Transfer Case problems of the 2004 Kia Motor Sorento

We purchased our sorrento used (approx 65k miles)about 3 years ago. Since then, we've had to replace the gas tank ($1500) among other things. This year has been absurd: had to replace the radiator, water pump, computer system (2 months, $4700), brakes ($750) and 2 batteries. 2-3 months ago, we noticed a clunking/chunking sound that grew steadily worse. It sounded as if the 4wd was engaging and disengaging every 3 seconds and felt very unsafe at high speeds. I took it to kia of cobb county and was just given a quote Friday for a new transfer case, drive shaft, "rear end chunk" (all the service rep could tell me) and 4 new tires. Quote for this work ($9767). The transfer case alone was around $5700. This vehicle now has 112k miles and is less than 10 years old. The blue book value is (was) around $5-6000 and we're told it'll take $10,000 to fix it? I called kia's corporate office to ask if this was to be expected at kia. I was told that our vehicle was not under warranty. I said, " I'm just asking if there's anyone at kia headquarters who believes in their product and wants to protect the kia name and you just keep apologizing. " the rep responded, "I'm sorry, sir. " we've found multiple complaints online from kia owners reporting similar issues (chunking, transfer case, etc). When does this become. A recall issue? a safety issue?.

My sister purchased this vehicle new and has had nothing but problems with it and problems with dealership/kia honoring their 10 year/100,000 mile warranty. She purchased this vehicle believing she would be driving a quality vehicle (advertising 10 year/100,000 mile warranty she assumed it must be of high quality because who would offer that kind of warranty if it was junk. . . . Wrong!) she has had nothing but stress, financial expense, lost work time, and a battle of her life trying to seek consumer justice. . . Dealership, Kia Motors, lemon law requires a part to fail four times, attorney generals office, conciliation court, writing to ruukivina, oberstar, and most recently amy klobuchar. . . All failed. No one has said that they will investigate kia and protect the consumers from this fraudulent automobile manufacturer. Why? the problems she has had with her vehicle consist of rust on the tailgate and rear doors just a few months after purchasing, all kinds of electrical problems from headlights and tail lights burning out numerous times, the digital dash for radio and heater going black, the heater not work, a relay switch for fan failed, foam between windshield and frame coming out tapping on the window, a problem with the coolant reservoir, the rear driveshaft failed, the transmission had to be replaced and most recently the transfer case. Safety issues and concerns would be with tail lights and headlights burning out prematurely and frequently and the crankshaft bolt broke causing to loose all ability to steer the vehicle. There are probably other problems she has had with the vehicle but I do not recall at this time.

The vehicle has a hesitation on acceleration. It vibrates while on the expressway. The check engine light comes on intermittently while traveling at high speeds. Most recently, the transfer case seized up and the front wheels locked up while I was turning and I almost crashed. It is now in the shop getting the transfer case replaced and I'm told there are even more problems with the transmission. Please advise me on what to do so the company can possibly buy this vehicle back from me.

I am complaining to let you know of a defect in my 2004 kia sorrento v. I. N. [xxx] and a potential highway disaster if the wheels locked up on this vehicle while I'm driving on the highway it will probably cause a major pile-up and lead to a lot of deaths if they don't fix this when I put the vehicle in four wheel drive it is like trying to drive with the emergency brake on I brought it in for service they said that is the way it's supposed to be and I'm not supposed to use the four wheel drive anyway unless it's absolutely needed this was the service manager at kia of lynnfield mass. Phone #781-596-0800 on the 25th of June 2004 I am bringing it in again on July 22nd 2004 but expect the same thing I further went on to question him about using the four wheel drive and he told me I'm not supposed to use it to in rain or snow or for any other reason unless I'm stuck and need it to get out of whatever the problem is so if this vehicle turns up in a disaster you know what happened and where to start your investigation I'm also going to follow up with the mass. Lemon law thank you for listening. Updated 07/25/2012 information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).