2002 Kia Optima: what breaks, and at what mileage
What breaks on the 2002 Kia Optima
On the 2002 Kia Optima, the failure owners report most often is control arm, ball joint or bushing failure, and the reports cluster around 125,000 miles. The earliest to appear is other body or interior problem, reported by a median of 85,000 miles. Overall it scores 68 out of 100, high risk for a 2002.
High risk for a 2002 — 170th riskiest of the 329 2002 vehicles we can rate. 168 owner reports; fleet size estimated from this year's own recall paperwork.
What breaks on the 2002 Kia Optima
Owners have reported 35 named failure modes on the 2002 Kia Optima, and the three most-reported carry 42% of everything filed.
Control arm, ball joint or bushing failure leads with 43 reports, about 3.3 per 1,000 vehicles and with the middle half of reports between 103k to 137,500 miles.
Other body or interior problem follows with 19 reports, usually reported between 71k to 115,000 miles.
Other electrical problem follows with 8 reports, median 75,000 miles. 1 of those report mention a fire.
By system, the reports fall mostly into suspension (50), body (25) and electrical (15).
When these failures get reported
141 of the reports on the 2002 Kia Optima came with an odometer reading, and half of those were filed before 89,000 miles.
Cumulatively, 25% by 50,000 miles, 56% by 100,000 miles and 89% by 150,000 miles of the dated reports had been filed, with 7 filed above the top of the chart.
The busiest stretch is between 130,000 and 140,000 miles, which alone holds 13% of the dated reports.
14% of the dated reports were filed below 36,000 miles.
Tick median reported mileage Solid middle half of reports Faint 10th to 90th percentile Colour how bad the failure is when it happens
Showing the 12 most-reported failure modes of 35. The full list is in the table below.
How reports accumulate
Every report with an odometer reading, cumulative, from 0 to 200,000 miles. A further 7 reports came in above that, which is why the line stops short of the top. A curve that climbs early is a car with early problems, whatever its total.
- Line share of reports filed by that mileage
- Dashed the median reported mileage
What happens when these parts fail
Across the named modes, 25 mention a crash, 5 a fire and 13 an injury. Those are the words owners used in their own complaints, and NHTSA does not verify them, but they are the closest thing in this data to a measure of what a failure actually did.
The average severity weight across every report on this year is 5.16, where a stalled engine or a failed airbag weighs many times more than a rattling trim panel, and a figure this high means the reports are dominated by failures with safety consequences rather than annoyances. The weighting is set out in full on the methodology page.
What the top failures cost to put right, as editorial estimates for an independent US shop rather than figures from NHTSA: control arm, ball joint or bushing failure at $400–$2,200, other body or interior problem at $200–$2,000, other electrical problem at $250–$2,000 and other suspension problem at $350–$2,000. Dealer labour, a seized bolt or a part that is no longer made can push any of these past the top of its range.
15% of the reports on this year sit in the engine, transmission, drivetrain or cooling systems — the four where a repair bill is usually four figures.
Every reported failure mode
| Failure mode | System | Reports | With reading | 25th | Median | 75th | Per 1,000 | Typical repair | Severity |
|---|---|---|---|---|---|---|---|---|---|
| Control arm, ball joint or bushing failure | suspension | 43 | 36 | 103k | 125k | 138k | 3.3 | $400–$2,200 | High |
| Other body or interior problem | body | 19 | 16 | 71k | 86k | 113k | 1.5 | $200–$2,000 | Moderate |
| Other electrical problem | electrical | 8 | 7 | — | 74k | — | 0.6 | $250–$2,000 | Moderate |
| Other suspension problem | suspension | 7 | 7 | — | 120k | — | 0.5 | $350–$2,000 | Moderate |
