Kia is recalling 342 units of its 2025 EV9 electric SUV in the United States due to a welding defect in the rear gear drive unit motor shaft, which could lead to reduced acceleration and motive power.
According to a safety recall report, the issue affects dual-motor all-wheel-drive variants of the EV9, built at Kia’s Georgia plant between October and December 2023.
See also: Everything You Should Know About Kia EV9
The problem stems from a supplier welding error, which may cause the motor shaft inside the rear gear drive unit to sustain damage. Affected vehicles may display warning signs such as an unusual noise or a “Check AWD/4WD” dashboard message.
Kia began investigating the issue in January after observing an increase in customer assistance cases, including one reported instance of power loss. An internal teardown revealed that the welding defect compromised the motor shaft’s durability. Engineers also tested an affected vehicle and found that it struggled to accelerate beyond 12 mph (19 km/h) under certain conditions.
See also: Kia EV9 Named ‘Best Electric Vehicle of 2025’ by Cars.com
The automaker has recorded ten reports of power loss or reduction but has not received any reports of related accidents or injuries. Kia will begin notifying affected owners later this week, and dealers will replace the rear gear drive unit. However, the repair process is expected to take more than six hours per vehicle.
The recall follows a string of quality concerns for the EV9, which has otherwise received strong market reception, including being named the 2024 World Car of the Year.
See also: Kia EV9 Electric SUV Earns Five Star Euro NCAP Crash Test