WOULD HAVE TO ACCESS THE FRONT PASSENGER SIDE DOOR TO ENTER OR EXIT THE VEHICLE. THE VEHICLE HAD NOT BEEN DIAGNOSED OR REPAIRED. THE MANUFACTURER HAD NOT BEEN NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 105,000.

DRIVERS DOOR WOULD NOT OPEN FROM INSIDE OR OUT, IT HAPPENED THREE TIMES AND THE STARTED WORKING AGAIN. *TR

TL* THE CONTACT OWNS 2004 KIA OPTIMA. THE CONTACT STATED THAT THE FRONT PASSENGER DOOR WAS INOPERABLE. ONCE LOCKED, IT COULD NOT BE OPENED FROM THE INTERIOR OR EXTERIOR OF THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS CONTACTED AND ADVISED THAT THERE WERE NO RECALLS FOR THE FAILURE AND OFFERED NO FURTHER ASSISTANCE. THE FAILURE MILEAGE WAS 93,580.

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THE DRIVERS SIDE DOOR WILL NOT OPEN WHEN IT'S UNLOCKED. THE CONTACT HAD TO ENTER THE VEHICLE THROUGH THE PASSENGER SIDE DOOR. THE CONTACT WAS UNABLE TO DETERMINE WHAT CAUSED THE DRIVERS SIDE DOOR TO MALFUNCTION. THE FAILURE WAS NOT DIAGNOSED BY A DEALER NOR A LOCAL MECHANIC. THE FAILURE MILEAGE WAS 95,000.

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE DRIVER SIDE DOOR WAS DEFECTIVE AND WOULD NOT OPEN FROM NEITHER THE INSIDE OR OUTSIDE OF THE VEHICLE. THE DEALER DIAGNOSED THAT A MODULE INSIDE THE DOOR WOULD NEED TO BE REPLACED. THE MANUFACTURER WAS NOT CONTACTED AND THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 85, 960 AND THE CURRENT MILEAGE WAS 86,000.

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE FRONT DRIVER SIDE DOOR WOULD BECOME STUCK AND HE WAS UNABLE TO OPEN THE DOOR. THE CONTACT WOULD HAVE TO EXIT THE VEHICLE THROUGH THE PASSENGER SIDE DOOR. THE CONTACT STATED THE VEHICLE WAS PREVIOUSLY REPAIRED FOR THE FAILURE FOUR YEARS PRIOR TO THE MOST RECENT RECURRENCE. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 32,000 AND THE CURRENT MILEAGE WAS 98,000.

THE RECALL CONCERNING THE 01 -04 KIA OPTIMA SUBFRAME CAUSING THE CAR TO BE UNABLE TO MAINTAIN ALIGNMENT IS NOT BEING HONORED BY DEALERS. I HAVE MADE MULTIPLE ATTEMPTS TO EITHER CONTACT DEALERS FOR AN APPOINTMENT TO WHICH THEY WOULD NOT RETURN PHONECALLS OR E-MAILS, OR IN ONE CASE ACTUALLY GOT HOLD OF A DEALER WHO TOLD ME THAT AT 130,000 MILES IT WAS TIME TO REPLACE THE SUBFRAME AND THAT I WOULD HAVE TO PAY FOR IT. I HAVE BEEN EATING TIRES AND HAVE NOT BEEN ABLE TO KEEP THIS CAR ALIGNED AFTER THE FIRST 20,000 MILES. I CONTINUE TO DRIVE THIS CAR BECAUSE I AM UNABLE TO REPLACE IT. I HAVE HAD TO PUT 2 CLUTCHES IN IT (THE FIRST ONE AFTER 29,000 MILES. FOR THE RECORD I HAVE DRIVEN STANDARDS FOR 27 YEARS BEFORE THIS AND HAD NEVER HAD TO REPLACE A CLUTCH) AND FOUND OUT AFTER THE SECOND CLUTCH (WHICH AT NO TIME WOULD KIA ACKNOWLEDGE A DESIGN FLAW OR ANY CULPABILITY) THAT THE ORIGINAL CLUTCHES WERE NOT LASTING ON THESE CARS AND A STANDARD PRESSURE PLATE CLUTCH HAD REPLACED THE ORIGINAL UNDER AN ENGINEERING CHANGE INSTEAD OF A RECALL. THIS CAR IS UNSAFE AND KIA CORPORATION AND ANY DEALER I HAVE ATTEMPTED TO CONTACT SO FAR HAS REFUSED EVER TO MAKE GOOD ON ANY ASPECT OF THIS CAR. THIS CAR AND ANY 01-04 KIA OPTIMA SHOULD HAVE TO BE REPLACED BY THE KIA CORPORATION FOR THEIR BLATANT DISREGARD TO THE CONSUMER FOR THEIR SAFETY AND COSTS. I AM GOING TO ATTEMPT A MEDIA BLITZ TO INFORM THE AMERICAN PUBLIC OF THIS BLATANT DISREGARD AND THESE SAFETY ISSUES IN THE NEXT FEW WEEKS AND FELT YOU WOULD WANT TO KNOW IN ORDER TO GET YOUR DATA IN ORDER. *TR

RECEIVED RECALL LETTER FROM KIA JUNE15,2009, POSSIBILITY OF CORROSION OF THE SUBFRAME. I CALLED MY DEALER WITHIN A COUPLE OF DAYS AND WAS TOLD NO PARTS IN THEY WOULD CALL ME. ON AUG. 03 I CALLED THE KIA CONSUMER ASSISTANCE CENTER AND THEY CALLED THE DEALER AND WAS TOLD STILL NOT PARTS. I WAS TOLD I WOULD BE CALLED BACK WITHIN TWO DAYS TO LET ME KNOW WHY NO PARTS HOWEVER IT WAS THE SAME NO CALL. I AM CONCERNED THAT MY CAR MAY BE FAULTY AND I CAN GET NO SERVICE OR HELP. IF IT IS A RECALL WHY CAN I NOT GET HELP TO HAVE IT CHECKED. KIA MOTORS AMERICA INC. GAVE NO REPLY AND THE DEALER STILL SAYS NO PARTS. ON AUG 15TH IT WILL BE TWO MONTHS AND NO HELP. THANK YOU (THIS IS FROM A RECALL LETTER TO ME). *TR