Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
570–25K
2325–50K
4250–75K
3075–100K
25100–150K
4150K+
181 reports with mileage · 218 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.
Engine. Review the 219 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Electrical System. Review the 62 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Power Train. Review the 40 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
14 crash reports27 fire reports17 injury reports
What owners actually said
399 reports
10,500 miles · Oct 23, 2017
Visibility/wiperInjury
MY SUNROOF "EXPLODED" ON SATURDAY, OCT. 14, 2017.I WAS DRIVING ON A HIGHWAY AND THERE WAS SOME TRAFFIC. AFTER THE INITIAL "BOOM" AND RUSH OF WIND WE HEARD GLASS SHATTERING. THE SUNROOF AND SHADE WERE CLOSED, THANKFULLY! I PULLED OVER AND ATTEMPTED TO COLLECT THE GLASS BUT I WAS GETTING CUT SO MOST OF THE GLASS REMAINED ON THE SU…
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MY SUNROOF "EXPLODED" ON SATURDAY, OCT. 14, 2017.I WAS DRIVING ON A HIGHWAY AND THERE WAS SOME TRAFFIC. AFTER THE INITIAL "BOOM" AND RUSH OF WIND WE HEARD GLASS SHATTERING. THE SUNROOF AND SHADE WERE CLOSED, THANKFULLY! I PULLED OVER AND ATTEMPTED TO COLLECT THE GLASS BUT I WAS GETTING CUT SO MOST OF THE GLASS REMAINED ON THE SUN SHADE.
NHTSA ODI #11035763
9,000 miles · Oct 15, 2017
StructureInjury
ON 8/30/17 I WAS DRIVING IN THE MIDDLE LANE OF THE HIGHWAY WHEN MY SUNROOOF EXPLODED. THERE WERE NO OVERPASSES AND VERY FEW CARS AROUND ME SO NOTHING HIT THE SUNROOF TO CAUSE THE EXPLOSION. I WAS ABLE TO SAFELY PULL OVER TO THE SHOULDER BECAUSE OF THE LIGHT TRAFFIC AT THE TIME. NORMALLY THIS SECTION OF THE HIGHWAY IS VERY BUS…
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ON 8/30/17 I WAS DRIVING IN THE MIDDLE LANE OF THE HIGHWAY WHEN MY SUNROOOF EXPLODED. THERE WERE NO OVERPASSES AND VERY FEW CARS AROUND ME SO NOTHING HIT THE SUNROOF TO CAUSE THE EXPLOSION. I WAS ABLE TO SAFELY PULL OVER TO THE SHOULDER BECAUSE OF THE LIGHT TRAFFIC AT THE TIME. NORMALLY THIS SECTION OF THE HIGHWAY IS VERY BUSY AND HAD I BEEN TRAVELING DURING COMMUTING TIMES THE OUTCOME COULD HAVE BEEN VERY DIFFERENT. I HAD A FEW CUTS AND THROBBING EARS FOR TWO DAYS DUE TO THE BUFFETING WIND WHEN THE ROOF OPENED UP. SHARDS OF GLASS COVERED THE ENTIRE INSIDE OF THE CAR AND I AM STILL FINDING GLASS EVEN AFTER THE DEALERSHIP CLEANED THE CAR. THE SUNROOF WAS REPAIRED AFTER LENGTHY DISCUSSIONS WITH KIA HEADQUARTERS. I WAS ABLE TO GET THE CAR BACK ONE MONTH LATER BUT NOW I KEEP THE SHADE CLOSED AND PROBABLY WILL CONTINUE TO DO SO. I PAID EXTRA FOR THIS FEATURE AND NOW WILL NOT USE IT. BILL DODGE KIA IN WESTBROOK MAINE PROMISED TO SEND ME THE REPAIR RECORD BUT HAVE NOT DONE SO TO DATE.
