Front Suspension Control Arm problems of the 2004 Kia Motor Sorento

2004 kia sorrento 97,000 miles. The left and right side rear control arm brackets rusted off.

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.

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. There will eventually be more of these failures and there is a potential for fatal accidents from loss of vehicle control. I am aware that in europe kia has been repairing Sorentos.

The contact owns a 2004 kia Sorento. The vehicle was diagnosed by an independent mechanic who stated that the rear control arm bracket was corroded. The vehicle was not repaired. The manufacturer was not notified. The approximate failure mileage was 112,000.

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.

Two brackets (one left, one right) that hold the rear upper control arms to the rear axle housing have completely snapped off. This leaves a very dangerous condition which will cause the rear axle of the car to rotate and fall out of the car. If this happens at speed, serious injury and/or death is likely. There are many many posts about this same problem online and kia refuses to address the problem stating that it's not a flaw or defect. It is if it happens to almost every vehicle of this year and model. Kia does not offer a replacement bracket that can be welded on and they suggest that the entire rear axle housing assembly is replaced at a cost of several thousand dollars per vehicle. Kia motors refuses to acknowledge the problem or assist affected customers in resolving it.