2004 KIA Optima body problems

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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.

NHTSA complaint #11480899 — an unverified report by a vehicle owner.

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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

NHTSA complaint #11081243 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #11051307 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #10981452 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #10943813 — an unverified report by a vehicle owner.

STRUCTURE:BODY:DOOR

TL* THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE DRIVER'S SIDE DOOR FAILED TO UNLOCK. THE CONTACT WAS ABLE TO GAIN ACCESS AFTER SEVERAL ATTEMPTS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 101,000.

NHTSA complaint #10934627 — an unverified report by a vehicle owner.

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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...

NHTSA complaint #10913613 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #10893697 — an unverified report by a vehicle owner.

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

NHTSA complaint #10837709 — an unverified report by a vehicle owner.

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OUT OF NOWHERE MY DAUGHTER'S CAR DOOR WOULD NOT OPEN, TRAPPING HER INSIDE. IT WON'T OPEN WITH THE KEY OR REMOTE. I CALLED KIA AND THEY SAID MY WARRANTY RAN OUT AND THERE IS NO RECALL DESPITE THIS BEING A COMMON ISSUE-- A VERY DANGEROUS SAFETY ISSUE I MUST SAY, SINCE THE DRIVER AND PASSENGERS COULD POSSIBLY BE TRAPPED AND DIE IN AN EMERGENCY.

NHTSA complaint #10807653 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #10790123 — an unverified report by a vehicle owner.

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SUB 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...

NHTSA complaint #10785782 — an unverified report by a vehicle owner.

STRUCTURE:BODY:DOOR

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.

NHTSA complaint #10723224 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #10714185 — an unverified report by a vehicle owner.

STRUCTURE:BODY:DOOR

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.

NHTSA complaint #10691649 — an unverified report by a vehicle owner.

STRUCTURE:FRAME AND MEMBERS

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.

NHTSA complaint #10681555 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #10652810 — an unverified report by a vehicle owner.

STRUCTURE:BODY:DOOR

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.

NHTSA complaint #10598494 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #10595400 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #10566354 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #10538400 — an unverified report by a vehicle owner.

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THE PASSENGER WHEEL CAME OFF THE CAR AS MY SON WAS BACKING OUT OF A PARKING SPACE AT A GROCERY STORE. I BOUGHT THIS CAR NEW. THAT PART OF THE CAR HAD NEVER BEEN WORKED ON. THE CAR HAD TO BE TOWED TO A GARAGE FOR REPAIR. KIA USED GLUE ON LIFE A SUPPORT NUT ON A BALL JOINT, WHERE THEY SHOULD HAVE USED A COTTER PIN. I HAVE BOUGHT FOUR (4) KIAS. THESE CARS ARE STILL IN THE FAMILY. THE KIA I DRIVE DAILY IS IDENTICAL (EXCEPT BEING AUTOMATIC) TO THE ONE THAT THE WHEEL CAME OFF.

NHTSA complaint #10534657 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #10532663 — an unverified report by a vehicle owner.

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ON MY 2004 KIA OPTIMA WHEN I UNLOCK THE DOORS WITH THE KEY ALL DOORS UNLOCK EXCEPT THE DRIVERS DOOR REAL BIG SAFETY CONCERN, IF I GET STUCK IN MY CAR DURING AN ACCIDENT AN CANNOT GET OUT I WILL SUE KIA MOTOR COMPANY FOR NOT ISSUING A SAFETY RECALL, I HAVE ALSO NOTICE A LOT OF POSTINGS BASED UPON THIS ISSUE ON FIXYA.COM FOR THE 2003-2006 KIA OPTIMA NEED ATTENTION ASAP.

NHTSA complaint #10507295 — an unverified report by a vehicle owner.

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THE DRIVERS DOOR WILL NOT OPEN EITHER FROM THE INSIDE OR THE OUTSIDE. THE DOOR REMAINS LOCKED AS THE BUTTON AND KEY DO NOT FULLY UNLOCK IT. USING BOTH BUTTON AND KEY AT THE SAME TIME, I WAS ABLE TO UNLOCK THE DOOR AND OPEN IT. DISSASSEMBLY OF THE DOOR AND LATCH LOCATED THE PROBLEM TO BE THE DOOR LATCH MECHANISM. THE DOOR LATCH IS DESIGNED TO FAIL AS EVIDENCED BY THE NUMBER OF COMPLAINTS LISTING THIS PART. THE LEVER THAT IS MOVED INTO PLACE WHEN THE DOOR IS UNLOCKED IS BLOCKED BY THE CAM THAT IT INTERFACES WITH BECAUSE THE CAM HAS ROTATED BEYOND THE POINT THAT IT SHOULD. THIS HAS THE POTENTIAL TO TRAP SOMEONE IN THE CAR IF IT SHOULD FAIL AT THE WRONG TIME.

NHTSA complaint #10502154 — an unverified report by a vehicle owner.

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DRIVERS SIDE DOOR WILL NOT OPEN WITH THE POWER LOCK OR BY KEY, I HAVE BEEN GETTING IN AND OUT OF MY CAR BY USING THE PASSENGER FRONT DOOR. MY HUSBAND FOUND A WAY TO UNLOCK MY DRIVER SIDE DOOR, NOW I CAN NOT LOCK MY CAR AGAIN.

NHTSA complaint #10458697 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #10446385 — an unverified report by a vehicle owner.

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DRIVER DOOR REFUSED TO OPEN. I HAVE A DISABILITY SO THIS CREATED A HUGE PROBLEM FOR ME. WHEN I PUT GAS IN MY CAR (REGARDLESS OF GRADE OR GAS STATION) MY CAR REFUSES TO START. WHEN I MAKE A U-TURN, MY CAR MAKES LOUD CLICKING SOUND. I HAD IT CHECKED...MY AXLE AND EVERY THING ELSE LOOKS FINE. NO ONE CAN ESTABLISH WHERE THE NOISE COMES FROM. MY CAR HAS LESS THAN 60,000 MILES ON IT, AND IT SHOULD NOT HAVE ALL THESE ISSUES BUT IT DOES.

NHTSA complaint #10444977 — an unverified report by a vehicle owner.

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

NHTSA complaint #10443894 — an unverified report by a vehicle owner.