NHTSA ODI #11033456
225 miles · Oct 15, 2017
Exterior Lighting
FMVSS 108,TABLE I-A, DAYTIME RUNNING LAMP (DRL), DEVICE ACTIVATION REQUIRES THAT DRLS BE "AUTOMATICALLY DEACTIVATED WHEN THE HEADLAMP CONTROL IS IN ANY 'ON' POSITION." ON THE 2017 KIA SPORTAGE THE DRLS REMAIN ON WITH THE HEADLAMP CONTROL IN ALL "ON" POSITIONS. THIS GIVES THE APPEARANCE THAT THE HIGH BEAMS ARE ON ALL THE TIME. …
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FMVSS 108,TABLE I-A, DAYTIME RUNNING LAMP (DRL), DEVICE ACTIVATION REQUIRES THAT DRLS BE "AUTOMATICALLY DEACTIVATED WHEN THE HEADLAMP CONTROL IS IN ANY 'ON' POSITION." ON THE 2017 KIA SPORTAGE THE DRLS REMAIN ON WITH THE HEADLAMP CONTROL IN ALL "ON" POSITIONS. THIS GIVES THE APPEARANCE THAT THE HIGH BEAMS ARE ON ALL THE TIME. OPPOSING DRIVES HAVE FLASHED THEIR LIGHTS AT ME TO INDICATE THAT MY HIGH BEAMS WERE ON WHEN THEY WERE NOT. THIS CREATES TENSION AND ANGER IN BOTH DRIVERS. I WAS EVEN STOPPED ONCE BY THE POLICE BECAUSE OF THE HIGH BEAM ON APPEARANCE. SINCE THESE LIGHT FAIL TO MEET FMVSS REQUIREMENTS, KIA SHOULD INITIATE A RECALL TO REMEDY THE PROBLEM. GIVEN THE COMMONALITY OF SYSTEMS MANUFACTURERS USE IN SEVERAL VEHICLE MODELS, OTHER KIA MODELS MAY BE SIMILARLY AFFECTED.
NHTSA ODI #11033443
10,700 miles · Sep 8, 2017
Exterior Lighting
THE FOCUSED BEAM HEADLIGHTS ON LOW BEAM ARE EXTREMELY BRIGHT WHEN SET TO KIA STANDARDS. ONCOMING TRAFFIC PERIODICALLY FLASHES HEADLIGHTS AT ME TO DIM MY HEADLIGHTS WHICH ARE ON LOW BEAM. A FEW ONCOMING CARS HAVE KEPT THEIR HIGH BEAM LIGHTS ON EVEN THOUGH I FLASH MY HIGH BEAMS TO LET THEM KNOW MY LOW BEAMS ARE ON. THE APPROACHING…
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THE FOCUSED BEAM HEADLIGHTS ON LOW BEAM ARE EXTREMELY BRIGHT WHEN SET TO KIA STANDARDS. ONCOMING TRAFFIC PERIODICALLY FLASHES HEADLIGHTS AT ME TO DIM MY HEADLIGHTS WHICH ARE ON LOW BEAM. A FEW ONCOMING CARS HAVE KEPT THEIR HIGH BEAM LIGHTS ON EVEN THOUGH I FLASH MY HIGH BEAMS TO LET THEM KNOW MY LOW BEAMS ARE ON. THE APPROACHING HIGH BEAM LIGHTS PARTIALLY BLIND ME RESTRICTING MY VISION. SOME CARS I AM FOLLOWING INDICATE MY LOW BEAM LIGHTS ARE TOO BRIGHT BY SLOWING DOWN OR USING THE TURN SIGNAL FLASHERS TO INDICATE MY LIGHTS ARE TOO BRIGHT. THESE ACTIONS OCCUR ON STATE HIGHWAYS WHILE I AM DRIVING AT NIGHT. I HAVE AN OPEN CASE WITH KIA. CASE NUMBER 12446047. KIA CUSTOMER SERVICE HAS ADVISED THEY CAN DO NO MORE BECAUSE THE FOCUSED BEAM HEAD LIGHTS ARE SET PER KIA SPECIFICATIONS.
