Brackets that hold the rear end upper control arms are completely rusted into two useless pieces. Only the lower control arms and side link or canard is holding the rear end in place, any torque applied could potentially twist the rear causing catastrophic damage, obviously the metal is bad and with no weep holes salt, water, etc. Hold in bracket. I thought the handling felt bad, and heard…
2005 Kia Sorento suspension problems
moderate 24 complaints filed with NHTSA · avg repair $900 · see suspension across all vehicles →
Failure mileage
Complaints
24
Recalls
0
Avg fix
$900
When does it fail?
Of the 24 suspension complaints filed for the 2005 Kia Sorento, here's the actual mileage breakdown — failures cluster heaviest at 125,000-150,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Among the 9 model years of Kia Sorento in our records for suspension problems, this one ranks #2 by owner-complaint volume.
No new NHTSA suspension complaint has been filed on this vehicle in over 14 years — the issue may be aging out of the active population.
The failure pattern owners describe
The 2005 Kia Sorento has a documented pattern of severe rear suspension bracket corrosion affecting multiple complaint narratives. Owners report that upper control arm brackets welded to the rear axle housing rust through and break away from the frame, with trailing arm brackets and sway bar brackets similarly affected. The brackets are designed with no drainage holes, allowing water and salt to accumulate in a cup-like formation and accelerate rust. Corrosion typically appears within 6–10 years and occurs even in non-rust-belt regions like Western Washington, suggesting a manufacturing defect rather than environmental necessity.
Symptoms include loud clanking and clunking from the rear, rattling over bumps, and steering difficulty. Dealers have declared affected vehicles unsafe to drive. Repair costs range from $1,300 to $3,000; one owner faced a $1,700 bill for rear axle replacement alone. Frame corrosion is so extensive in some cases that entire rear ends require replacement.
Kia USA has consistently denied warranty coverage and repair responsibility, claiming vehicles are out of warranty. However, Kia issued a service bulletin and repair program in the UK covering model years 2002–2008, and Hyundai (Kia's parent) issued a US recall for the identical issue on Santa Fe models. No US recall has been issued for Sorento, leaving American owners responsible for all repair costs on a defect Kia acknowledges in other markets.
Same Kia Sorento suspension reports on nearby years: 2006
Failure modes owners describe
Upper Control Arm Brackets - Rust and Failure
The upper control arm brackets welded to the rear axle housing corrode severely and rust through, eventually breaking away from the axle housing. Owners report the brackets are fabricated with no drainage holes, creating a cup that traps water and salt, accelerating corrosion. When brackets fail, the rear suspension loses structural support.
When: 6-10 years, typically between 93k and 145k miles; corrosion visible earlier
Symptoms owners cite: Loud clanking or clunking from rear suspension; Rattling noise when hitting bumps or over uneven road; Rattling and shaking while driving at various speeds; Difficulty steering, potential for rear axle to shift; Noise when applying brakes
Repairs/costs cited: Complete bracket replacement requires removing and fabricating new brackets, welding to axle housing. Repair costs quoted from $1,300 to $3,000 for parts and labor. Some owners report replacement of entire rear axle and differential housing quoted at $1,700 to replace. Salvage yard replacement suggested by some dealers. No OEM part available through Kia dealer parts.
Recalls/TSBs owners mention: Kia USA has denied warranty coverage and repair responsibility, citing vehicles are out of warranty. Kia acknowledged the issue in the UK with a service bulletin for model years 2002-2008 and provided free repairs in the UK under a repair program that ended April 2016. Hyundai (parent company) issued NHTSA Campaign 13V354000 for the identical issue on Hyundai Santa Fe. Kia offered one owner $1,500 for the vehicle as scrap value when repair was estimated at $3,000.
Frame Corrosion - Extensive Rust with Structural Holes
The rear frame and axle housing develop extensive corrosion with multiple holes rotted completely through, compromising structural integrity. Owners report frame rusted through in multiple areas with no other rust visible on rest of vehicle, suggesting a localized design flaw. One dealer assessment stated 'entire frame and rear end would need to be replaced.'
When: 8-10 years (reported at 9 years for one vehicle); 100k to 124k miles
Symptoms owners cite: Rattling and shaking while driving; Grinding sound when turning left; Excessive rattling when hitting bumps; Vehicle deemed unsafe to drive by dealers
Repairs/costs cited: Entire rear frame and rear end replacement needed. Repair costs quoted as exceeding the vehicle's value. One dealer stated cost would be extremely high. Repairs not completed by owners due to cost.
Recalls/TSBs owners mention: Kia denied warranty coverage. Dealers advised customers to drive at own risk. No recalls issued in US. Service bulletin exists in UK; repair program in UK existed as of complaint filing.
Rear Axle and Differential Rust - Bracket Failure
The rear axle and differential develop rust and corrosion, with brackets holding the axle in place rusting away. One owner's rear axle bracket was found hanging, held only by the shock. Trailing arm brackets also reported as completely rusted away and detached.
When: 9 years of ownership; 94k miles noted in one complaint
Symptoms owners cite: Vehicle instability; Loss of structural support for rear suspension
Repairs/costs cited: Rear axle and differential replacement quoted at $1,700. One owner also discovered transmission pan needed replacement during the same repair visit.
Recalls/TSBs owners mention: Kia denied responsibility, citing cheap metal manufacturing. No warranty coverage offered. Referred owner to pay full repair cost.
Trailing Arm Bracket Corrosion
Driver side and passenger side trailing arm brackets corrode and rust. Owners report brackets completely rusted and no longer attached to the rear axle, or heavily rusted but not yet separated.
When: Within 10 years; one report noted discovery shortly after another suspension repair
Symptoms owners cite: No symptoms reported prior to discovery during inspection
Repairs/costs cited: Repair cost quoted in hundreds of dollars. One mechanic suggested contacting Kia because failure should not have occurred on a low-mileage, relatively new vehicle.
Recalls/TSBs owners mention: Kia did not provide warranty coverage or repair assistance in US. Issue reportedly addressed in UK repair program.
Rear Axle Sway Bar Brackets - Severe Rust
Sway bar brackets on rear axle develop severe rust and corrosion.
When: By 119k miles
Symptoms owners cite: No symptoms reported; discovered during dealer inspection
Repairs/costs cited: Vehicle not repaired; no repair estimate provided.
Recalls/TSBs owners mention: Manufacturer not made aware of failure per complaint narrative.
Synthesized from 24 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
Tl* the contact owns a 2005 Kia sorento. The contact stated that while driving at approximately 50 MPH, the contact heard a loud noise coming from the rear of the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the brackets on the rear end of the vehicle were corroded and needed to be replaced. The vehicle was not repaired. The manufacturer was not informed…
Had suspension trouble with your 2005 Kia Sorento?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the suspension problem on the 2005 Kia Sorento?
It's a documented issue but not catastrophic. 24 complaints have been filed. Repairs average $900 and most owners catch it before it causes a breakdown.
At what mileage does the suspension typically fail?
Across the 22 complaints that reported odometer mileage, most suspension failures cluster between 95,847 and 120,000 miles, with the median around 108,000. A quarter of owners report trouble before 95,847; a quarter make it past 120,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $900 for suspension repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to suspension?
No active recalls currently cover suspension issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Kia/Sorento.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.