2020 Telluride AWD rear end jerking thumping and vibrating

[TONYK11]

My 2022 EX with 35K miles developed a minor but discernably clunking rear drive train clunking at around 20K miles. Dealership had a shot at a "repair" which was obviously ineffective when driving it for the first time. The clunk has been getting progressively worse, and was diagnosed as a failed AWD Viscose Coupler earlier this week. Parts are ordered. Tech reports that replacement takes a full day if everything goes right, and is covered under warranty.

The lease is up in July 2024 and since the buyout is close to $10K below current market value I was thinking about keeping it. When things like this start failing at 30 - 35K that may not be a great idea!

 

[Tell2Tow]

My clunking/gear slipping sensation started this summer while towing our pop up camper (2022 EX, 30,000 miles at the time). Scheduled an appointment upon return, but symptoms disappeared so I cancelled. It came back a month ago, so I took it in. Took the tech for a ride and he could not diagnose it. Dealer opened a ticket on the Kia Techline. Scheduled another appointment two weeks later as Kia wanted specific tests run and they concluded it was the AWD coupler. Told me the part is now on back order so timeline for fixing is TBD, but then they found a different Kia dealer with a coupler in stock. Not sure if they were able to procure that part or not -- just waiting for a call. Dealership has been helpful and scheduling has been no problem.

 

[jkbenzene]

I dropped mine off at our local dealership today. I told the service person I wanted to take them for a ride so they could see/hear the issue. The Service Lead sitting right next to them said "Yeah, I diagnosed one with similar symptoms last week...why don't you and I go for a ride." They instantly got the vehicle to make the sounds. And then he said if he locked it in 4WD it would be even worse. Sure enough, it was. We did a few 90-degree turns going up a hill on their lot. They took it in and had a tech look at it and are replacing the coupler and rear diff. I asked if there was an upgraded part that is being distributed by Kia and he said yes. Unfortunately, the diff is on backorder so I don't know how long we will be Telly-less.

Also to note I asked if this would be covered under the 100k powertrain warranty, he didn't even flinch and said absolutely and then rattled off all that was covered.

Hope this helps some others!

@reverend_sean wondering if you could expand upon your conversation on the dealership about what they specifically said about the "upgraded part" when you got your repair completed (others may be interested also). Kind of was wondering if that applied to the rear diff, the awd coupler, or both. And then I also wondered what you specifically said to the service counter to explain the problem and then how you drove around the parking lot to demonstrate the issue. I am only just above 9K miles on a '23 but I have already noticed the issue. Maybe my issue is slightly less severe than yours but I want to make sure I am armed appropriately at the dealership. I am dreading the "I don't hear/feel anything" response.

Also, others have noted that this AWD coupler issue doesn't fall under the 100K powertrain warranty, and is only covered to 60K when service departments have specifically asked/looked up the warranty for the coupler (maybe the differential is). Not sure exactly how a critical component of the AWD system isn't powertrain is beyond me, but apparently that is what Kia decided. Seems like dealerships are mixed on replacing tires also due to this issue. I have noted before that I don't think people are going to get much help from Michelin because their warranty does not cover original equipment tires anymore.

 

[reverend_sean]

I finally got the car back yesterday. So it was sitting there from 9/21-10/31, just waiting on parts from across the ocean. It does feel good and the clunking is definitely gone.

wondering if you could expand upon your conversation on the dealership about what they specifically said about the "upgraded part" when you got your repair completed (others may be interested also)

Not sure if I can really expand on anything re the "upgraded parts". I haven't done any research to try and find old vs new part numbers so it's all speculation based on what the service guy told me. The part numbers from my invoice are as follows; 4wd viscous coupling 47800-4G500, rear diff carrier assembly 53000-4G500.

Specifically, I said "I have a clunking feeling that translates through the vehicle when making 90-degree turns from a dead stop and when accelerating hard on lower speed turns (like 35mph zones with sharp turns)". The write-up on the invoice from the service advisor says "took vehicle for a test drive, once vehicle is up to operating temperature rear differential is binding along with coupling"

Maybe try out that 4wd lock test that I called out above prior to going. If it makes it worse, it might make your argument easier. I do feel I got lucky that my service advisor knew of the issue right away. LMK if you have other questions, glad to help!

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[PittPa]

Did you go to where I went?

 

[reverend_sean]

Did you go to where I went?

No. Robinson since that’s where I purchased it.

 

[Wee]

So does anyone potentially have an idea if we are all just going to start running into the same issues down the road even after the AWD coupler is replaced? I guess maybe some people will get lucky with the replacement and get one installed with better tolerances.

