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April 16, 2024 NHTSA CAMPAIGN NUMBER: 24V271000
Improperly Tightened Differential Bolts
A loss of drive power or differential lock up can increase the risk of a crash.
NHTSA Campaign Number: 24V271
Manufacturer Kia America, Inc.
Components POWER TRAIN
Potential Number of Units Affected 8
Summary
Kia America, Inc. (Kia) is recalling certain 2023 Niro EV and 2024 EV9 vehicles. The differential gear bolts in the gear drive unit may not be tightened properly, which can result in a loss of drive power or cause the differential to lock up.
Remedy
Dealers will replace the gear drive unit, free of charge. Owner notification letters are expected to be mailed May 17, 2024. Owners may contact Kia customer service at 1-800-333-4542. Kia’s number for this recall is SC308.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Check if your Kia has a Recall
2023MY Niro EV & 2014MY EV9
Gear Drive Unit (GDU) Chronology
Basis of Safety Defect Determination 573.6(c)(6)
March 11, 2024
Kia Corporation (Kia HQ) informs Kia North America (Kia NA) Safety Office of two (2) customer complaints in the global market of noise while driving from the Gear Drive Unit (GDU) involving 2023MY Niro EV vehicles. Kia HQ provides Kia NA Safety Office with preliminary investigation results. Returned parts show differential gear bolts within the GDU insufficiently torqued resulting in noise and damage to GDU housing.
Kia HQ’s review of supplier torque data indicates insufficient torque of differential gear bolts in certain GDUs in Niro EV and EV9 vehicles. Kia HQ confirms no related EV9 claims in global market.
Kia NA Safety Office requests Kia HQ evaluate any potential loss of motive power associated with condition.
March 20, 2024—April 2, 2024
Kia HQ conducts vehicle testing of a Niro EV GDU with artificially loosened differential gear bolts. Kia HQ shares results with Kia NA Safety Office and identifies loosened differential bolts will result in drivetrain noise. As bolts are loosened, damage to GDU housing can occur and a potential loss of motive power may result.
Kia NA Safety Office monitors field data.
April 9, 2024
Kia HQ confirms differential lockup is also a potential consequence if the vehicle continues to be operated in this condition. Kia HQ provides potentially affected VINs based on a review of vehicle production and supplier records.
April 10, 2024
Kia NA Safety Office field data analysis confirms no incidents in the U.S. associated with condition.
April 10, 2024
Kia NA decides to recall certain 2023MY Niro EV and certain 2024MY EV9 vehicles. No injuries, crashes, or fatalities.
2 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| KIA | EV9 | 2024 |
| KIA | NIRO EV | 2023 |
3 Associated Documents
Recall Acknowledgement
RCAK-24V271-4412.pdf 645.376KB
2023MY Niro EV & 2024MY EV9 Gear Drive Unit (GDU) Chronology
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Defect Notice 573 Report
RCLRPT-24V271-2924.PDF 214.157KB
Latest Recalls Documents
For the Latest and Most recent Recall Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V271&docType=RCL
- Contains extraordinary anti-wear and lubricity agents, ensuring exceptional protection against wear and reducing drag
- Helps to control heat
- Incorporates Lucas cutting-edge additive technology derived from top-rated Lucas Heavy Duty Oil Stabilizer, the number one supplemental oil in the heavy-duty industry
- Available in 1 quart and 1 gallon bottle sizes
- Protects against severe temperatures to help extend service life
- Formulated with extreme-pressure additives to minimize gear wear from shock loads
- Helps protect against gear wear from scuffing, scouring, corrosion and pitting
- Recommended for conventional hypoid differentials and non-synchronized manual transmissions in passenger cars, light trucks, sport utility vehicles, vans and heavy-duty trucks where an API-GL5 or GL-4 fluid is specified
- Formulated To Maintain Excellent Low Temperature Fluid Protection.Fit Type: Universal Fit
- Helps Provide Outstanding Thermal Stability For Cleanliness And Longer Service Life
- Contains Special Additives To Assist In Protecting Gear Teeth From Rust And Corrosion And Reduce Chattering In Limited-Slip Differentials
- Recommended For Conventional And Limited Slip Differentials And Non-Synchronized Manual Transmissions Where Api Gl-5 Or Api Gl-4 Fluid Is Specificed
- Contains extraordinary anti-wear and lubricity agents, ensuring exceptional protection against wear and reducing drag
- Helps to control heat
- Incorporates Lucas cutting-edge additive technology derived from top-rated Lucas Heavy Duty Oil Stabilizer, the number one supplemental oil in the heavy-duty industry
- Available in 1 quart and 1 gallon bottle sizes
- Mobil 1 Synthetic Gear Lube LS is a supreme performance, synthetic, multipurpose, automotive gear lubricant
- Meet or exceed the highest level of performance requirements of many modern passenger vehicles – including limited slip applications
- Helps protect against thermal and oxidative degradation, wear and corrosion, and viscosity loss associated with premature shearing
- Promotes outstanding power transfer performance - even in some of the most severe driving conditions
- Sold as 6 pack
- Direct replacement for Mercury Marine 858064K01
