Kia America, Inc. is recalling up to 462,896 Telluride SUVs from model years 2020 to 2024 due to a condition where the power seat motors for the front seats may overheat due to a stuck adjustment knob.
The condition can result in a fire while parked or driving, according to a June 5 filing with the National Highway Traffic Safety Administration.
No injuries, crashes or fatalities were reported. However, until the recall is complete, Telluride owners are being advised to park their vehicles outdoors and away from structures.
The SUV is one of Kia's most popular U.S. models. The automaker reported sales of 10,315 Tellurides in May and 44,842 in the first five months of 2024.
The problem with the front seat motors was first identified in December 2022, after a customer took their Telluride to a dealership complaining of smoke coming from under the driver’s seat.
Several months later, in March 2023, Kia’s North American Safety Office received a Techline case involving another Telluride SUV where the passenger side seat was inoperative and the customer reported a burning smell.
The automaker’s Techline was established to assist dealers with vehicle repair related technical concerns. After this incident, Kia began to collect suspected parts for a more detailed inspection to determine the root cause.
In December 2023, Kia’s safety office received another complaint of smoke coming from underneath the driver's seat of a 2023 Telluride. Following that incident, Kia’s safety team inspected the vehicle and found evidence of an overheated seat tilt motor with the wires melted at the connector. A similar problem was found on the passenger side seat tilt motor of a 2020 Telluride in January 2024.
In March 2024, Kia’s safety office identified knob damage and stuck seat switches with continuous seat motor operation. It suspected that the knob damage was due to “external force.”
Also in March, Kia received a report from a dealer of a driver’s seat catching fire on 2023 model year Telluride while the customer was driving. The dealer submitted photo evidence to Kia showing it originated from the driver side seat motor area. The automaker repurchased the vehicle in order to conduct a more detailed inspection and found that the seat switch back cover dislodged and seat slide knob was stuck in the upward position.
Kia’s safety engineers also performed CT scans of the seat switch back covers of the suspected vehicles. After reviewing the scans last month, its safety engineers discovered that misalignment of internal micro switches was causing continuous motor operation.
After documenting seven separate incidents involving front power seat motors in the Telluride, Kia’s safety office issued the recall on May 29.
To repair the vehicles, dealers will install a bracket to reinforce the power seat switch back covers and replace the seat slide knobs at no cost. The faulty switch units were supplied to Kia by Duck-il Industry, an automotive supplier based in South Korea that manufactures vehicle interior parts, electronics and switches.
Owner notification letters are expected to be mailed by July 30.