I know that I have seen a mention somewhere (not sure if it was on another thread in this forum) that someone had their coupler replaced and apparently got info from the tech that the part had been "updated". However, I also saw a report that some dealerships were ordering replacement couplers and basically getting some that were unusable. Not sure what was going on with those.

Kind of concerned since I have '23 Telluride with only 9000 miles. I am 95% sure my vehicle is starting to exhibit signs of a failing coupler.

Very valid and legit concerns.
Kia has a real winner on their hands from a design point, unfortunately I don't think these will stand the test of time from what I've experienced and seen. There will be plenty of owners who put 100k+ miles with no issues, but I fear and foresee there will many more than what is acceptable that experience a variety of issues within 5yrs that frankly shouldn't exist as often as they do (just my $.02)

I'm with you which is why I'm currently sitting in a Mazda showroom. I've owned my Telluride for over 3 years, put 50k miles on it, got things fixed under warranty and had my fun. My warranty is up in 7k miles and it's time to move on. I don't know who would think this car is good for a reliable long run but it's not me.

This! unfortunately......as we loved the tangibles the Telly has to offer compared to the competition.

 

[Tell2Tow]

My clunking/gear slipping sensation started this summer while towing our pop up camper (2022 EX, 30,000 miles at the time). Scheduled an appointment upon return, but symptoms disappeared so I cancelled. It came back a month ago, so I took it in. Took the tech for a ride and he could not diagnose it. Dealer opened a ticket on the Kia Techline. Scheduled another appointment two weeks later as Kia wanted specific tests run and they concluded it was the AWD coupler. Told me the part is now on back order so timeline for fixing is TBD, but then they found a different Kia dealer with a coupler in stock. Not sure if they were able to procure that part or not -- just waiting for a call. Dealership has been helpful and scheduling has been no problem.

Update -- Coupler replaced three days ago. Took 5 hours, but problem is resolved.

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[Rocketdog]

Yesterday with cruise control engaged at 70 mph on a flat road all of a sudden the whole vehicle starts to shudder. Upon braking which disengaged the CC the shaking stopped. Reengaging the CC later everything was normal. A bit scary to be sure.
Secondly, I'm staring to feel the vibration while accelerating that others have noticed (though not when turning). We have towed a 16ft camper which is about 4500 lbs for over 10,000 miles and not had an issue, now I feel it and even went not towing. When you let off the gas the vibration goes away. 28K miles on vehicle. Just had it dealer serviced two months ago with tires rotated and balanced.

I know this is two issues but both are about vibrations.

 

[Tbrew85]

Yesterday with cruise control engaged at 70 mph on a flat road all of a sudden the whole vehicle starts to shudder. Upon braking which disengaged the CC the shaking stopped. Reengaging the CC later everything was normal. A bit scary to be sure.
Secondly, I'm staring to feel the vibration while accelerating that others have noticed (though not when turning). We have towed a 16ft camper which is about 4500 lbs for over 10,000 miles and not had an issue, now I feel it and even went not towing. When you let off the gas the vibration goes away. 28K miles on vehicle. Just had it dealer serviced two months ago with tires rotated and balanced.

I know this is two issues but both are about vibrations.

Mine is a 2020 with 65K miles at time of issue. I had same 70 MPH issue. Long story short, it was the right front drive axle. They replaced under powertrain warranty (after much back and forth and dealing with incompetent "master technician" issues).

Im now having the clunk on acceleration with turning. They have already diagnosed as the AWD Differential coupler PN# 47800-4G500. My service writer is "waiting to hear from Kia if this is covered under basic warranty or powertrain warranty". I've read differing accounts on this forum as to which warranty covers this $1800 job. I cant imagine a world in where a viscous coupler/AWD differential is NOT considered part of the powertrain.

 

[Tbrew85]

Mine is a 2020 with 65K miles at time of issue. I had same 70 MPH issue. Long story short, it was the right front drive axle. They replaced under powertrain warranty (after much back and forth and dealing with incompetent "master technician" issues).

Im now having the clunk on acceleration with turning. They have already diagnosed as the AWD Differential coupler PN# 47800-4G500. My service writer is "waiting to hear from Kia if this is covered under basic warranty or powertrain warranty". I've read differing accounts on this forum as to which warranty covers this $1800 job. I cant imagine a world in where a viscous coupler/AWD differential is NOT considered part of the powertrain.

Update: I was informed that this part IS covered under the 100,000 mile powertrain warranty and I have an appointment scheduled for next Wednesday to have the repair done. Ya'll scared me. haha

 

[Shaeboy1503]

Update: I was informed that this part IS covered under the 100,000 mile powertrain warranty and I have an appointment scheduled for next Wednesday to have the repair done. Ya'll scared me. haha

Please reply once you get this fixed. Mine is a 2020 also with 77k miles. Same issue at parking lot speeds. I can get it to mess up after vehicle is warmed up. I was in a parking lot with a slight hill and turn the wheel to the right or left. My 10 year old felt it in the rear. I thought it might be the AWD system. Also feel it when accelerating from a stop while turning on take off. So glad it sounds like it is covered under the 100k powertrain. Calling to schedule dealer appointment today.

