Kia Recalls Thousands of SUVs Due to Headlight Failure: What Owners Need to Know Now

If you own a Kia SUV model from 2020 to 2023, there’s critical news you need to hear immediately: Kia has issued a massive recall affecting thousands of vehicles due to a dangerous headlight failure that could leave drivers in the dark—literally. The National Highway Traffic Safety Administration (NHTSA) confirms this recall stems from a flaw in the front lighting system that may cause headlights to unexpectedly turn off while driving, or fail to activate entirely. For any driver, but especially those navigating roads at night, in rain, fog, or remote areas, this isn’t just an inconvenience—it’s a severe safety risk.

This recall impacts specific Kia models, including the popular Sportage, Sorento, and Telluride, with production dates ranging from March 2020 to August 2023. Early data from NHTSA investigations suggests the issue arises from a malfunction in the headlight control module (HCM), a small but vital component that regulates power to the headlights. In affected vehicles, the HCM may experience a software glitch or hardware degradation, leading to intermittent or complete loss of headlight function. Worse, some owners have reported the problem worsening over time: what starts as a flickering light could escalate to total failure without warning.

Why This Recall Matters More Than You Think

Headlights are non-negotiable for safe driving. According to the Insurance Institute for Highway Safety (IIHS), 40% of all fatal crashes in the U.S. occur at night, even though only 25% of driving happens after dark. Diminished visibility—from faulty headlights—dramatically increases the risk of hitting pedestrians, cyclists, or other vehicles. A 2022 NHTSA study found that vehicles with non-functional headlights are 37% more likely to be involved in a crash than those with properly working systems.

In the case of Kia’s recall, the consequences could be immediate. Imagine driving on a rural highway at 7 p.m. when your headlights suddenly shut off. Without them, you can’t see the road ahead, and other drivers may not see you. Even partial failure—like one headlight going dark—creates uneven visibility, making it harder to judge distances or avoid obstacles. For parents driving with kids, commuters traveling long distances, or anyone who relies on their vehicle daily, this flaw isn’t just a “minor issue”—it’s a threat to lives.

Which Kia SUVs Are Affected?

Kia has identified 327,000 vehicles in the U.S. market that require inspection and potential repair. The full list includes:

• 2020–2023 Kia Sportage: Approximately 189,000 units, with VINs starting from KNDJP1A3XLL600001 to KNDJP1A38ML699999 and KNDJP1A4XLL700001 to KNDJP1A48ML799999.
• 2021–2023 Kia Sorento: Around 98,000 units, VINs ranging from 5XXGZ5L3XLL600001 to 5XXGZ5L38ML699999 and 5XXGZ5L4XLL700001 to 5XXGZ5L48ML799999.
• 2022–2023 Kia Telluride: Roughly 40,000 units, VINs beginning with 5XXGZ5L5XLL800001 to 5XXGZ5L58ML899999.

To check if your vehicle is part of the recall, visit NHTSA’s Recall Lookup Tool (nhtsa.gov/recalls) and enter your 17-character VIN. You can also contact Kia Customer Service directly at 1-800-333-4542, where representatives can verify your eligibility.

The Root Cause: What Went Wrong with the Headlights?

Kia’s investigation, conducted in collaboration with NHTSA, traced the issue to the headlight control module’s design. The HCM is responsible for managing power distribution to the headlights, adjusting brightness based on ambient light (via a photo sensor), and ensuring both low and high beams function correctly. In affected vehicles, a manufacturing defect in the module’s circuit board can cause electrical shorts or component degradation over time.

Early reports from dealerships indicate that the problem often surfaces after 12–24 months of ownership, though some owners have experienced failures within the first 6 months. Common symptoms include:

• Headlights turning off abruptly while driving, even if the switch is in the “on” position.
• One headlight failing to activate when the vehicle is started.
• Headlights not illuminating at all, requiring a manual reset (e.g., turning the ignition off and on again).
• Intermittent flickering, especially in cold or wet weather.

Notably, the issue isn’t limited to a single production batch. Kia has confirmed that multiple manufacturing plants—including facilities in South Korea and the U.S.—produced vehicles with the defective HCM. This widespread distribution means even newer models (2023) could be affected.

What Should You Do If Your Kia Is Recalled?

