2009 Kia Borrego Problems: 4 Issues Every Owner Should Know

2009 model year · 220+ owner reports · Updated May 2026

According to Au7o's analysis of 220+ owner reports, the 2009 Kia Borrego has 4 documented known issues, with 3 rated critical. The most serious are 3.8L Lambda V6 Timing Chain Stretch and Rattle ($1,500-$3,500 repair), Transfer Case Chain Noise and 4WD Engagement Failure ($200-$3,000 repair) and Body-on-Frame Rust and Undercarriage Corrosion ($100-$2,000 repair). Across all issues, repair costs range from $100 to $3,500. DIY maintenance guides at au7o.io.

All 4 Known Issues

Community Reported

85 owners

On the 2009-2011 Kia Borrego 3.8L Lambda V6, the Borrego's 3.8L Lambda V6 is prone to timing chain stretch, causing a persistent rattle from the front of the engine. The chain stretches beyond the tensioner's ability to compensate, causing cam timing to drift. This triggers check engine lights for cam position correlation errors. The chain guides also deteriorate, with plastic pieces breaking off and entering the oil pan. If the chain stretches enough to jump a tooth, it causes valve-to-piston contact on this interference engine.

This issue also affects: Buick LeSabre, Buick Park Avenue, Buick Enclave

Common Symptoms

Persistent rattling noise from front of engine
Check engine light with P0016/P0017/P0018/P0019 codes
Rough idle and reduced power
Engine misfires (P0300 series codes)
Noise increases with engine RPM

How to Fix

Replace the timing chain, tensioners, and all chain guides as a complete set. The job requires removing the front timing cover and takes 8-12 hours of labor. Use a quality timing chain kit from Cloyes or Melling with improved chain guide material. Change the oil and filter immediately after the repair to flush out any chain guide debris. This is a preventive replacement — don't wait for the chain to jump.

What Owners Are Using

Parts and tips from 85+ owners who fixed this issue

UpgradeCloyes 9-0908SA timing chain kit — complete set with chains, guides, tensioners, and sprockets for Lambda 3.8L V6 (Cloyes #9-0908SA)
View on Amazon
TipIf the chain is rattling, schedule the repair within 2-4 weeks — do not wait. A jumped chain bends valves and turns a $2,500 repair into a $5,000+ engine rebuild
NoteChange oil immediately after timing chain replacement to flush out plastic guide debris — this debris can clog the oil pickup screen

Typical repair cost:$1,500 - $3,500

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Community Reported

Low Confidence85 reportsLast reported by owners Mar 2026Reviewed Mar 2026

Community Reported

70 owners

On the 2009-2011 Kia Borrego, the Borrego 4WD models use a BorgWarner transfer case that develops chain noise (whining/grinding) and can fail to engage 4WD or 4WD Lock modes. The transfer case chain stretches over time, and the encoder motor that controls mode selection can fail from water intrusion at the electrical connector. The transfer case fluid also breaks down faster than the 60,000-mile factory interval suggests, especially with towing or off-road use.

This issue also affects: Cadillac Escalade ESV, Chevrolet Silverado 2500HD, Chevrolet Silverado 1500

Common Symptoms

Whining noise from underneath vehicle that increases with speed
4WD or 4WD Lock mode won't engage
Service 4WD warning message
Grinding noise when shifting between 2WD and 4WD
Vibration at highway speed from driveline

How to Fix

Change transfer case fluid every 30,000 miles with the correct ATF specification. If chain noise is present, a transfer case rebuild or replacement is needed. The encoder motor can be replaced separately if 4WD mode selection is failing. Inspect the encoder motor wiring connector for corrosion — clean and apply dielectric grease to prevent future water intrusion. A used transfer case from a Mohave (the Borrego's international market name) can be sourced from import recyclers.

What Owners Are Using

Parts and tips from 70+ owners who fixed this issue

TipChange transfer case fluid every 30,000 miles, not the factory 60,000 — the Borrego transfer case runs hotter than most due to vehicle weight
TipInspect the encoder motor wiring connector for corrosion before replacing the motor itself — clean contacts and dielectric grease often fix engagement issues for free
NoteDo not drive with 4WD engaged on dry pavement — this overloads the transfer case chain and accelerates wear
UpgradeMobil 1 75W-90 synthetic gear oil for differential and transfer case (Mobil 1 Synthetic Gear Oil 75W-90)
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UpgradeFel-Pro gasket kit for drivetrain service (Fel-Pro Gasket Kit)
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Typical repair cost:$200 - $3,000

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Community Reported

Low Confidence70 reportsLast reported by owners Mar 2026Reviewed Mar 2026

Community Reported

65 owners

On the 2009-2011 Kia Borrego, the Borrego is one of the few Kia models with a body-on-frame construction (shared with the Mohave platform). The frame is susceptible to surface rust and perforation in rust-belt states, particularly at the rear crossmember and spring perch areas. The frame was not adequately treated with corrosion-resistant coating from the factory. Since the Borrego was discontinued after only 3 model years, rust protection updates were never implemented.

Common Symptoms

Visible orange/brown rust on frame rails
Flaking metal under the vehicle
Clunking noise from loose components on rusted frame mounts
Failed inspection due to frame condition (rust-belt states)
Exhaust system hangers pulling through rusted frame

How to Fix

Inspect the frame annually for surface rust. Wire brush and treat surface rust with a rust converter (POR-15, Corroseal) followed by a rubberized undercoating or Fluid Film. For perforated areas, a qualified frame shop can weld in repair plates. Apply Fluid Film or NH Oil Undercoating annually as a preventive treatment. Focus on the rear crossmember, spring mounts, and fuel tank crossmember.

