Au7o mascotAu7o
Known IssuesTest Hub demo
  1. Au7o
  2. /
  3. Known Issues
  4. /
  5. Kia
  6. /
  7. Optima
Kia · Known Issues

2004 Kia Optima Problems: 1 Known Issue

2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026

Share:@au7o.io

2004 · All trims · All engines

Choose the year and equipment for your written issues and visual request.

No email neededHow interest is saved

Interest applies to the selected vehicle and configuration; it is not a reservation. Voting stores a first-party identifier for up to 180 days to prevent repeat votes. No account or email is needed. Clearing cookies or using another device may count separately. Privacy

Visual coming soon

Your interest helps us choose what to build next.

Visual Known Issues · Coming soon

$4.99/month plus taxes at launch · No payment today

Preview the XT6 example
Known IssuesMotorcycle IssuesDTC LookupDrivePricingAboutTermsPrivacyCookiesConsentData rightsCopyrightFeedback
Share:@au7o.io

Vehicle data and repair guidance on this site are compiled with AI assistance and may contain errors. Always verify with your service manual or a qualified mechanic.

Data protection representation

DataRep representative in the United KingdomDataRep representative in the European Union
Au7o · 2026
Built for DIY mechanics. Privacy-first.
Explore free Hub demo
Issue summary

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Kia Optima has 1 documented issue, with 1 rated critical. The most serious is Front Subframe Corrosion and Suspension Collapse. DIY maintenance guides at au7o.io.

In This Article

  • Optima Suspension1
  • Recalls4
  • FAQ
Get Started
Back to top

In This Article

  • Suspension1
  • Recalls4
  • FAQ

All 1 Known Issue

Filter:
ALL YEARS20202019201820172016201520142013201220112010200920082004200320022001

On the 2001-2004 Kia Optima, nHTSA recall 09V-183 covers 2001-2004 Optimas originally sold in or currently registered in specified salt-belt states and the District of Columbia. Road salt can cause progressive internal corrosion of the front subframe near the lower-control-arm connection, leading to wheel misalignment, steering stress or abnormal tire wear; subframe separation can cause a crash.

Common Symptoms

  • Wheel misalignment
  • Noticeable steering stress
  • Accelerated abnormal tire wear

How to Fix

Check the VIN and registration history for recall 09V-183 eligibility and have the free Kia dealer repair completed. Do not select control arms or other parts from this page before the subframe is inspected under the campaign; no retail part is linked for the VIN- and corrosion-dependent remedy.

Research This Issue

GoogleRedditYouTubeNHTSA
Manually Verified
High ConfidenceVerifiedReviewed Aug 2026
NHTSA Recalls4 recalls

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

SOME PASSENGER VEHICLES MAY CONTAIN A FUEL TANK ASSEMBLY VALVE THAT MAY NOT CLOSE PROPERLY. IF A VEHICLE WITH A FUEL TANK ASSEMBLY VALVE THAT IS NOT PROPERLY CLOSED WERE TO ROLL OVER, FUEL SPILLAGE MAY OCCUR.

Campaign #04V18000012/04/2004

SUSPENSION:FRONT

KIA MOTORS CORPORATION (KMC) IS RECALLING 36,538 MODEL YEAR 2001-2004 OPTIMA VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. ROAD SALT APPLIED IN THESE STATES DURING THE WINTER MONTHS MAY RESULT IN PROGRESSIVE, INTERNAL CORROSION OF THE FRONT SUBFRAME. OVER TIME, SUCH SUBFRAME CORROSION NEAR THE CONNECTION TO THE LOWER CONTROL ARM CAN LEAD TO WHEEL MISALIGNMENT AND/OR OTHER NOTICEABLE STRESS IN STEERING, OR ACCELERATED ABNORMAL TIRE WEAR.

Campaign #09V18300027/05/2009

ELECTRICAL SYSTEM:STARTER ASSEMBLY

ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH 2.5 AND 2.7 LITER V6 ENGINES, THE CRANKSHAFT POSITION SENSOR (CKP) CASES DID NOT MEET DIMENSIONAL SPECIFICATIONS.

🔧
A mechanic who knows YOUR exact car
Answers tuned to your year, make, model & trim — not generic advice. Save your garage so it always has the right context.
Get ahead of Kia Optima problems — free
Leave your email and we'll alert you the moment there's a new recall or known issue for your Kia Optima. Free, no account needed.

Don't see your problem? Describe your symptoms to get a diagnosis, or get a full repair guide.

Other Kia Models

Kia Forte31Kia Telluride28Kia Carnival26Kia Sportage25Kia K523Kia EV621

Frequently Asked Questions

What are the most common Kia Optima problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Kia Optima has 1 documented issue. The documented issue is: Front Subframe Corrosion and Suspension Collapse. Of these, 1 is rated critical and should be addressed promptly.

Is the Kia Optima reliable?

The 2004 Kia Optima has 1 known issue compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 1 issue is rated critical: Front Subframe Corrosion and Suspension Collapse. 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.

What is the 2001-2004 Kia Optima Front Subframe Corrosion and Suspension Collapse?

NHTSA recall 09V-183 covers 2001-2004 Optimas originally sold in or currently registered in specified salt-belt states and the District of Columbia. Road salt can cause progressive internal corrosion of the front subframe near the lower-control-arm connection, leading to wheel mi… Severity: high.

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data compiled from NHTSA recalls, manufacturer TSBs, automotive forums, and AI-assisted research. No aggregated owner-report counts available for this vehicle yet.

Campaign #03V06700004/03/2003

AIR BAGS:SIDE/WINDOW

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE SIDE AIR BAG WIRE HARNESS FOR THE DRIVER POSITION COULD BE MIS-ROUTED, WHICH COULD RESULT IN IT BEING PINCHED OR CUT BY THE SEAT CUSHION TILT MECHANISM.

Campaign #01V15600001/05/2001

Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.