2004 Kia Sorento: ball joint or control arm failure

Filed Jan 10, 2020 · Suspension · 97,000 miles · NY

2004 kia sorrento 97,000 miles. The left and right side rear control arm brackets rusted off.

Filed Feb 15, 2018 · Suspension · 100,000 miles · MA

While driving approximately 35 MPH, the rear of the vehicle shook violently. The vehicle was taken to an independent mechanic who noticed that the crossmember bars were severely corroded through and were not able to be repaired. The vehicle was not repaired. Major safety hazard. The entire bracket holding the differential rusted through. The frame rear cross member also rusted through causing the control arms is detached from the rear end also creating a safety hazard.

Filed Jul 29, 2016 · Suspension, Transmission · 162,000 miles · NJ

Rusted brackets posing a dangerous safety risk, 2004 kia sorento with 162,000 miles. The entire bracket holding the differential rusted through. The frame rear cross member also rusted through causing the control arms is detached from the rear end also creating a safety hazard. There is a design flaw that allows water to stay inside the hollow cross member that caused the corrosion. Drain or weep holes in the cross member and an anti-corrosion coating would have prevented this. When the bracket(s) breaks the rear axle is no longer held in place there are reports on the federal safety agency where these brackets have rotted away and failed causing loss of control of the vehicle. This is a known design flaw that has been appearing on the older cars where the entire frame and rear end would have to be replaced. There will eventually be more of these failures and there is a potential for fatal accidents from loss of vehicle control. I am aware that in europe kia has been repairing sorentos.

Filed Jan 8, 2016 · Suspension · 112,000 miles · OH

Tl* the contact owns a 2004 kia sorento. The vehicle was diagnosed by an independent mechanic who stated that the rear control arm bracket was corroded. The vehicle was not repaired. The manufacturer was not notified. The approximate failure mileage was 112,000. Updated 02/26/16*lj the consumer stated the control arm bracket completely detached from the axle. Updated 03/01/16.

Filed Nov 5, 2015 · Body · 144,000 miles · RI

A section of the main frame rail is rotted completely through, where the rear sway control arm which attaches to the rear drivetrain. The vehicle is unsafe to drive as the rear drivetrain is at risk of detaching from the vehicle.

Filed Sep 21, 2015 · Suspension · 110,000 miles · MA

I brought this vehicle for inspection and was told it will not pass because one of the control arms is detached in the rear end. I was told not to drive the vehicle at all because it is not safe. Additionally there is rot under the entire vehicle. The left side frame was welded and repaired by the previous owner but the right side is now rusted badly and in need of repair. Axles are leaking due to rust. Brakes are a problem but I haven't investigated further to know if its caused by rot. I have been on multiple forums for this issue and it seems many people have same issues especially the control arm problem. I can not return this vehicle because I was scammed and am now stuck with a dangerously rotted car. I am told its not worth fixing. This car looks fine and without looking underneath a person would not know a problem existed perhaps until an accident.

Filed May 13, 2014 · Engine · FL · 1 injury

While driving there was a noise from the engine compartment,power steering failedby the grace of god was able to get the vehicle off of the interstate. Looked under the hood and seen the crank shaft pulley and bolt laying on the tie rod under close examination the spring pin was sheared off from the timing chain pulley. The first time took the vehicle to kia of brandon florida , inwhich they said other things were wrong with the vehicle as well, the total bill came to around 800.00 dollars. I think they just tightened down the bolts because the crank shaft pulley came off again, went back to kia of brandon and they would not repair it, stating that they were not going to repair the vehicle for free, they wanted to charge another 800.00 dollars...so vehicle was taken to a mechanic that reattached the pulley...and the pulley came off again this time the bolt broke off in the crank shaft,the timing chain sprocket also came off. Called the dealership and they are only repairing certain VIN numbers of that year.

Filed Aug 1, 2013 · Body · 114,000 miles · PA

Tl* the contact owns a 2004 kia sorento. The contact stated that while having an annual inspection performed, the technician determined that the upper control arm hangers were completely corroded. As a result, the entire rear end of the vehicle needed to be replaced. The manufacturer was made aware of the failure. The vehicle was not repaired. The failure and current mileage was 114,000. ...updated 12/03/13 *bf the vehicle was repaired on 09/13/13

Filed Sep 12, 2012 · Body · 131,000 miles · NY

Tl* the contact owns a 2004 kia sorento. The contact stated that the brakes were being serviced by a personal mechanic when he noticed that the bracket that held the control arm to the vehicle was rusted. The manufacturer had not been notified. The vehicle was not repaired. The failure and current mileages were 131,000.

Filed Aug 18, 2012 · Suspension, Transmission · 75,000 miles · NJ

Two brackets (one left, one right) that hold the rear upper control arms to the rear axle housing have completely snapped off. This leaves a very dangerous condition which will cause the rear axle of the car to rotate and fall out of the car. If this happens at speed, serious injury and/or death is likely. There are many many posts about this same problem online and kia refuses to address the problem stating that it's not a flaw or defect. It is if it happens to almost every vehicle of this year and model. Kia does not offer a replacement bracket that can be welded on and they suggest that the entire rear axle housing assembly is replaced at a cost of several thousand dollars per vehicle. Kia motors refuses to acknowledge the problem or assist affected customers in resolving it.

Filed Mar 20, 2012 · Suspension · 105,000 miles · NY

Vehicle is only 8 years old. I constantly have this problem. The first time I had this problem I slid while trying to hold brakes, there was also a lot of weird sounds and the rear end did not feel sturdy. I took it to my mechanic and he found metal bracket welded to the rear axle that holds the upper control arms had completely failed! The normal torque from the rear axle was broken both brackets holding the upper control arm to the cars frame. All that is holding the rear axle in place is the lower control arms and the sway bars. There are no weep holes to allow water to drain out of the bracket weldment, causing water to fill the cup-like condition created. This condition has (an will) cause premature failure of all kia sorento rear axle/upper control arm connections. While driving the rear axle could become detached from the vehicle due to excessive stress placed on the remaining parts. Regular driving could cause a catastrophic failure, and render the vehicle uncontrollable, with the likelihood of massive injury and possibly death as a result!!! He also said that it cannot be repaired. This is a huge problem for me because I still have a car note to pay. This is an extremely dangerous condition!!! These cars need to be recalled now before someone is killed!!!

Filed Dec 3, 2011 · Suspension, Transmission · 118,000 miles · OH

Vehicle is only 7 years old. Metal bracket welded to the rear axle that holds the upper control arms has completely failed! The normal torque from the rear axle has broken both brackets holding the upper control arm to the cars frame. All that is holding the rear axle in place is the lower control arms and the sway bars. There are no weep holes to allow water to drain out of the bracket weldment, causing water to fill the cup-like condition created. This condition has (an will) cause premature failure of all kia sorento rear axle/upper control arm connections. While driving the rear axle could become detached from the vehicle due to excessive stress placed on the remaining parts. A typical traffic maneuver could cause a catastrophic failure, and render the vehicle uncontrolable, with the likelyness of massive pain, injury and death as a result!!! This is an extremely dangerous condition!!! These cars need to be recalled now before someone is killed!!! Ps if you see a kia sorento on the freeway...stay away from it for your own safety!