2004 Kia Optima Body & Structure Problems

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.

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.

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.

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.

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.

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

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.

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.

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...

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.

I WAS DRIVING ON I-10 WESTBOUND, KATY TX FREEWAY, TRAVELLING ABOUT 65 MILES PER HOUR. THE PASSENGER'S SIDE FRONT TIRE BLEW OUT CAUSING THE CAR TO GO BACK AND FOURTH BETWEEN TWO LANES OF TRAFFIC. IN THE PROCESS, I WAS HITTING THE RUBBER DIVIDERS, DAMAGING THE HOOD OF THE CAR AND THE WINDSHIELD. THE BLOWN TIRE CAUSED DAMAGE TO THE OIL PAN, THE RADIATOR, AND EVENTUALLY THE TRANSMISSION. I GOT THE CAR TO THE EMERGENCY LANE. THE CAR WAS TOWED OFF THE FREEWAY AND EVENTUALLY PICKED UP AND TRANSPORTED TO A CAR REPAIR SHOP. A FEW DAYS LATER, THE INSURANCE ADJUSTER AND THE REPAIR SHOP OWNER BOTH AGREED THE CAR WAS A TOTAL LOSS. I HAD TO BUY A NEW CAR. *TR

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

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. *TR

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 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.

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.

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. *TR

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.