| Rust or structural corrosion | body | 5 | 5 | — | 140k | — | 0.4 | $500–$6,000 | High |
| Tail light, brake light or signal failure | lighting | 5 | 5 | — | 52 | — | 0.4 | $100–$900 | Moderate |
| Other engine problem | engine | 5 | 4 | — | 118k | — | 0.4 | $300–$4,000 | High |
| Other fuel system problem | fuel | 5 | 5 | — | 86k | — | 0.4 | $300–$2,200 | High |
| Timing chain, belt or tensioner failure | engine | 4 | 2 | — | 73k | — | 0.3 | $1,200–$4,500 | Critical |
| No-start or intermittent start failure | engine | 4 | 3 | — | 36k | — | 0.3 | $200–$1,800 | Moderate |
| Overheating | cooling | 4 | 4 | — | 44k | — | 0.3 | $400–$3,500 | High |
| Ignition switch, key fob or immobilizer failure | electrical | 4 | 3 | — | 102k | — | 0.3 | $250–$1,500 | High |
| Seat belt or retractor failure | airbag | 4 | 4 | — | 8k | — | 0.3 | $200–$900 | High |
| CV axle or driveshaft failure | drivetrain | 3 | 3 | — | 133k | — | 0.2 | $450–$2,200 | High |
| Control module (ECM/PCM/BCM) failure | electrical | 3 | 3 | — | 4k | — | 0.2 | $700–$3,000 | High |
| Master cylinder or brake booster failure | brakes | 3 | 3 | — | 6k | — | 0.2 | $450–$2,200 | Critical |
| Premature brake pad or rotor wear | brakes | 3 | 3 | — | 47k | — | 0.2 | $300–$1,400 | Moderate |
| Parking brake failure | brakes | 3 | 3 | — | 62k | — | 0.2 | $250–$1,300 | Moderate |
| Airbag failed to deploy in a crash | airbag | 3 | 0 | — | — | — | 0.2 | $1,000–$5,000 | Critical |
| Airbag warning light or occupant sensor fault | airbag | 3 | 3 | — | 74k | — | 0.2 | $300–$1,600 | High |
| Other powertrain problem | transmission | 3 | 3 | — | 86k | — | 0.2 | $400–$4,500 | High |
| Other brake problem | brakes | 3 | 2 | — | 88k | — | 0.2 | $300–$1,800 | High |
| Other steering problem | steering | 2 | 1 | — | 138k | — | 0.2 | $350–$2,400 | High |
| Other speed control problem | adas | 2 | 2 | — | 83k | — | 0.2 | $250–$2,000 | Critical |
| Other visibility problem | glass | 2 | 1 | — | 60k | — | 0.2 | $150–$1,400 | Moderate |
| Stalling while driving | engine | 1 | 0 | — | — | — | 0.1 | $300–$2,500 | Critical |
| Water pump failure | cooling | 1 | 0 | — | — | — | 0.1 | $500–$2,200 | High |
| Fuel tank, filler or EVAP failure | fuel | 1 | 1 | — | 52k | — | 0.1 | $250–$1,800 | Moderate |
| ABS module or sensor failure | brakes | 1 | 1 | — | 6k | — | 0.1 | $500–$2,400 | High |
| Airbag deployed without a crash | airbag | 1 | 1 | — | 48k | — | 0.1 | $2,500–$8,000 | Critical |
| Steering rack, gear or tie rod failure | steering | 1 | 1 | — | 150k | — | 0.1 | $700–$2,600 | High |
| Tire blowout or tread separation | wheels | 1 | 1 | — | 37k | — | 0.1 | $200–$1,500 | Critical |
| Door latch or handle failure | body | 1 | 1 | — | 75k | — | 0.1 | $250–$1,200 | High |
| Other lighting problem | lighting | 1 | 1 | — | 100k | — | 0.1 | $120–$1,200 | Moderate |
| Other driver assistance problem | adas | 1 | 1 | — | 64k | — | 0.1 | $250–$1,800 | High |
| Unclassified problem | other | 8 | 5 | — | 86k | — | 0.6 | — | Moderate |
Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound. Repair costs are typical independent-shop ranges for the failure, not figures from these reports.
How often, against how many were built
Scaled by an estimate of how many of these cars exist, the 2002 Kia Optima draws about 13 per 1,000 vehicles, which puts it in the 89th percentile of complaint rates among 2002 vehicles we can rate.
That denominator is the weakest number on the page and it is fair to say so plainly. Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound.
The working figure is 12,901 vehicles. If the true number is twice that, every rate on this page is half what it says; the ranking against other 2002 vehicles, which is what the risk score uses, is far more robust than the rate itself.
What owners wrote
Verbatim from NHTSA complaint narratives, trimmed for length. The odometer reading is the one the owner gave.
