Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Kia Optima owners, lightly cleaned up (personal details are redacted by NHTSA).
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.
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.
Tl* the contact owns a 2004 Kia Optima. When the vehicle was taken to bill doraty Kia (2925 medina rd, medina, oh 44256, [phone]) 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. …
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.
Tl* the contact owns a 2004 Kia Optima. While driving at approximately 20 MPH, the power steering seized. Also, the subframe was fractured. The vehicle was not taken to a dealer and was not diagnosed or repaired. The manufacturer was notified of the failure. The contact believed that the failure was related to NHTSA campaign number: 09V183000 (suspension). The approximate failure mileage was 91,700.
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 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.
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.
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 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.
Body complaints in other Optima years
Frequently asked questions
How common are body problems on the 2004 Kia Optima?
NHTSA has 42 complaints about the body & structure of the 2004 Kia Optima, 19% of the model year's 225 complaints. The component named most often is body (28 mentions).
Is there a recall for 2004 Kia Optima body problems?
No. NHTSA lists no body & structure recall for the 2004 Kia Optima, though it has 1 recall for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Kia Optima body problems start?
Half of the complaints with a recorded mileage happened before about 105,000 miles, and 3% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 0 injuries to body & structure problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.