2004 Kia Sorento Problems

What owners report

Owners of the 2004 Sorento most often write about rusted rear suspension brackets and cross members that no longer hold the rear axle in place, and about the crankshaft pulley bolt breaking off while driving and taking the accessory belts and power steering with it. Reports also cover coolant reservoir and radiator leaks that lead to overheating, hard or delayed shifting, and frequent bulb and battery failures. Most complaints arrive well past 60,000 miles, and many describe gradual rust and wear rather than a sudden failure.

1. 1
   Suspension

   Rusted rear brackets and cross member (rear axle)

   • 51 complaints (23%)
   • median 111,000 mi at 11.2 yrs old (46 state mileage)
   • owner-quoted repair $4,000 (median of 5 quotes)
   • filed 2004–2020

   Owners describe the brackets welded to the rear axle, and the rear cross member, rusting through until the upper control arms or the differential carrier come loose from the frame. They often hear a bang or feel the rear end step out, or the problem is found during an inspection or an oil change. Several say the dealer or mechanic told them not to drive the vehicle and that replacement parts were not available; others report the repair was quoted but not carried out at the manufacturer's expense. Mostly reported between roughly 50,000 and 165,000 miles on older vehicles, often after the vehicle has been driven in road-salt climates.

   What to check: Look underneath at the rear cross member and the brackets joining the axle to the frame; poke at any flaking metal and check for perforation. Have the vehicle inspected on a lift before purchase, especially if it came from a state that salts its roads.

   2 excerpts from owner complaints in NHTSA records

   “My son was driving this car when he heard a loud bang and lost control of vehicle while driving in a roundabout in taunton mass and nearly crashed this vehicle due to losing the ability of stabilizing it, but was able to pull off to side of road thankfully because of the speed of travel at the time, thankfully he was not on the highway or I may be telling a different story. …”

   NHTSA complaint #10648938, filed 2014-10, 125,000 miles

   “Took my car in for nys inspection and was alerted to an issue with my rear suspension. The rear cross member is completed rotted out and the upper trailing arm have become separated from the cross member due to rust and corrosion. This is a 2004 Kia Sorento ex that I purchased new and now has 103,000 miles. This corrosion is an extremely hazardous situation and the vehicle cannot be repaired. Needless to say it cannot be driven.”

   NHTSA complaint #11132949, filed 2018-10, 103,000 miles
2. 2
   Engine

   Crankshaft pulley bolt breaks off

   • 61 complaints (28%)
   • median 96,000 mi at 9.1 yrs old (49 state mileage)
   • 2 mention a crash, fire or injury
   • owner-quoted repair $3,000 (median of 9 quotes)
   • filed 2004–2021

   Complaints describe the crankshaft or harmonic balancer bolt shearing off while driving, so the pulley and belts come off and power steering assist is lost. Some owners report the noise and stall happening more than once, including after the bolt or pulley was replaced. Dealers replaced the bolt or pulley in some cases and told owners the engine or crankshaft might need replacement in others; several owners mention that a prior campaign had already been performed on their vehicle. Reported from very low mileage up to about 160,000 miles, with many between roughly 35,000 and 110,000 miles.

   1 related service bulletin

   What to check: Ask whether the crankshaft pulley bolt has been replaced and keep records of it, since owners describe repeat failures. Listen for belt squeal or a rattling noise from the front of the engine and check that power steering assist is steady.

   2 excerpts from owner complaints in NHTSA records

   “We have had 4 instances with the same issue in the fixing the pulley crank shaft. June 30, 08, (recall) october 6, 09, aug 10, 10 and once again sept 18,12. This is the same issue that causes you to loose steering while driving with apparently no warning. I find this extremely troubling as we have a new driver learning with this car. We are lucky to report that there have been no accidents or deaths but I think it is a very dangerous situation that will soon happen. …”

   NHTSA complaint #10476561, filed 2012-09, 77,178 miles

   “I was driving the car when I suddenly started hearing rattling noises from the engine. The power steering stopped working and the steering wheel would not turn. Thankfully, I was on a side street with no other traffic. If I had been in traffic or traveling at a higher speed, this would surely have caused a crash. My mechanic says that the crankshaft bolt is sheared off and must be drilled out to be replaced. Kia won't cover this expensive repair, says it is not covered by their warranty. …”

   NHTSA complaint #10498323, filed 2013-02, 74,000 miles
3. 3
   Engine cooling

   Coolant leaks and overheating (reservoir, radiator)

   • 23 complaints (10%)
   • median 64,000 mi at 6.0 yrs old (21 state mileage)
   • owner-quoted repair $4,300 (median of 6 quotes)
   • filed 2005–2013

   Owners report the coolant overflow reservoir or radiator cracking and leaking, sometimes with no warning, followed by the temperature gauge climbing and the engine stopping. Complaints describe steam, lost coolant and a resulting engine replacement, and say the dealer attributed the damage to overheating after the leak. Others mention replacing the radiator, water pump and related parts within a short period. Often reported between roughly 45,000 and 90,000 miles, on both low- and higher-mileage vehicles.