Control arm, ball joint or bushing failure
Tl*the contact owns a 2002 kia optima. While performing a routine oil change, the mechanic discovered that the cradle, or subframe, underneath the vehicle was rusting out. The mechanic stated that any major bump could cause the drivetrain to collapse and potentially cause dangerous driving conditions. He also stated that the entire frame could collapse and separate the engine compartment from the vehicle. The manufacturer stated that the frame would not be covered under warranty and they could not assist with the repairs. The failure and current mileages were 85,304. Updated 05/06/09. *lj updated 05/07/09.*jb
Tl*the contact owns a 2002 kia optima. The contact stated that the subframe on the passenger side of his vehicle was very rusty. The vehicle is unable to be driven and the contact has no control of the steering because the a-arm was separated from the subframe. The dealer acknowledged the failures, but there are no recalls available. The failure mileage was 91,400. Updated 05/19/09 *bf updated 05/20/09. *jb
Other body or interior problem
Vehicle model is a 2002 kia optima 4 door sedan and the problem is regarding the drivers left door. The power lock door locks on its own immediately after the door is unlocked using the key. The car was then taken to get fixed on 05/24/02 and ounce again the same problem occurred on 01/31/08 this time cost to fix is $233.16. After the problem was fixed, again for the second time, it occurred again. I am convinced that the power locks are defect and dangerous risks of becoming trapped in the car. This problem is unpredictable it occurs from time to time, and I am unable to get it fixed because mechanics must be there to see when problem occurs in order to try to fix it. In one incident I was forced to crawl out of the window in order to get out of the car. I feel very insecure and unsafe in case of an accident if I would be able to get out of the car which is why I am raising awareness of this problem. *tr
2002 kia optima, we have only had the car less than 2 years and it has 2 fist size rust holes in frame one each side by a-arms, due to these defects tires wearing quickly and needs air continually to be put in them. Handling worsening and making thumping noise in front end, can not drive over 35-40 MPH. Called kia and they said they would not do anything about this problem. Read where hyundai and kia are made by same company and this has been a problem with the 1999 to 2002 models. Feel this is their responsibility to make right before something happens and there is an accident. Need information on who to contact and how to get this taken care of. *tr
Other electrical problem
Tl*the contact owns a 2002 kia optima. The contact researched her insurance agency's website and noticed a recall for the crank position sensor. The kia dealer stated that NHTSA campaign id number 03v067000 (electrical system:starter assembly) does not apply to her VIN. While driving at an unknown speed, the vehicle automatically stopped. She took the vehicle to another dealer and the vehicle was repaired at the contacts expense. The powertrain was unknown. The failure mileage was 74,000 and current mileage was 77,000. Updated 02-14-08 *bf updated 02/14/08 *tr
When you turn my car on it does not want to turn off. When you are driving the car it suddenly shuts off and stops. I have read similar reports of the same thing happening and under the recalls it lists this as a complication. I have called kia and was told that my VIN number doesn't have a recall on it and was told that any repairs would be out of pocket. I have already had to replace the top half of my motor costing me 3500 out of pocket for well know problems and recalls that were not included in this cars VIN number I do not think a car should have this many issues and or repairs in the last year alone I have put 2 grand into this car I am very unhappy about this situation everything that has been recalled already I have had to fix it out of my pocket because this model of car is not included in the recalls I don't feel like this car is safe to drive and I have 2 small children who ride in the car I can not risk my children's lives and have this car shutting off in the middle of the road. I need something done about all the problems going on in this car due to manufacturing defaults. *tr
Recalls on the 2002 model year
NHTSA has issued 3 recall campaigns covering the 2002 Kia Optima, affecting an estimated 27,785 vehicles. A recall is a different kind of evidence from a complaint: it is the regulator and the manufacturer agreeing that something has to be fixed, and the fix is free for as long as the car exists.
The campaigns cover suspension:front, fuel system, gasoline:storage:tank assembly and electrical system:starter assembly. Whether the work was actually done on the car in front of you is a question only the VIN can answer, and the manufacturer or NHTSA will answer it free.
One caution about reading these together: a recall usually raises the complaint count for the same part, because owners who read about it go and file. The mileages stay informative; the counts get noisy.
SUSPENSION:FRONT
36,538 vehicles 2009-05-27- Defect
- Kia motors corporation (kmc) is recalling 36,538 model year 2001-2004 optima vehicles originally sold in or currently registered in the states of connecticut, delaware, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia, wisconsin, and the district of columbia. Road salt applied in these states during the winter months may result in progressive, internal corrosion of the front subframe. Over time, such subframe corrosion near the connection to…
- Consequence
- Corrosion of the front subframe could lead to separation, possibly resulting in a vehicle crash.
- Remedy
- Kmc will notify owners and dealers will repair the vehicles free of charge. The safety recall began on june 15, 2009. Owners may contact kia's consumer assistance center at 1-800-333-4542.
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
25,803 vehicles 2004-04-12- Defect
- Some passenger vehicles may contain a fuel tank assembly valve that may not close properly. If a vehicle with a fuel tank assembly valve that is not properly closed were to roll over, fuel spillage may occur.
- Consequence
- Fuel spillage in the presence of an ignition source could result in a fire.
- Remedy
- Dealers will install an additional fuel tank assembly valve. Owner notification began june 25, 2004. Owners should contact kia at 1-800-333-4542.
ELECTRICAL SYSTEM:STARTER ASSEMBLY
11,501 vehicles 2003-03-04- Defect
- On certain passenger vehicles equipped with 2.5 and 2.7 liter v6 engines, the crankshaft position sensor (ckp) cases did not meet dimensional specifications.