NHTSA ODI #11022317
Mileage unknown · Jul 13, 2017
Exterior Lighting
RE: 2017 KIA SPORTAGE EX. THE REAR TURN SIGNALS AND THE BACK-UP LIGHTS ARE IN-CONSPICUOUSLY LOCATED. 16" LOWER THAN TAIL/BRAKE LIGHTS AND LOWER THAN LICENSE PLATE DEEMS A PROBABLE TRAFFIC SAFETY HAZARD. THE 9" CURVED LENSES ILLUMINATE APPROX 2-3 " IN THE REAR AND APPROX 6-7" ON THE SIDE. A CERTAIN DAYTIME HAZARD. VERY POOR ENGI…
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RE: 2017 KIA SPORTAGE EX. THE REAR TURN SIGNALS AND THE BACK-UP LIGHTS ARE IN-CONSPICUOUSLY LOCATED. 16" LOWER THAN TAIL/BRAKE LIGHTS AND LOWER THAN LICENSE PLATE DEEMS A PROBABLE TRAFFIC SAFETY HAZARD. THE 9" CURVED LENSES ILLUMINATE APPROX 2-3 " IN THE REAR AND APPROX 6-7" ON THE SIDE. A CERTAIN DAYTIME HAZARD. VERY POOR ENGINEERING THIS PROBABLE UNSAFE HAZARD TAKES PLACE EVERY TIME THE TURN SIGNALS ARE APPLIED OR THE VEHICLE IS IN REVERSE. AN ACCIDENT HAS NOT OCCURRED DIRECTLY OR INDIRECTLY TO THIS COMPLAINT...YET. THIS COMPLAINT IS ONGOING SINCE I PURCHASED THE VEHICLE, 5/17/2017. PLEASE INVESTIGATE AND RETURN FURTHER INFORMATION. THANK YOU
NHTSA ODI #11005140
400 miles · May 19, 2017
Unknown Or Other
HAVE BEEN FIGHTING WITH KIA SINCE I PURCHASED THIS CAR IN DEC. OF 2016 TO NO AVAIL. PAID AN ADDITIONAL $4700 TO GET THE AUTONOMOUS BRAKING SYSTEM WHICH DOES NOT WORK. I HAVE GONE TO OTHER KIA DEALERS UNDER THE GUISE OF PURCHASING THIS VEHICLE AND NOT ONE OF THE FOUR DEALERS THAT I TESTED THE CAR AT COULD GET THIS SYSTEM TO WORK.…
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HAVE BEEN FIGHTING WITH KIA SINCE I PURCHASED THIS CAR IN DEC. OF 2016 TO NO AVAIL. PAID AN ADDITIONAL $4700 TO GET THE AUTONOMOUS BRAKING SYSTEM WHICH DOES NOT WORK. I HAVE GONE TO OTHER KIA DEALERS UNDER THE GUISE OF PURCHASING THIS VEHICLE AND NOT ONE OF THE FOUR DEALERS THAT I TESTED THE CAR AT COULD GET THIS SYSTEM TO WORK. I HAVE INFORMED KIA OF THIS FACT BUT JUST KEEP STONE WALLING ME. MY NEXT COURSE OF ACTION IS TO GO TO THE BBB, I THINK YOU SHOULD KNOW ABOUT THIS SINCE IT IS A VERY IMPORTANT SAFETY ISSUE. I ALSO INTEND TO INFORM THE CENTER FOR AUTO SAFETY AND CONSUMER UNION WHO HIGHLY RATED THIS CAR. HOPE TO HEAR FROM YOU SOON [XXX] [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).'*JB
NHTSA ODI #10990684
6,350 miles · May 14, 2017
Engine
WHILE TRAVELING AT HIGHWAY SPEED MY VEHICLE EXPERIENCED NEAR INSTANT LOSS OF MORE THAN 50% ENGINE POWER WITH CONTINUAL LOST OF THE REMAINING POWER. MOVING FROM THE MIDDLE LANE INTO THE RIGHT LANE WAS DIFFICULT AND RISKY DURING HEAVY TRAFFIC. I WAS LUCKY FINDING A SAFE SPOT TO PULL OVER. AMBLING TO THE SAFE SPOT THE ENGINE SPU…
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WHILE TRAVELING AT HIGHWAY SPEED MY VEHICLE EXPERIENCED NEAR INSTANT LOSS OF MORE THAN 50% ENGINE POWER WITH CONTINUAL LOST OF THE REMAINING POWER. MOVING FROM THE MIDDLE LANE INTO THE RIGHT LANE WAS DIFFICULT AND RISKY DURING HEAVY TRAFFIC. I WAS LUCKY FINDING A SAFE SPOT TO PULL OVER. AMBLING TO THE SAFE SPOT THE ENGINE SPUTTERED, HESITATED AND REACTED VERY LITTLE TO ANY FOOT ACTION ON THE THROTTLE, LEAVING ME WITHOUT THE ABILITY TO EFFECTIVELY CONTROL THE VEHICLE.