   2 related service bulletins

   What to check: Check the coolant level and look for cracks, residue or staining on the plastic reservoir and around the radiator seams. Ask whether the timing belt and cooling components have been serviced, since a leak can lead to overheating.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2004 Kia sorrento which I purchased new. It currently had 64,000 mile and I have kept up with all maintenance items and have had them performed by Kia service in the dealership. While I have had some mechanical problems with the car (bad lifters, valves, radiator leaks, etc), my main issue is the electrical system. To date, I have replaced various brake light bulbs, headlight bulbs, dome light bulb and my radio unexplainable turns on/off. …”

   NHTSA complaint #10215316, filed 2008-01, 64,000 miles

   “Just normal driving the reserve radiator tank split at the seem. The car has 60,000 miles on it. It leaked all over in my garage and my two puppies almost licked up the coolant from the floor.”

   NHTSA complaint #10420851, filed 2011-08, 60,000 miles
4. 4
   Transmission and drivetrain

   Hard or delayed shifting, transfer case noise

   • 13 complaints (6%)
   • median 10,243 mi at 1.3 yrs old (11 state mileage)
   • filed 2004–2015

   Owners describe a delay or hesitation before the vehicle moves after being put in gear, hard or tight shifting, and a clunking that sounds like the four-wheel-drive system cycling on and off. Some report the transfer case failing and the vehicle being difficult to control, with the dealer quoting a transfer case replacement. Others note vibration or noise on acceleration that was traced to the driveshaft or rear differential. Reported from very low mileage up to around 115,000 miles, including several vehicles under 10,000 miles.

   2 related service bulletins

   What to check: Test the shift from park and reverse to drive when cold and note any delay or clunk. Ask whether the transmission fluid and transfer case have been serviced, and have the driveshaft and differential checked for play and noise.

   2 excerpts from owner complaints in NHTSA records

   “Since buying my Sorento in february 2004, I have noticed that the car sometimes has to think before going into gear and there is no predictability as to when this will happen. In example I was in the center lane merging into traffic when the car just would not get going it hesitates and then drops into gear. I have taken the car in and the service manager said that he has had several complaints like mine but there is nothing he could do to help. …”

   NHTSA complaint #10093245, filed 2004-09, 5,000 miles

   “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.”

   NHTSA complaint #10106296, filed 2005-01, 14,000 miles
5. 5
   Electrical system

   Lights, battery and electrical gremlins

   • 34 complaints (15%)
   • median 100,000 mi at 8.4 yrs old (27 state mileage)
   • 5 mention a crash, fire or injury
   • filed 2007–2019

   Owners report repeated failures of headlight, tail, fog and brake light bulbs, batteries that fail early, and a cooling fan that keeps running after the engine is shut off until the battery drains. Some describe the radio turning on and off on its own, and dash lights dimming with the engine losing power. Complaints note that electrical checks found no fault, and that the dealer did not identify a cause. Reported from about 5,000 to 150,000 miles, with many cases in the 60,000 to 100,000 mile range.

   1 related service bulletin

   What to check: Walk around with the lights on and off and confirm every lamp works, and ask how often bulbs have been replaced. After a test drive, make sure the cooling fan stops when the engine is switched off.

   2 excerpts from owner complaints in NHTSA records

   “I was driving approximately 35-40 MPH and my car suddenly lost power with all the dash lights briefly coming on (battery, oil, etc.). Fortunately I was close to a side street and was able to make a hard turn and coast to the curb. I waited a minute and was able to restart the vehicle. I drove home and there was one more incident when the car started to lose power (lights dimmed) however I pushed on the gas and it powered up again. I have had the lights dim and the car seemingly lose power several times. …”

   NHTSA complaint #10749069, filed 2015-08, 92,400 miles

   “The original battery failed at 2 1/2 years and the replacement battery (Kia battery) failed after only 1 1/2 years. I have replaced the headlights (4 times), fog lights (2 times), tail lights (2 times), and license plate light. Electrical system check showed no problems that could be causing all of these failures.”

   NHTSA complaint #10224893, filed 2008-04, 46,800 miles

Buying note. A pre-purchase inspection on a lift matters more than mileage on this model year: check the rear frame and bracket condition first, then the crankshaft pulley bolt and cooling system records. Well-kept examples exist, but budget for rust repair and for the accessories that appear repeatedly in owner reports.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.