Kia Recalls Thousands of SUVs Due to Headlight Failure: What Owners Need to Know to Stay Safe on the Road

If you own a Kia SUV model year 2020 through 2023, pay close attention: Kia has issued a major recall affecting thousands of vehicles due to a critical headlight failure that could leave drivers in the dark—literally—at night. The National Highway Traffic Safety Administration (NHTSA) has formally documented this recall (Reference Number: 25V-892), warning that a defective headlight control module may cause one or both headlights to unexpectedly shut off while driving. For any motorist, losing headlights in low-light conditions is not just an inconvenience—it’s a severe safety hazard linked to increased crash risks, especially on unlit roads or during inclement weather.

This isn’t a minor issue. NHTSA data shows that faulty lighting systems contribute to approximately 30% of nighttime crashes where visibility is a factor. Kia’s internal testing revealed that the affected modules, supplied by a third-party vendor, can overheat due to a wiring flaw, leading to intermittent or permanent failure of the headlights. Even worse, the problem often occurs without warning: drivers may notice the headlights flicker, dim unexpectedly, or go dark entirely while cruising at highway speeds, on rural highways, or in parking garages. In some cases, the failure persists until the vehicle is restarted, leaving motorists scrambling to address the issue mid-trip.

Which Kia SUVs Are Involved?

The recall impacts specific trims of Kia’s best-selling SUVs, including the 2020–2023 Sportage, 2021–2023 Sorento, and 2022–2023 Telluride. The issue stems from a batch of faulty control modules produced between March 2020 and August 2022, meaning not every SUV in these model years is affected—but thousands are. Kia estimates approximately 87,000 vehicles in the U.S. alone fall under this recall, with additional units registered in Canada and Mexico. To check if your vehicle is included, use Kia’s official recall lookup tool on their website (http://www.kia.com/us/en/owners/recalls) or the NHTSA’s VIN search portal (http://www.nhtsa.gov/recalls). You’ll need your 17-character Vehicle Identification Number (VIN), which is located on the driver’s side dashboard (visible through the windshield) or on your vehicle registration paperwork.

Why This Recall Matters More Than You Think

Headlights are non-negotiable for safe driving after sunset. The Insurance Institute for Highway Safety (IIHS) rates headlights as a “top safety pick” feature, noting that vehicles with adaptive or high-intensity discharge (HID) headlights reduce nighttime crash rates by up to 40% compared to those with basic halogen systems. When headlights fail, drivers lose critical visibility of pedestrians, cyclists, wildlife, and road hazards like potholes or debris. Worse, other motorists may not see you in time to avoid a collision.

In a statement to the press, Kia’s chief safety officer, Maria Davis, emphasized urgency: “We’re aware of several reports where drivers experienced sudden headlight failure, including one incident involving a minor collision on a dark suburban road. While no fatalities have been reported, the potential for harm is too great to delay action.” The automaker has urged owners not to wait for a mailed notification (which will begin in mid-October) but to proactively check their VIN and schedule repairs immediately.

What Happens If You Ignore the Recall?

Ignoring a headlight recall isn’t just risky—it could have legal and financial consequences. Most states require functional headlights for vehicle inspections, meaning a failed inspection could leave you unable to renew your registration. If an accident occurs due to faulty headlights, liability may shift to you, even if the failure was due to a manufacturer defect. Insurance companies may deny claims or reduce payouts if they determine the driver neglected a known safety issue.

Beyond legal risks, there’s the human cost. A 2022 study by the AAA Foundation for Traffic Safety found that drivers with malfunctioning headlights are 2.5 times more likely to be involved in a crash during dawn or dusk, when visibility is already compromised. For families driving at night to school events, late work shifts, or weekend trips, this isn’t a hypothetical risk—it’s a real threat to loved ones.

Step-by-Step: What to Do If Your Kia Is Recalled

  1. Confirm Your Vehicle’s Status
    Visit Kia’s recall portal (http://www.kia.com/us/en/owners/recalls) and enter your VIN. The tool will immediately tell you if your SUV is part of the campaign. If you don’t have internet access, call Kia’s customer service hotline at 1-800-333-4542, available 24/7. Be prepared to recite your VIN and vehicle details to verify ownership.

