2002 Kia Optima Body & Structure Problems

A fire started inside your driver's side door panel, filling the car with heavy black smoke and making the driver's side door unable to open. Your wife had to escape through the passenger side door and climb over the gear shift and emergency brake to get out. The fire was caused by a faulty electrical actuator in the door mechanism and required the entire door to be replaced.

Your car has developed holes in the sub-frame due to rust and corrosion, which an independent mechanic says requires sub-frame replacement. This issue appeared around 160,000 miles. Fixing this will likely involve removing and replacing the rusted sub-frame, which is a major structural repair.

While your 2002 Kia Optima was being serviced, a mechanic discovered that the subframe—a critical structural component under your vehicle—had rusted through and needed replacement. This is a serious structural issue that affects your vehicle's integrity and safety. The repair would involve removing and replacing the rusted subframe with a new one.

FRONT DOOR FAILS TO UNLOCK AFTER MULTIPLE ATTEMPTS. DOOR MUST BE UNLOCKED WITH A KEY, USING THE POWER LOCKS OR MANUALLY FLIPPING THE DOOR LOCK DOESN'T DO IT, AND THE KEY ONLY UNLOCKS IT APPROXIMATELY 1 OUT OF EVERY 20 TRIES. THERE ARE MULTIPLE COMPLAINTS ABOUT THIS ONLINE, SEE FOR INSTANCE: HTTP://WWW.KIA-FORUMS.COM/1G-2G-2001-2006-MAGENTIS-OPTIMA/47179-2004-OPTIMA-DOOR-LOCK-FAULT.HTML. *TR

TL* THE CONTACT OWNS A 2002 KIA OPTIMA. THE CONTACT STATED THAT WHILE DRIVING SHE HEARD AN UNFAMILIAR SOUND COMING FROM THE UNDER CARRIAGE. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE IT WAS CONFIRMED THAT THE SUB FRAME WAS SEVERELY RUSTED WHICH CAUSED IT TO FAIL. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED ABOUT THE ISSUE. THE FAILURE AND CURRENT MILEAGE WAS NOT AVAILABLE.

TL*THE CONTACT OWNS A 2002 KIA OPTIMA. WHILE DRIVING APPROXIMATELY 45 MPH, THE SUB FRAME SEPARATED FROM THE VEHICLE. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC. THE MECHANIC STATED THE SUB FRAME, TIE ROD, FRONT TIRE AND RIM NEEDED TO BE REPLACED. THE MANUFACTURER WAS CONTACTED AND A COMPLAINT WAS FILED. THE MANUFACTURER ALSO STATED THERE WAS A RECALL (NHTSA CAMPAIGN ID NUMBER: 09V183000 COMPONENT: SUSPENSION: FRONT) BUT THE VIN WAS NOT INCLUDED. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 150,000.

THIS IS CONCERNING MY 2002 KIA OPTIMA, AND THE SUBFRAME RECALL THAT WAS ISSUED ON THIS CAR. . THE SUB FRAME WAS REPLACED DUE TO CORROSION BUT THE GARAGE HAS DONE SOMETHING WRONG BECAUSE THE GRINDING NOISE THAT IS COMING FROM UNDER THIS CAR IS JUST RIDICULOUS! I TOOK THE CAR BACK TO THE KIA DEALER WHO REMOVED THE RUSTED SUB FRAME AND REPLACED IT WITH THE NEW, TO FIND OUT WHY ITS MAKING THIS HORRID NOISE,OH YES THEY ALSO FORGOT TO PUT A BOLT IN. AND STILL DON'T KNOW WHY THE PART IS GRINDING SO. SO THEN I CALLED THE KIA CORPORATION TO LET THEM KNOW THAT MY CAR IS NOT RIGHT AND SOMETHING IS WRONG. AND THEY DID NOTHING BUT PUT IT ON THE COMPUTER I WAS NOT SATISFIED. NOW I HAVE TO TAKE THIS CAR TO A BODY SHOP AND PAY FOR THIS TO BE REPAIRED OUT OF MY POCKET. I KNOW THERE WAS NO PROBLEM WITH THIS BEFORE AND NO NOISE GOING INTO THE SHOP, I DON'T EXPECT THIS TO BE GOING ON NOW. I HAVE TAKEN THIS TO 2 BODY SHOPS ONE BODY SHOP WONT TOUCH IT BECAUSE IT IS A RECALL, THE OTHER WILL TAKE A LOOK AND SEE, HE THINKS THEY BROKE SOMETHING REMOVING THE SUBFRAME. IN EITHER CASE THE CAR NEEDS FIXING OF A PART THAT WAS SUPPOSED TO BE COVERED UNDER A RECALL! WHAT EVER IS WRONG WAS CAUSE BY THIS SUBFRAME. *TR