NHTSA ODI #10985641
4,400 miles · Mar 28, 2017
Exterior Lighting
WHEN PURCHASED IN MAY, 2017, THE HEADLIGHTS HAD TO BE ADJUSTED AS THEY WERE AIMED TOO HIGH. THE ADJUSTMENT MADE THE LIGHTS TOO LOW AND WITH A VERY SHORT "CUT-OFF" POINT. IT IS ALMOST IMPOSSIBLE TO SEE THE ROADWAY IN FRONT OF THE VEHICLE AT NIGHT.
NHTSA ODI #10969185
5,343 miles · Jan 30, 2017
EngineVehicle Speed Control
TL* THE CONTACT OWNS A 2017 KIA SPORTAGE. WHILE DRIVING APPROXIMATELY 75 MPH ATTEMPTING TO PASS ANOTHER VEHICLE, THE SPEED DROPPED TO APPROXIMATELY 50 MPH AND THE ACCELERATOR PEDAL DID NOT RESPOND WHEN DEPRESSED. THE CONTACT DROVE THE VEHICLE HOME AT A VERY SLOW SPEED. THE FAILURE HAD BEEN OCCURRING SINCE THE BEGINNING OF JANUAR…
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TL* THE CONTACT OWNS A 2017 KIA SPORTAGE. WHILE DRIVING APPROXIMATELY 75 MPH ATTEMPTING TO PASS ANOTHER VEHICLE, THE SPEED DROPPED TO APPROXIMATELY 50 MPH AND THE ACCELERATOR PEDAL DID NOT RESPOND WHEN DEPRESSED. THE CONTACT DROVE THE VEHICLE HOME AT A VERY SLOW SPEED. THE FAILURE HAD BEEN OCCURRING SINCE THE BEGINNING OF JANUARY AND THE CHECK ENGINE WARNING INDICATOR WAS CONSTANTLY ILLUMINATED. THE DEALER DID NOT HAVE THE REMEDY AVAILABLE TO REPAIR THE VEHICLE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 5,343.
