Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Kia Sorento owners, lightly cleaned up (personal details are redacted by NHTSA).
Rusted brackets posing a dangerous safety risk, 2004 Kia Sorento with 162,000 miles. The entire bracket holding the differential rusted through. The frame rear cross member also rusted through causing the control arms is detached from the rear end also creating a safety hazard. There is a design flaw that allows water to stay inside the hollow cross member that caused the corrosion. Drain or weep holes in the cross member and an anti-corrosion coating would have prevented this. When the bracket(s) breaks the rear axle is no longer held in place there are reports on NHTSA where these brackets have rotted away and failed causing loss of control of the vehicle. This is a known design flaw that has been appearing on the older cars where the entire frame and rear end would have to be replaced. …
Was driving wife to work , stopped at light when light turned green I pushed the gas pedal and I heard a bang so loud I thought someone hit us from behind. I drove car home and looked under it and I couldn't believe it ! The rust on the rear end brackets and the two bars connected to them were totally rusted through and hanging off. I went to the Kia dealer where I originally bought the car and asked them about it they said they never heard of that problem. I told them there are hundreds of complaints on the internet about it ,they told me don't believe everything you see on the internet. Then they said that it's not a Kia problem it's a road salt problem. I told them nothing else under the car was rusted that bad , and I believe it's a design problem. They said there is nothing they can do, so now I have a car with only 83,000 miles on it that is too dangerous to drive. …
My daughter took my car a 2004 Kia Sorento in for a nysi and the shop dead lined the car and made me flatbed it home due to the fact that the rear end was falling out due to excessive rot on the brackets and they deemed the car unsafe to drive. The women that runs the shop told my daughter and son that this isn't the first time that she has seen this on a Kia. In fact its a prevalent issue! Upon coming home I did some research on the internet and found that this is a major issue that the federal government should be looking into ordering Kia to do a recall,my daughter could have been killed driving this vehicle.I also saw on the internet that in the uk Kia had taken care of this issue with consumers. I would like consideration in having Kia repair this car free or purchace the vehicle back at blue book pricing. …
On Monday, August 10th, 2015 I was driving my 2004 Kia Sorento lx and heard a loud bang and then the vehicle began to fishtail. I was traveling at a low speed of around 35 MPH. I immediately slowed down and managed to drive the vehicle to a nearby garage. At the garage the vehicle was placed on the lift and it was identified that the drivers side frame rail had completely broken in half and was severely corroded. The passenger side was also severely corroded but not broken all the way through. The cross-member above the rear axle is almost completely gone. I now have an 11 year old vehicle which should have a retail value of around $5K which is now completely worthless. I did some internet research and found I am not the only one experiencing this severe corrosion problem with this year and model Kia. I am surprised there have been no safety recalls for this problem. …
I brought this vehicle for inspection and was told it will not pass because one of the control arms is detached in the rear end. I was told not to drive the vehicle at all because it is not safe. Additionally there is rot under the entire vehicle. The left side frame was welded and repaired by the previous owner but the right side is now rusted badly and in need of repair. Axles are leaking due to rust. Brakes are a problem but I haven't investigated further to know if its caused by rot. I have been on multiple forums for this issue and it seems many people have same issues especially the control arm problem. I can not return this vehicle because I was scammed and am now stuck with a dangerously rotted car. I am told its not worth fixing. This car looks fine and without looking underneath a person would not know a problem existed perhaps until an accident.
Picked up vehicle after having rear support bearings repaired driving back home at 65mph on I-35/texas 410 east started to experience strong smell of exhaust fumes in passenger compartment. During drive home started to rain, activated wipers, drivers side wiper blade fell off during rainstorm had to open driver side window to navigate! Upon arrival at home noticed, smoke coming from engine compartment (passengers side) and smoke underneath vehicle from catalytic converter. Looked underneath vehicle and catalytic converter, was smoking, inside engine compartment a hose at the rear of the engine compartment (sorry not a mechanic) had a hole in it and was smoking also? Vehicle has not been driven since 12/7/12, vehicle was purchased 10/4/12, has limited warranty.
Rusted brackets recalled in europe, refused by Kia to replace even tho they were rusted under warranty, pose a dangerous safety risk to unsuspecting owners. The entire bracket holding the differential rusted through creating a safety hazard. Presented with a small squeak in rear. I asked Kia to send people letters warning and they would not address the request. How Kia is getting away with severe rust, causing safety hazards in all vehicles, is beyond me. I know they are less expensive, is it worth it? Can someone please address the issue and at least let the public know it is happening before someone gets severely injured or god forbid dies. There are thousands still on the road. I paid for their diagnostic worthlessness to make sure it was documented.
This is a follow up to NHTSA id #10852665. I contacted manufacturer regarding the rusted frame. Suggested towing to dealer for diagnosis. Towed to dealer, who called saying it was bad and to call Kia back. Called Kia and a case was opened #k3156514. Was told I would hear back by Wednesday the 6th of April have not received any return calls, left 2 voicemails car is still at dealer, its been 8 days and no info..Kia needs to step up and recall these vehicles before someone gets killed! This complaint starts at 2003 and so far have read up to 2005 for thi issue. Europe recalled it but not here? Mileage was 92000 not 82000.
Tl* the contact owns a 2004 Kia Sorento. The contact stated that the stability bar/torque bar that supports the rear suspension for the tire was not structurally sound and had extensive rust and corrosion on the piping. The parts needed to be replaced. The mechanic indicated that the manufacturer needed to provide a permanent repair or solution to repair the vehicle, and recommended that the vehicle be inspected and diagnosed by a dealer. The manufacturer was notified of the failure. The approximate failure mileage was 150,000. Updated 10/13/16
While driving approximately 35 MPH, the rear of the vehicle shook violently. The vehicle was taken to an independent mechanic who noticed that the crossmember bars were severely corroded through and were not able to be repaired. The vehicle was not repaired. Major safety hazard. The entire bracket holding the differential rusted through. The frame rear cross member also rusted through causing the control arms is detached from the rear end also creating a safety hazard.
Suspension complaints in other Sorento years
Frequently asked questions
How common are suspension problems on the 2004 Kia Sorento?
NHTSA has 30 complaints about the suspension of the 2004 Kia Sorento, 14% of the model year's 220 complaints. The component named most often is front › control arm › lower ball joint (1 mentions).
Is there a recall for 2004 Kia Sorento suspension problems?
No. NHTSA lists no suspension recall for the 2004 Kia Sorento. 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 Sorento suspension problems start?
Half of the complaints with a recorded mileage happened before about 103,000 miles.
Is it dangerous?
Owners linked 1 crash, 1 fire and 0 injuries to suspension 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.