- Consequence
- Internal gaps within the cases allowed epoxy to contact the printed circuit board, which resulted in cracking of the circuit board capacitor. A damaged ckp capacitor could result in engine stalling.
- Remedy
- Dealers will replace the ckp. Owner notification began march 28, 2003. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact kia at 1-800-333-4542.
Recall work is free at a franchised dealer regardless of the car's age. Check the VIN at nhtsa.gov/recalls before assuming it was done.
How it ranks in the 2002 field
The score at the top of the page, placed among its peers. The zones are the same thresholds the scorer applies, read out of the scorer itself, so the picture and the band word cannot disagree.
Scores are ranked within the model year, never across years, because an older car has had longer to accumulate reports.
- Left fewer and less serious reports
- Right more, or worse
- Marker this vehicle
Better and worse years of the same car
High risk for a 2002 — 170th riskiest of the 329 2002 vehicles we can rate. Every score on this site is a rank inside its own model year, which is what makes a 2004 and a 2019 comparable at all.
Across the 20 model years of this car that carry enough reports to score, 2005 comes out best at 57 and 2019 worst at 80, with 2002 itself at 68.
If the model year is negotiable, 2005, 2003, 2007, 2006 and 2004 score lower than 2002 by a margin worth acting on. Same body, same engines, different luck — usually a supplier change or a mid-cycle fix, which the complaint data can show but never explain.
Within the 2001–2004 generation specifically, 2003 is the strongest year at 62 and 2001 the weakest at 70.
Scores compare each year against other cars of the same model year, so a low number on an older car is a real result and not an artefact of age.
Shorter is better. Years with too few reports to score are shown without a bar rather than as a zero, because no data is not good news.
Within the 2001-2004 generation, 2003 Kia Optima scores best at 62 and 2001 Kia Optima worst at 70.
Where to spend the inspection money
The mileages below are where the first quarter of reports for each mode had already been filed, which makes them the point at which a fault is worth looking for rather than the point at which it happens: other body or interior problem from about 71k and control arm, ball joint or bushing failure from about 103k.
On a 2002 Kia Optima with more miles than that on it, the useful question to put to a seller or a mechanic is whether other body or interior problem has been dealt with, and if so with what parts and at whose expense. A car that has already had the repair is in a different position from one that has not.
Treat it as where to point the inspection, not as a prediction. A well-maintained example can sail past every mileage on this page, and a neglected one can fail well before the first of them.
Where these figures stop being useful
168 owner reports; fleet size estimated from this year's own recall paperwork. Every count on this page is therefore a floor: it is the number of owners who went to the trouble of filing with a federal agency, which is a small and self-selected fraction of the owners who had the fault.
Of those 168 reports, 141 carried an odometer reading, so the mileages here describe 84% of the sample rather than all of it. Owners also round: readings pile up on multiples of ten thousand, which is why this site publishes "about 90,000 miles" and not "91,438".
The failure modes are assigned by software reading the owner's own words, which is accurate in bulk and wrong in individual cases. A mode with a handful of reports may contain a misfiled one.
And nothing here predicts what one car will do. These are other people's complaints, filed years apart, on cars maintained by strangers. Read the page as a map of where this model year has previously gone wrong, then have the specific car in front of you inspected.
Questions this page answers
What are the most common problems with the 2002 Kia Optima?
The most-reported failures are control arm, ball joint or bushing failure (43 reports, median 125,000 miles), other body or interior problem (19 reports, median 85,000 miles) and other electrical problem (8 reports, median 75,000 miles). Counts come from owner complaints filed with NHTSA, which are voluntary, so they show what owners bothered to report rather than every fault that occurred.
At what mileage do 2002 Kia Optima problems start?
Other body or interior problem is the earliest failure mode to show up, with a median reported mileage of 85,000 miles and a quarter of reports before 70,000 miles. Across all failure modes on this year, the median report sits at 89,000 miles.
Is the 2002 Kia Optima reliable?
It scores 68 out of 100 on our risk index, which is high — 170th riskiest of the 329 2002 vehicles we can rate. The score is a comparison against other 2002 vehicles, not a prediction about any individual car, and it is built from complaint rates, severity and how early failures appear.
Which year of the Kia Optima is best?
Within the 2001–2004 generation, 2003 scores best at 62 out of 100 and 2001 worst at 70. Same body, same engines, different luck.
Where this comes from. Every figure above is computed from NHTSA owner complaints and recall records for this exact make, model and year. Complaints are voluntary and self-selected, so treat counts as a floor. The methodology page writes out each formula, and the same numbers are available as JSON.
What breaks at my mileage Compare with another car
Source Owner complaints and recall records published by the US National Highway Traffic Safety Administration, model years 1996–2027 Figures rebuilt Published by AtWhatMileage How every figure is computed