What Owners Are Using

Parts and tips from 65+ owners who fixed this issue

UpgradeFluid Film NAS undercoating spray — annual application prevents rust progression on exposed frame surfaces (Fluid Film NAS Undercoating)
View on Amazon
TipApply Fluid Film or NH Oil Undercoating every fall before winter — this is the single best investment for preserving the Borrego's frame in salt states
NoteIf frame perforation is found near suspension mounting points, the vehicle should be taken off the road until repaired — a failed mount is a catastrophic safety issue

Typical repair cost:$100 - $2,000

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Community Reported

Low Confidence65 reportsLast reported by owners Mar 2026Reviewed Mar 2026

On the 2009-2010 Kia Borrego, the power steering fluid cooler lines develop leaks at the crimped fittings, causing fluid loss and heavy steering. The cooler is mounted in front of the AC condenser and is exposed to road debris damage.

This issue also affects: Acura TL, Chevrolet Uplander, Mercedes-Benz S-Class

Common Symptoms

Power steering fluid leak
Heavy steering
Groaning noise when turning
Low fluid level in reservoir
Fluid spray on undercarriage

How to Fix

Replace power steering cooler and lines. Flush system with fresh power steering fluid. Inspect steering rack seals for damage from running low on fluid. Top off and bleed system by turning wheel lock to lock with engine running.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

UpgradeCardone remanufactured power steering pump — OE-spec (Cardone Power Steering Pump)
View on Amazon
UpgradePrestone power steering fluid — compatible with most systems (Prestone Power Steering Fluid)
View on Amazon

Typical repair cost:$200 - $450

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Community Reported

Medium Confidence0 reportsLast reported by owners Invalid DateReviewed Invalid Date

Frequently Asked Questions

What are the most common Kia Borrego problems?

According to Au7o's analysis of 220+ owner reports, the 2009-2009 Kia Borrego has 4 documented issues. The most frequently reported are: 3.8L Lambda V6 Timing Chain Stretch and Rattle, Transfer Case Chain Noise and 4WD Engagement Failure, Body-on-Frame Rust and Undercarriage Corrosion. Of these, 3 are rated critical and should be addressed promptly.

Is the Kia Borrego reliable?

The 2009-2009 Kia Borrego has 4 known issues documented across 220+ owner reports. 3 issues are rated critical: 3.8L Lambda V6 Timing Chain Stretch and Rattle and Transfer Case Chain Noise and 4WD Engagement Failure and Body-on-Frame Rust and Undercarriage Corrosion. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Kia Borrego problems?

Repair costs for known Kia Borrego issues range from $100 to $3,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 3.8L Lambda V6 Timing Chain Stretch and Rattle, typically costs $1,500-$3,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2009-2011 Kia Borrego 3.8L Lambda V6 Timing Chain Stretch and Rattle?

The Borrego's 3.8L Lambda V6 is prone to timing chain stretch, causing a persistent rattle from the front of the engine. The chain stretches beyond the tensioner's ability to compensate, causing cam timing to drift. This triggers check engine lights for cam position correlation e… Repairs typically run $1,500-$3,500. Severity: high.

What is the 2009-2011 Kia Borrego Transfer Case Chain Noise and 4WD Engagement Failure?

The Borrego 4WD models use a BorgWarner transfer case that develops chain noise (whining/grinding) and can fail to engage 4WD or 4WD Lock modes. The transfer case chain stretches over time, and the encoder motor that controls mode selection can fail from water intrusion at the el… Repairs typically run $200-$3,000. Severity: high.

What is the 2009-2011 Kia Borrego Body-on-Frame Rust and Undercarriage Corrosion?

The Borrego is one of the few Kia models with a body-on-frame construction (shared with the Mohave platform). The frame is susceptible to surface rust and perforation in rust-belt states, particularly at the rear crossmember and spring perch areas. The frame was not adequately tr… Repairs typically run $100-$2,000. Severity: high.

What is the 2009-2010 Kia Borrego Power Steering Cooler Line Leak?

The power steering fluid cooler lines develop leaks at the crimped fittings, causing fluid loss and heavy steering. The cooler is mounted in front of the AC condenser and is exposed to road debris damage. Repairs typically run $200-$450. Severity: medium.

2009 Kia Borrego Problems: 4 Issues Every Owner Should Know

All 4 Known Issues

2009-2011 Kia Borrego: 3.8L Lambda V6 Timing Chain Stretch and Rattle#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2009-2011 Kia Borrego: Transfer Case Chain Noise and 4WD Engagement Failure#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2009-2011 Kia Borrego: Body-on-Frame Rust and Undercarriage Corrosion#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2009-2010 Kia Borrego: Power Steering Cooler Line Leak#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

Other Kia Models

Frequently Asked Questions

What are the most common Kia Borrego problems?

Is the Kia Borrego reliable?

How much does it cost to fix common Kia Borrego problems?

What is the 2009-2011 Kia Borrego 3.8L Lambda V6 Timing Chain Stretch and Rattle?

What is the 2009-2011 Kia Borrego Transfer Case Chain Noise and 4WD Engagement Failure?

What is the 2009-2011 Kia Borrego Body-on-Frame Rust and Undercarriage Corrosion?

What is the 2009-2010 Kia Borrego Power Steering Cooler Line Leak?