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Kia Sedona, Brakes, Van
#189 of 210 Kia Sedona brake rotor issues
Aug 06, 2010 (10:46 am)
My issues with Kia brake rotors captured in this letter to Kia:
Dear Mr. Ahn and Kia America,
I have discussed the above referenced case with [Kia Motors Customer Service rep] without resolution from my view. [Service rep] response to the case was that brakes (rotors) are not a warranty item and Kia Motors will therefore not cover the cost of their replacement.
I agree that [service rep] applied the letter of your warranty. However, I am surprised that your rotors need replacing at approximately 20,000 miles due to warping / hard spots, which may have been the result of Kia Motors or Kia dealer actions. I am also surprised that Kia Motors is only concerned with two possible causes of this warping: caliper defect (which was not the case), and driver misuse. There are additional cited causes for warping rotors that I have found (some research included below): poor quality castings of rotors, and mis-tightening of the lug nuts. We have had our tires rotated at Kia dealers, who could have mis-tightened the lug nuts. Regarding driver misuse, we had a Honda Odyssey (with same driver, driving habits, and mix of local and highway driving) that we drove in steeper terrain and had no brake issues until 60,000 miles.
I am very disappointed that Kia Motors is unwilling to actively consider all the potential reasons for the warping of the rotors on our Sedona, and participate in the expense of the repair, given that fault for either driver misuse or dealer mis-tightening of lug nuts is not possible to prove (that I am aware of). [service rep] spoke with the dealer who was willing to provide a 10% discount on the parts and labor, which I do not believe fully addresses that there is a possibility that the dealer was at fault for mis-tightening the lug nuts, nor does it address the possibility that there as a problem with the castings from Kia Motors
[Service rep] was not willing to look at the research I had done, nor was she informed on the potential causes for rotor warping beyond the information that the dealer had told her. I would expect Kia Motors to have a depth of knowledge on all parts of their vehicle, especially a part as important as the brakes. Service rep was also not willing to have Kia Motors inspect the rotor for material defects beyond the dealer looking at the rotors, which I do not know if that level of visual inspection can determine a problem with the castings.
I request two things from Kia Motors: consideration of all the possible causes for the rotors warping on our Sedona at approximately 20,000; a fair participation in the cost of replacement given the potential causes.
[Information from internet research – I would be very pleased to receive copies of research that Kia Motors has available on rotor life and causes for rotor warping]
• Rotor warpage. Variation in the thickness of the rotor or uneven spots on either rotor face will cause the brake pedal to pulsate or shudder when the brakes are applied. Flatness can be checked by placing a straight edge against both faces of the rotor. Thickness must be checked with a micrometer at six or more points around the rotor.
• If parallelism between rotor faces exceeds OEM specs (generally about .0005 in.), or if the rotor is warped or has hard spots (which are often discolored blue or black), the rotor should be resurfaced or replaced. Hard spots that develop from overheating or uneven tightening of lug nuts can create raised areas on the surface that often extend below the surface. The metallurgical changes in the rotor often cause the hard spots to return after a few thousand miles so replacing the rotor may be the best long-term fix.
A brake pedal pulsation or shudder is one of the most common symptoms that indicates rotor trouble. The cause may be too much runout in a rotor and/or variation in the thickness of the rotor. Runout occurs when the rotor wobbles as it rotates. This may be due to runout in the hub, runout in the way the rotor was originally machined, rust or dirt between the rotor and hub, or uneven torquing of the lug nuts that causes distortion in the rotor and hub (which is why lug nuts should always be tightened to specifications with a torque wrench, not an impact gun).
http://www.tomorrowstechnician.com/Article/703/the_great_rotor_debate__knowing_w- - hen_to_resurface_or_replace.aspx
Anybody who works on brakes for a living knows that rotors can cause a lot of brake problems. Uneven rotor wear (which may be due to excessive rotor runout or rotor distortion) often produces variations in thickness that can be felt as pedal pulsations when the brakes are applied. The condition usually worsens as the rotors continue to wear, eventually requiring the rotors to be resurfaced or replaced.
Rotors can also develop hard spots that contribute to pedal pulsations and variations in thickness. Hard spots may be the result of poor quality castings or from excessive heat that causes changes in the metallurgy of the rotors. A sticky caliper or dragging brake may make the rotor run hot and increase the risk of hard spots forming. Hard spots can often be seen as discolored patches on the face of the rotor. Resurfacing the rotor is only a temporary fix because the hard spot usually extends well below the surface and usually returns as a pedal pulsation within a few thousand miles. That is why most brake experts replace rotors that have developed hard spots.
