An electronics issue in the hydraulic clutch actuators in a total of 121,411 Niro Hybrid and Plug-in Hybrids in the U.S. is leading to a major recall for Kia. Although no fires have been reported in the field yet, the automaker with a checkered safety record has found in testing that the risk of one exists.
Kia North America’s Safety Office first became aware of the problem in January of this year, when it received reports of an incident in which, after the hybrid warning light illuminated, dealers found localized heat damage to a Niro Hybrid’s hydraulic clutch actuator connector and harness.
Later that month, the preliminary evaluation dug up another case of a similar issue occurring on a Niro Plug-in Hybrid. The automaker decided to continue monitoring dealer data and to collect parts involved in these incidents.
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By May, it decided to perform X-ray imaging to look deeper into the connector. Working with its supplier, Schaeffler Automotive, it discovered that there was corrosion on the printed circuit board, near where the melting occurred.
With the help of a third-party engineering firm, it determined that fluid, potentially from an external source, contaminated the printed circuit boards in which melting occurred. This caused a short circuit, which can lead to a fire in some cases.
Fortunately, Kia is not yet aware of any fires occurring in vehicles in customers’ hands. However, it is aware of three confirmed, and seven potential cases of localized melting due to a short circuit.
As a result, it has resolved to start a recall campaign of all 2017-2022 Kia Niro hybrids, and all 2018-2022 Kia Niro PHEVs in America. Starting on September 29, it will reach out to owners, and ask them to return their vehicle to a nearby dealership. There, the hydraulic clutch actuator will be investigated and replaced where necessary. In all vehicles, it will replace the associated fuse with one that has a different capacity, in order to mitigate the risk of a fire.
