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
2023 MY NIRO EV & 2024 MY EV9 VEHICLES – GEAR DRIVE UNIT (GDU)
SAFETY RECALL CAMPAIGN (SC308)
Q & A
April 19, 2024
Q1. What type of campaign is Kia conducting?
A1. Kia America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act, is conducting a Safety Recall Campaign to address a condition involving the Gear Drive Unit (GDU).
Q2. What vehicles are affected by the recall?
A2. Certain 2023 MY Niro vehicles manufactured from November 7, 2022 through May 16, 2023 and Certain 2024 MY EV9 vehicles manufactured from October 27, 2023.
Q3. How many customer vehicles are affected by this recall?
A3. 8 vehicles (4 units of Niro EV and 4 units of EV9 vehicles).
Q4. What is the concern with the Gear Drive Unit (GDU)?
A4. The differential gear bolts within the Gear Drive Unit (GDU) in the subject vehicles 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 drive power and/or cause the differential to lock up. A loss of drive power and/or differential lock up increases the risk of a crash.
Q5. Can you describe the recall campaign and fix?
A5. Kia dealers will replace the GDU assembly with a new one.
Q6. How will owners of the affected vehicles be notified?
A6. All owners of the subject vehicles will be notified by first class mail with instructions to contact their authorized Kia dealer to have the recall campaign performed beginning on May 17, 2024.
Q7. What should vehicle owners do when they receive the notification?
A7. Upon receipt of the letter, owners are to contact their authorized Kia dealer to arrange to have the recall campaign performed on their vehicle free of charge at no cost to them.
Q8. Where were these vehicles produced?
A8. The affected vehicles were produced at a Kia assembly plant in South Korea.
Q9. Will this cost vehicle owners any money?
A9. No. Kia will perform the recall repair free of charge at no cost to the customer.
Q10. Are there any restrictions on an owner’s eligibility?
A10. No.
Q11. If a customer has an immediate question, where can they get further information?
A11. The customer can contact their local authorized Kia dealership or call Kia’s Customer Care Center at 1-800-333-4KIA (4542), Monday through Friday, 5 AM to 6 PM Pacific Time, or via the internet at www.kia.com (Owner’s Section).
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
6 Associated Documents
Recall Acknowledgement
RCAK-24V271-4412.pdf 645.376KB
2023MY Niro EV & 2024MY EV9 Gear Drive Unit (GDU) Chronology
Defect Notice 573 Report
RCLRPT-24V271-2924.PDF 214.157KB
Manufacturer Notices(to Dealers,etc)
Manufacturer Notices(to Dealers,etc)
Manufacturer Notices(to Dealers,etc)
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SEOCONTENT-START
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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SC308
April 19, 2024
ATTENTION: ALL DEALER PARTS & SERVICE MANAGERS
Kia America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act, is conducting a Safety Recall Campaign regarding the Gear Drive Unit (GDU) on the following vehicles:
•
Certain 2023 MY Niro EV vehicles manufactured from November 7, 2022 through May 16, 2023 and
•
Certain 2024 MY EV9 vehicles manufactured from October 27, 2023 through December 14, 2023.
The differential gear bolts within the Gear Drive Unit (GDU) in the subject vehicles 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 drive power and/or cause the differential to lock up. A loss of drive power and/or differential lock up increases the risk of a crash.
All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Kia dealer. Dealers will replace the GDU with a new one. This recall will be performed free of charge at no cost to the customer.
The Technical Service Bulletin that provides vehicle inspection and repair procedures, affected VIN production range, and warranty claim information will be posted on the Kia Global Information System (KGIS) at www.kiatechinfo.com during the week of April 19, 2024.
Enclosed you will find a copy of the owner notification letter and a Q&A Guide for recall questions, both of which describe the issue. Note that any vehicle owner who has already paid for related repairs can submit a request for reimbursement online via the Owner’s Section of www.kia.com. Kia will mail notices to the affected vehicle owners beginning on May 17, 2024.
Also, please make certain the appropriate personnel in your dealership are familiar with the details of this recall to ensure proper responses to customer inquiries and requests to have the recall performed on their vehicles. This Safety Recall Campaign represents an opportunity for your service department to deliver an exceptional service experience (e.g., flexible service appointment process, car wash and vacuum and timely service).
NHTSA ADVISORY: It is a violation of Federal law for a dealer to deliver a new motor vehicle covered by this notification under a sale or lease until the defect is remedied.
LEGAL PRIVACY LIABILITY NOTICE: Pursuant to the terms of the Dealer Sales and Service Agreement and the Gramm-Leach-Bliley federal consumer privacy act, you are required to keep confidential any and all information and documents provided to you by Kia America, Inc. or generated by you in the conduct of carrying out work under that Agreement regarding Kia vehicle purchasers and owners, including but not limited to warranty claim information. Kia dealers may use such owner information for the sole purpose of conducting and performing this safety recall campaign, and for no other purpose.
If you have any questions, please contact your Kia District Parts and Service Manager.
Sincerely, Kia Service Department Enclosures
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SC308
April 19, 2024
ATTENTION: ALL DEALER PRINCIPALS
Kia America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act, is conducting a Safety Recall Campaign regarding the Gear Drive Unit (GDU) on the following vehicles:
•
Certain 2023 MY Niro EV vehicles manufactured from November 7, 2022 through May 16, 2023 and
•
Certain 2024 MY EV9 vehicles manufactured from October 27, 2023 through December 14, 2023.
The differential gear bolts within the Gear Drive Unit (GDU) in the subject vehicles 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 drive power and/or cause the differential to lock up. A loss of drive power and/or differential lock up increases the risk of a crash.
All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Kia dealer. Dealers will replace the GDU assembly with a new one. This recall will be performed free of charge at no cost to the customer.
Your Service Manager was sent a copy of the owner notification letter and a Q&A guide for recall questions both of which describe the issue and information on how to access the list of affected vehicles. Kia will start mailing notices to the affected vehicle owners beginning on May 17, 2024.
What Should You Do?
Please make certain the appropriate personnel in your dealership are familiar with the details of this recall to ensure proper responses to customer inquiries and requests to have the recall performed on their vehicles.
NHTSA ADVISORY: It is a violation of Federal law for a dealer to deliver a new motor vehicle covered by this notification under a sale or lease until the defect is remedied.
LEGAL PRIVACY LIABILITY NOTICE: Pursuant to the terms of the Dealer Sales and Service Agreement and the Gramm-Leach-Bliley federal consumer privacy act, you are required to keep confidential any and all information and documents provided to you by Kia America, Inc. or generated by you in the conduct of carrying out work under that Agreement regarding Kia vehicle purchasers and owners, including but not limited to warranty claim information. Kia dealers may use such owner information for the sole purpose of conducting and performing this safety recall campaign, and for no other purpose.
If you have any questions, please contact your Kia District Parts & Service Manager.
Sincerely, Kia Service Department
Enclosures
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