TL*THE CONTACT OWNS A 2002 KIA OPTIMA. THE CONTACT STATED THAT DURING A ROUTINE OIL INSPECTION A MECHANIC DISCOVERED CORROSION ON THE FRAME. AS A CONSEQUENCE THE ENTIRE FRAME COULD COLLAPSE, WHICH INCREASED THE RISK OF SERIOUS INJURY. HE NOTIFIED THE MANUFACTURER AND WAS ADVISED BY A REPRESENTATIVE THAT THE REPAIR WAS A NON-WARRANTY ITEM, THEREFORE THEY WOULD NOT ASSUME RESPONSIBILITY. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 85,304. *LJ UPDATED 05/07/09.*JB

TL*THE CONTACT OWNS A 2002 KIA OPTIMA. WHILE PERFORMING A ROUTINE OIL CHANGE, THE MECHANIC DISCOVERED THAT THE CRADLE, OR SUBFRAME, UNDERNEATH THE VEHICLE WAS RUSTING OUT. THE MECHANIC STATED THAT ANY MAJOR BUMP COULD CAUSE THE DRIVETRAIN TO COLLAPSE AND POTENTIALLY CAUSE DANGEROUS DRIVING CONDITIONS. HE ALSO STATED THAT THE ENTIRE FRAME COULD COLLAPSE AND SEPARATE THE ENGINE COMPARTMENT FROM THE VEHICLE. THE MANUFACTURER STATED THAT THE FRAME WOULD NOT BE COVERED UNDER WARRANTY AND THEY COULD NOT ASSIST WITH THE REPAIRS. THE FAILURE AND CURRENT MILEAGES WERE 85,304. UPDATED 05/06/09. *LJ UPDATED 05/07/09.*JB

2002 KIA OPTIMA SUB FRAME IS ALL RUSTED OUT DEALER SAYS TOTAL SUSPENSION IS ABOUT TO FAIL NEED TO BE REPLACED THIS IS THE ONLY THING ON THE CAR THAT IS RUSTED OUT. *TR

OUR 2002 KIA OPTIMA EXPERIENCED STEERING PROBLEMS WHICH I THOUGHT COULD BE CORRECTED WITH A BASIC FRONT END ALIGNMENT. REPAIR FACILITY INFORMED US THAT THE VEHICLE COULD NOT BE ALIGNED BECAUSE THE SUB-FRAME HAD RUST DAMAGE. THE SUB-FRAME ON THE PASSENGER SIDE HAD A "GOLF SIZE" HOLE IN IT AND THE WELDING JOINTS WERE COMPLETELY ROTTED THROUGH. THE VEHICLE ONLY HAD 70,000 MILES AND WAS ALWAYS WELL MAINTAINED. OIL CHANGES AND INSPECTIONS WERE PERFORMED AT KIA DEALERSHIPS AND THE DEFECT WAS EITHER NOT DETECTED OR NEVER REPORTED TO US PRIOR TO THE EXPIRATION OF THE WARRANTY. THE DEALER AND KIA MOTORS WERE CONTACTED ABOUT THE ISSUE; KIA DID REPLACE THE SUB-FRAME UNIT (EST COST $1,500) BUT WOULD NOT COVER THE COST FOR LABOR ($655). I BELIEVE A BIGGER PROBLEM EXIST WITH THIS DEFECT AND A RECALL SHOULD BE CONSIDERED TO PREVENT INJURY TO DRIVERS. REVIEWING PREVIOUS COMPLAINTS, THIS SAME DEFECT HAS BEEN REPORTED ON THREE VIN #'S. *TR

2002 KIA OPTIMA, WE HAVE ONLY HAD THE CAR LESS THAN 2 YEARS AND IT HAS 2 FIST SIZE RUST HOLES IN FRAME ONE EACH SIDE BY A-ARMS, DUE TO THESE DEFECTS TIRES WEARING QUICKLY AND NEEDS AIR CONTINUALLY TO BE PUT IN THEM. HANDLING WORSENING AND MAKING THUMPING NOISE IN FRONT END, CAN NOT DRIVE OVER 35-40 MPH. CALLED KIA AND THEY SAID THEY WOULD NOT DO ANYTHING ABOUT THIS PROBLEM. READ WHERE HYUNDAI AND KIA ARE MADE BY SAME COMPANY AND THIS HAS BEEN A PROBLEM WITH THE 1999 TO 2002 MODELS. FEEL THIS IS THEIR RESPONSIBILITY TO MAKE RIGHT BEFORE SOMETHING HAPPENS AND THERE IS AN ACCIDENT. NEED INFORMATION ON WHO TO CONTACT AND HOW TO GET THIS TAKEN CARE OF. *TR

ROTTED SUB FRAME ON 2002 KIA OPTIMA. KIA DOES NOT WANT TO CONSIDER THIS THEIR PROBLEM. *TR