The Kia EV9, has garnered significant acclaim, notably securing the prestigious 2024 World Car of the Year award. However, alongside its accolades, the EV9 is facing a growing number of recalls, raising concerns about potential quality control issues. The latest recall affects 342 units from the 2025 model year, centering on a potential defect in the rear gear drive unit motor shaft, which may have been improperly welded during manufacturing.
According to the safety recall report issued by Kia, the affected EV9 models are those equipped with a dual-motor all-wheel-drive system. The root cause of the issue is attributed to a "supplier welding error" during the manufacturing process. This error can lead to damage to the motor shaft within the rear gear drive unit, potentially resulting in a reduction in acceleration and motive power.
The affected vehicles were manufactured at Kia's facility in Georgia between October and December of the previous year. Owners of these vehicles may receive indications of a problem through unusual noises emanating from the rear of the vehicle or the appearance of a "Check AWD/4WD" warning message on the vehicle's dashboard.
Kia's awareness of the issue stemmed from observations made in January, when the company noticed a pattern in assistance cases and received a report of a loss of motive power. This prompted an internal investigation, which involved a thorough tear-down of a suspected faulty unit. The investigation revealed that the motor shaft within the rear gear drive unit had sustained damage due to the aforementioned welding error. Further testing conducted by a Kia engineer on an affected EV9 confirmed the issue, with the vehicle failing to accelerate beyond 19 km/h under specific conditions.
Kia has acknowledged receiving ten reports from owners claiming a loss or reduction in motive power. However, it is important to note that, as of the time of this report, there have been no reported accidents or injuries directly related to this particular defect.
Kia plans to initiate owner notifications later this week, informing affected customers of the recall and the necessary corrective action. Authorized Kia dealerships will replace the rear gear drive unit in the affected vehicles. While this solution addresses the underlying issue, the replacement process is estimated to take over six hours, indicating a significant undertaking for both dealerships and customers. This lengthy repair time underscores the complexity of the issue and the effort required to rectify it.
The increasing frequency of recalls for the Kia EV9, despite its numerous accolades, raises questions about the consistency of quality control during its production. While the company has acted swiftly to address the identified defect and mitigate potential risks, the recalls may impact consumer confidence in the long term. The situation highlights the challenges faced by automakers in ensuring the reliability and safety of complex electric vehicles, particularly as they rapidly expand their production and introduce new models. Kia's commitment to addressing these issues and ensuring customer safety will be crucial in maintaining the EV9's reputation and building trust among consumers.