Rotor runout can be caused by several things: variations in manufacturing tolerances, sloppy resurfacing procedures, a buildup of rust and corrosion between the rotor and hub, and uneven torque on the lug nuts.
#190 of 210 Re: Kia Sedona brake rotor issues [kiasedona2008]
Nov 01, 2010 (4:42 pm)
kiasedona2008 - loved your posting in August - way too informed & technical for Kia though as there was no snappy response from their forum guru, lavishrevo. I have a 2004 Kia Sedona with brake problems that I can't sell or trade in because everyone outside of "Kia world" knows the problem exists and nothing can or will be done about it. Interesting but nothing ever changes......
#191 of 210 Re: Kia Sedona brake rotor issues [kiasedona2008]
Nov 01, 2010 (7:04 pm)
GREAT research!! I got the same line of crap about driver misuse, blah blah blah. The issue surfaced at 20k miles and I actually got them to resolve but now at 46k I am on my own. I just purchased new pads from Pep Boys. They installed the ceramic pads and it has only been a few weeks but so far so good...the squealing, pulsing, grinding noises are gone and we have the stopping power back. Worth looking at ceramic pads...I know this is not what I was looking for in an ownership experience!
#192 of 210 Re: Kia Sedona brake rotor issues [azbakers]
Nov 10, 2010 (12:04 pm)
AZBakers - PLEASE update us. Has your fix lasted? If so, what exact brand and type of pads did you purchase?
I have been through this whole list and have the same severe pulsating problem on my 2005 Sedona. I do NOT ride my brakes, drive with two feet, or drive agressively. Anyone who claims that's the reason is full of it. And I live in central Ohio, one of the flattest regions in the country. And I have driven probably 200,000 miles in various modern passenger cars and minivans with NO such problems.
I have been to the Kia dealer multiple times, and the ONLY change is that I am now over $1000 poorer. Absolutely no fix, and they will not repair further unless I keep paying them. I do not see how that's legal, so I am exploring my options.
Anyone who found a fix - PLEASE POST IT!!
#193 of 210 Kia Brakes
Nov 10, 2010 (12:20 pm)
Go to the House Committee on Oversight and Government Reform site and report them
#194 of 210 Re: Kia Sedona brake rotor issues [dml550]
Nov 10, 2010 (7:04 pm)
I had a 2007 Sedona and fixed my issue with the drilled cross rotors and pads from R1Concepts. I changed my car into a 2009 Sedona and I changed them directyly from 13.000 just in case and I have been having them for another 13k and doing good. The R1 concepts have very good customer service and as a return customer I got a discount, 450 plus the 150 to change them. I am good, no squealing. I am happy with my Sedona.
#195 of 210 Re: Kia Sedona brake rotor issues [armyvet]
Nov 14, 2010 (6:37 am)
Thanks, that helps!
#196 of 210 Re: Kia Sedona brake rotor issues [dml550]
Nov 16, 2010 (11:22 pm)
OK so now about a month after getting the pads changed and I am still squeal and pulsing free!!!! The whole service from Pep Boys was under $200 and they had to do a little rotor work. It was the ceramic pads, nothing fancy beyond that!
Here is a link to their page...
Pep Boys Brakes
Good luck! I would be interested to hear what you end up doing.
#197 of 210 Re: Kia Sedona brake rotor issues [azbakers]
Nov 17, 2010 (6:56 am)
Thanks for updating Bryan, I appreciate that! Not sure yet what we're going to do, the wifey is about out of patience with both the car and the dealer and wants completely out. (I left out a lot of details, but trying to fix these brakes this has been an ordeal. The dealer service dept. is out of ideas but still charging $, and Kia as a company has been less than useless. Utterly unresponsive.) If I get my vote, we're going the Pep Boys route.
#198 of 210 2010 Sedona - Clicking Sound When Brake is Applied
Dec 27, 2010 (5:38 pm)
When pressing the brake pedal in our 2010 Sedona when the vehicle is in Park, Drive or Neutral, a clicking sound is coming from the area under/around the gear shifter. When in Drive, the clicking sound only occurs when the vehicle is stopped or when the vehicle slows to a near stop (i.e. when coming to stop for a traffic signal/stop sign, etc.). The clicking sound does not occur when the vehicle is in Reverse (and the brakes are applied). Has anyone experienced this issue with a Sedona? If so, what was the resolution/cause? Any insight would be appreciated. Thanks.