NHTSA ODI #10948543
12,000 miles · Jan 24, 2017
EngineVehicle Speed Control
I HAVE HAD 4 INSTANCES OF WHAT FEELS LIKE THE CAR SLIPPING OUT OF "DRIVE". WHILE IN DRIVE, WHEN I PRESS ON ACCELERATOR BUT WHILE THE RPM'S GO UP, THE CAR DOESN'T MOVE.. ONCE I REMOVE MY FOOT AND THEN PRESS AGAIN ON THE ACCELERATOR, IT PROCEEDS NORMALLY. KIA CANNOT FIND ANYTHING WRONG WITH VEHICLE BUT LAST INSTANCE WAS LESS TH…
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I HAVE HAD 4 INSTANCES OF WHAT FEELS LIKE THE CAR SLIPPING OUT OF "DRIVE". WHILE IN DRIVE, WHEN I PRESS ON ACCELERATOR BUT WHILE THE RPM'S GO UP, THE CAR DOESN'T MOVE.. ONCE I REMOVE MY FOOT AND THEN PRESS AGAIN ON THE ACCELERATOR, IT PROCEEDS NORMALLY. KIA CANNOT FIND ANYTHING WRONG WITH VEHICLE BUT LAST INSTANCE WAS LESS THAN 30 DAYS AGO. THIS IS AFTER KIA HAD TO REPLACE THE BLOCK THE FIRST MONTH OF OWNERSHIP OF THIS BRAND NEW VEHICLE.
Kia America, Inc. (Kia) is recalling certain 2016-2022 Sorento, 2021-2022 Sorento Hybrid (HEV), 2022-2023 Sorento Plug-In Hybrid (PHEV), and 2017-2022 Sportage vehicles equipped with a tow hitch harness installed as original equipment, or purchased as an accessory through a Kia dealership. Debris and moisture accumulation on the tow hitch harness module printed circuit board (PCB) may cause an electrical short, which can result in a fire.
Consequence & remedy
Consequence: A fire while parked or driving can increase the risk of injury.
Remedy: Owners are advised to park outside and away from structures until the recall repair is complete. Dealers will inspect the vehicle, and, as necessary, replace the fuse and/or tow hitch harness module, free of charge. Owner notification letters were mailed August 11, 2023. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC249.
Kia Motors America (Kia) is recalling certain 2017-2021 Sportage and Cadenza vehicles. The electrical circuit in the Hydraulic Electronic Control Unit (HECU) may short-circuit, which can cause a fire in the engine compartment.
Consequence & remedy
Consequence: An engine compartment fire can increase the risk of injury.
Remedy: Owners are advised to park outside and away from structures as a precaution until the recall repair is complete. Kia will notify owners, and dealers will replace certain fuses in the electrical junction box. Vehicles equipped with an electronic parking brake (EPB) will also receive a HECU software update. Repairs will be performed free of charge. The recall began on April 30, 2021. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC206.
Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.
Consequence & remedy
Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.
Additional source detail variants (2)
Engine
Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.
Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.
Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.
Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.
Kia Motors America (Kia) is recalling certain model year 2016-2017 Sorento vehicles manufactured October 27, 2014, to August 25, 2016, and 2017 Sportage vehicles manufactured December 10, 2015, to August 26, 2016. The affected vehicles are equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."
Consequence & remedy
Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.
Remedy: Kia will notify owners, and dealers will replace the trailer tow hitch harness, free of charge. The recall began January 18, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC142.
Additional source detail variants (2)
Trailer Hitches
Kia Motors America (Kia) is recalling certain model year 2016-2017 Sorento vehicles manufactured October 27, 2014, to August 25, 2016, and 2017 Sportage vehicles manufactured December 10, 2015, to August 26, 2016. The affected vehicles are equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."
Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.
Remedy: Kia will notify owners, and dealers will replace the trailer tow hitch harness, free of charge. The recall began January 18, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC142.
Electrical System
Kia Motors America (Kia) is recalling certain model year 2016-2017 Sorento vehicles manufactured October 27, 2014, to August 25, 2016, and 2017 Sportage vehicles manufactured December 10, 2015, to August 26, 2016. The affected vehicles are equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."
Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.
Remedy: Kia will notify owners, and dealers will replace the trailer tow hitch harness, free of charge. The recall began January 18, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC142.
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
2
AQ23002 · Hyundai And Kia Abs Module Fires
Opened Nov 17, 2023 · No close date supplied
Status: open (inferred from source dates) · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module
The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.
DP22003 · Loss Of Motive Power
Opened Sep 12, 2022 · Closed Dec 12, 2023
Status: closed (inferred from source dates) · Engine
The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing. There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
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