- Lower unit gear oil formulated to protect against corrosion and excessive wear
- Designed for outboard motor lower unit and sterndrive applications above 75hp
- Extreme pressure synthetic additives protect gears from metal to metal contact
- SAE 90 viscosity
- Provides excellent protection against wear under extreme pressure and high torque operation
- High resistance to thermal breakdown
- Helps prevent foaming, rust, and corrosion
- Smooths and quiets operation
- Protects against oxidative degradation
- Contains “climbing additives” that ensure total lubrication
- Fortified with anti-wear and lubricity agents that combat wear and drag
- Designed for hypoid gears and power dividers
- Non-foaming
- Can be used in limited slip differentials
- Fit Type: Vehicle Specific
- Package Dimensions: 31.75 H x 15.24 L x 15.24 W (centimeters)
- Country of Origin : United States
- Package Weight: 3.447 kilograms
- Fit type: Vehicle Specific
- Package Dimensions: 31.0 H x 15.0 L x 15.0 W (centimeters)
- Country of Origin : China
- Package Weight: 7.892 pounds
Last update on 2024-04-19 / Affiliate links / Images from Amazon Product Advertising API
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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-271
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Kia America, Inc. APR 16, 2024 NHTSA Recall No. : 24V-271 Manufacturer Recall No. : SC308 Manufacturer Information :
Manufacturer Name : Kia America, Inc.
Address : 111 Peters Canyon Road
Irvine CA 92606 Company phone : 800-333-4542
Population :
Number of potentially involved : 8
Estimated percentage with defect : 1 %
Vehicle Information : Vehicle 1 : 2023-2023 Kia Niro EV Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : Certain 2023 model year Niro EV vehicles manufactured from November 7, 2022 through May 16, 2023 (4 units). The recall population was determined by a review of vehicle and supplier production records. The vehicles subject to this recall were not produced in VIN order.
Customers seeking information about their specific vehicle will be referred to Kia’s Customer Care Center or their Kia dealer. Production Dates : NOV 07, 2022 – MAY 16, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2024-2024 Kia EV9 Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : Certain 2024 model year EV9 vehicles manufactured from October 27, 2023 through December 14, 2023 (4 units). The recall population was determined by a review of vehicle and supplier production records. The vehicles subject to this recall were not produced in VIN order.
Customers seeking information about their specific vehicle will be referred to Kia’s Customer Care Center or their Kia dealer. Production Dates : OCT 27, 2023 – DEC 14, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 24V-271 Page 2 Description of Defect :
Description of the Defect : The differential gear bolts within the vehicle’s Gear Drive Unit (GDU) may not have been properly torqued during the assembly by the differential gear supplier. Over time, the differential bolts within the GDU may loosen and damage the GDU housing and/or reduction gear while driving. Continued driving with a grinding noise from a damaged GDU housing or reduction gear may result in a loss of motive power and/or cause the differential to lock up.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : A loss of motive power and/or differential lock up increases the risk of a
crash.
Description of the Cause : Improperly torqued differential gear bolts. Identification of Any Warning
that can Occur : Grinding noise while driving. Involved Components : Component Name 1 : NIRO EV: MOTOR-GDU ASSY Component Description : Gear Drive Unit Assembly Component Part Number : 36501-0EDA0 Component Name 2 : EV9: MOTOR-GEAR DRIVE UNIT ASSY, RR
Component Description : Gear Drive Unit Assembly Component Part Number : 44000-18MD0 Supplier Identification : Component Manufacturer
Name : Hyundai Transys
Address : 105 Sindang 1-ro, Seongyeon-myeon, Chungcheongnam-do Seosan-Si Foreign States 31930
Country : Korea, Republic of The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-271
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Chronology :
See attached document titled “2023MY Niro EV & 2024MY EV9 Gear Drive Unit (GDU) Chronology”.
Description of Remedy :
Description of Remedy Program : All owners of the subject vehicles will be notified by first class mail with
instructions to bring their vehicles to a Kia dealer. Kia dealers will replace the Gear Drive Unit with a new one.
Kia will reimburse owners for repair expenses already incurred pursuant to Kia’s General Reimbursement Plan filed May 10, 2022.
How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
The differential gear bolts in the remedy component have been properly torqued.
Niro EV vehicles manufactured beginning on 5/17/2023 and EV9 vehicles manufactured beginning 12/15/2023 are equipped with Gear Drive Units with properly torqued differential bolts Recall Schedule :
Description of Recall Schedule : The planned dealer notification begin and end date is April 19, 2024. The
planned owner notification begin and end date is May 17, 2024.
Planned Dealer Notification Date : APR 19, 2024 – APR 19, 2024
Planned Owner Notification Date : MAY 17, 2024 – MAY 17, 2024
* NR – Not Reported
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