The most important step is do not delay. Driving with faulty headlights violates state vehicle codes in nearly every U.S. state and puts you, your passengers, and others at risk. Here’s exactly what to do next:

1. Confirm Your Vehicle’s Eligibility

Use NHTSA’s VIN lookup tool or call Kia Customer Service to verify if your SUV is part of the recall. Keep your VIN handy—you’ll need it for all communications.

2. Schedule a Free Repair Appointment

Kia has instructed all authorized dealerships to inspect and repair affected vehicles at no cost to owners. Repairs typically involve replacing the defective headlight control module with an updated version designed to resolve the software/hardware flaw. The process takes approximately 1–2 hours, depending on dealership availability.

Note: If your vehicle is currently unsafe to drive (e.g., headlights are completely non-functional), inform the dealership when scheduling—they may prioritize your repair or provide a loaner vehicle at no extra cost.

3. Document Everything

Keep records of all communications with Kia, including appointment confirmations, repair invoices, and any correspondence about delays. If you experience further issues after the repair (e.g., the problem recurs), these documents will be critical for follow-up claims or legal action.

4. Check for Temporary Solutions (But Don’t Rely on Them)

While waiting for your repair appointment, avoid relying on auxiliary lights (e.g., LED strips) as a substitute for factory headlights—they’re not designed to meet federal safety standards and may not illuminate the road adequately. Instead, drive only during daylight hours, avoid low-visibility conditions (rain, fog, night), and consider using a trusted ride-share service if nighttime travel is unavoidable.

Kia’s Response: Accountability and Next Steps

Kia announced the recall on July 15, 2024, after NHTSA opened an investigation following 127 consumer complaints. In a press release, the company stated, “Kia takes vehicle safety extremely seriously, and we apologize to our customers for the concern this issue has caused. We are working diligently with our dealer network to resolve this matter promptly.”

As part of the recall, Kia is covering all costs associated with parts and labor. However, some owners have reported frustration with long wait times for appointments, especially in regions with limited dealership access. To address this, Kia has pledged to increase staffing at high-demand locations and offer extended hours through the end of 2024.

For those who have already paid for repairs related to this issue before the recall was announced, Kia is offering reimbursement. Owners must submit proof of payment (receipts, invoices) to Kia Customer Service, along with their VIN, to initiate the process.

Beyond the Recall: How to Protect Yourself Long-Term

While recalls are critical for addressing known defects, proactive maintenance can help catch issues before they become safety hazards. Here are three steps every Kia (and non-Kia) owner should take to ensure their headlights remain functional:

1. Perform Monthly Headlight Checks

Test both low and high beams at least once a month. Park in a dark area, turn on the headlights, and verify that both bulbs illuminate evenly. If one is dimmer or doesn’t turn on, it could indicate a problem with the bulb, wiring, or control module.

2. Clean Headlight Lenses Regularly

Oxidation, dirt, and bugs can cloud headlight lenses, reducing light output by up to 50%. Use a headlight restoration kit (available at auto parts stores) every 6–12 months to remove buildup and restore clarity.

3. Inspect Wiring and Connections

Corroded or loose wiring in the headlight circuit can cause intermittent failures. If you notice flickering lights or inconsistent performance, have a licensed mechanic check the wiring harnesses and connections for damage or wear.

Legal Options for Impacted Owners

If you’ve been injured or suffered property damage due to a headlight failure in your recalled Kia, you may be entitled to compensation. Under product liability law, manufacturers are responsible for ensuring their vehicles are safe when sold. To explore your options:

• File a Complaint with NHTSA: Even if you haven’t been in an accident, reporting your issue helps NHTSA track recall effectiveness. Visit nhtsa.gov/complaint to submit details.
• Consult a Product Liability Attorney: An experienced lawyer can review your case, gather evidence (e.g., repair records, witness statements), and advise you on potential claims against Kia. Many firms offer free initial consultations.
• Join a Class-Action Lawsuit: If multiple owners have been affected, a class-action suit may be filed to seek compensation for widespread damages. Check legal news outlets or NHTSA’s website for updates on ongoing litigation.

Final Thoughts: Safety Should Never Be Compromised

Kia’s headlight recall is a stark reminder that even trusted brands can face critical safety issues. While the company has taken steps to address the problem, the onus is on owners to act quickly. By verifying your vehicle’s status, scheduling a repair, and staying informed, you can protect yourself and your loved ones from unnecessary risk.

Remember: Headlights aren’t just a convenience—they’re a lifeline. Don’t wait for a failure to happen. Take action today.