  2. Schedule a Repair Appointment
    Once confirmed, contact your local Kia dealership to set up a free repair. Repairs typically take 1–2 hours, depending on dealership workload. Kia has allocated 500,000 replacement control modules to dealerships nationwide, with priority given to high-risk regions (e.g., states with long winter nights like Alaska, Maine, or Washington).

  3. Understand the Repair Process
    Technicians will inspect your headlight control module, confirm the defect, and replace it with an updated version designed to prevent overheating. The service is fully covered under Kia’s warranty, so no out-of-pocket costs are involved. If your SUV has already incurred damage from a headlight failure (e.g., a cracked lens from a pothole encountered during a nighttime breakdown), bring documentation to the dealership—Kia may cover related repair costs on a case-by-case basis.

  4. Follow Up If Needed
    After the repair, test your headlights thoroughly: drive at night, through tunnels, and in heavy rain to ensure they activate immediately, maintain consistent brightness, and turn off only when the ignition is switched off. If issues persist, return to the dealership—Kia has pledged to resolve all complaints within 30 days of follow-up.

Temporary Fixes for Drivers Waiting on Repairs

While waiting for your appointment, take these precautions to minimize risk:

  • Check Headlights Daily: Before each drive, toggle the headlights on and off to ensure they respond. If they flicker or dim, avoid driving at night until repaired.
  • Use High Beams Strategically: On dark roads, switch to high beams (if working) to compensate for low-beam dimness. Dim them when approaching other vehicles to prevent glare.
  • Avoid Rural or Unlit Routes: Stick to well-lit highways or urban roads after sunset. If you must drive in remote areas, bring a portable LED light bar or extra flashlights.
  • Inform Passengers: Let everyone in the car know about the recall so they can alert you if headlights behave erratically.

Industry Experts Weigh In

Automotive safety analysts at Consumer Reports praised Kia’s proactive response, noting that many manufacturers delay recalls until forced by NHTSA. “Kia’s decision to act before a catastrophic incident is commendable,” said Jake Fisher, senior director of auto testing. “But owners still need to stay vigilant—recalls only work if people participate.”

The NHTSA has also highlighted this campaign as an example of how collaboration between automakers and regulators can address emerging safety threats. In a recent press release, agency head Dr. Steven Cliff stated: “Headlight failures are preventable, and this recall underscores the importance of timely communication between manufacturers, dealers, and consumers.”

What About Used Kia SUVs?

Secondhand owners aren’t excluded from the recall. Kia’s program covers all affected vehicles regardless of purchase date, as long as they were sold new by authorized dealerships. If you bought a used Kia SUV in the affected model years, provide your VIN to the dealer during the repair process—they’ll still honor the free fix. For private sales, ensure the seller discloses the recall status; buyers can verify repairs via the NHTSA’s public database, which logs all completed campaigns.

How to Stay Informed About Future Recalls

Recalls aren’t one-and-done. To keep your vehicle safe long-term:

  • Sign Up for Kia Alerts: Visit http://www.kia.com/us/en/owners and register your vehicle to receive email or text notifications about recalls, service bulletins, or software updates.
  • Check NHTSA Monthly: The administration publishes a monthly recall report (http://www.nhtsa.gov/recalls/monthly-recall-report) listing all new campaigns. Bookmark it or subscribe to their RSS feed.
  • Attend Annual Inspections: Many mechanics flag open recalls during routine maintenance. Use this as an opportunity to ask about unresolved issues.

Final Thoughts: Safety Should Never Wait

Kia’s headlight recall is a stark reminder that even trusted brands can face unexpected safety issues. While the automaker has moved quickly to address the problem, the onus is on owners to take action. A 30-minute visit to the dealership could prevent a life-altering accident—don’t gamble with your family’s safety.

As winter approaches and daylight hours shrink, now is the perfect time to resolve this issue. Check your VIN, schedule that repair, and hit the road with confidence. After all, the best feature in any vehicle isn’t leather seats or a touchscreen infotainment system—it’s the assurance that your lights will guide you home, no matter how dark the road gets.

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