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[reverend_sean]

Just chiming in for the record books. My coupler and rear diff were replaced at 12k miles. We just rolled over to 24k miles and it is happening again. Taking it to have it diagnosed next week. I asked if "upgraded parts" were being used when my first one was replaced, I was told yes.

 

[NickyRay]

Did you try to have the wheels road-force balanced (more precise than regular wheel balancing)? That's what I did to my 2022 after wheel balancing helped diminish but not fix the vibration from 63-73 mph. The mechanic at Kia also noticed the vibration and performed the road-force balance which eliminated the problem.

Same thing over here. We bought new tires...it is still vibrating and shaking the whole car. It usually happens at high speeds but is not constant. Sometimes it lasts along time, then goes away and comes back 20 - 30 min later. We notice it more on the freeway and especially when we have longer road trips. It is scary!

 

[NickyRay]

@Theauharem, thanks for the suggestions. I also do my own tire changeover at home using star pattern. I torque to OEM recommended 94lbs so I'll try torquing it +10 to 104 ftlbs instead.

@Wee, I also felt the vibration in the steering wheel and also from the seat. No one was in the backseat so not sure. I even checked at a truck stop to make sure there's no loose lug nuts. Verified no loose lug nuts. I'm sorry to hear your problem has gotten worse. I hope mine was just one time thing.

Same thing over here. We bought new tires...it is still vibrating and shaking the whole car. It usually happens at high speeds but is not constant. Sometimes it lasts along time, then goes away and comes back 20 - 30 min later. We notice it more on the freeway and especially when we have longer road trips. It is scary!

 

[NickyRay]

The first thing to check when experiencing steering wheel vibration at speed, is to have the front wheels re-balanced. If that doesn't fix it then you'll have to dig deeper.

Same thing over here. We bought new tires...it is still vibrating and shaking the whole car. It usually happens at high speeds but is not constant. Sometimes it lasts along time, then goes away and comes back 20 - 30 min later. We notice it more on the freeway and especially when we have longer road trips. It is scary!

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[NickyRay]

Same thing over here. We bought new tires...it is still vibrating and shaking the whole car. It usually happens at high speeds but is not constant. Sometimes it lasts along time, then goes away and comes back 20 - 30 min later. We notice it more on the freeway and especially when we have longer road trips. It is scary!

 

[NickyRay]

Just got my 2022 SX this week and it has the dreaded vibration. Going to get the wheels balanced tomorrow and wondering if anyone has an update with their issues (and hopeful resolution). I downloaded the TSB and will bring it with me to the dealer near me (I bought it in Ewing NJ, about 1.5 hrs from me).

Same thing over here. We bought new tires...it is still vibrating and shaking the whole car. It usually happens at high speeds but is not constant. Sometimes it lasts along time, then goes away and comes back 20 - 30 min later. We notice it more on the freeway and especially when we have longer road trips. It is scary!

 

[NickyRay]

Thanks for sharing your post. On March 21 2022, KIA escalated my case. My contact has proved to be useless just like everyone has found. Here is what they emailed to me, maybe it will help if we all call them.

In the event that you believe Kia has been unable to satisfactorily address the concern, a special alternative resolution program called BBB AUTO LINE is available to you. This independent program is administered by BBB National Programs and is provided at no cost to you. You may contact them at: BBB AUTO LINE a Division of BBB National Programs, Inc. 1676 International Drive, Suite 550, McLean, VA 22102; Ph: (800) 955-5100.

Same thing over here. We bought new tires...it is still vibrating and shaking the whole car. It usually happens at high speeds but is not constant. Sometimes it lasts along time, then goes away and comes back 20 - 30 min later. We notice it more on the freeway and especially when we have longer road trips. It is scary!

 

[crimscrem]

I posted this elsewhere not having seen this thread. Sorry for basically double posting.

Looking back through this, it looks like others have had this vibration issue "show up" down the road. Our Telluride is a 2020 that we purchased in January of 2020. So, as luck would have it, we're taking it to the dealership just a couple of weeks past the 5 year warranty mark.

Had no issues with high way speeds or accelerations for 4 years plus. Got new tires in November and have had issues since. I'm pretty confident that this is not a tire issue given that we've had them road forced balanced/checked 3 times now and the alignment done/checked twice. Vibration issue is similar to what I'm seeing here. Mainly highway speeds above 60. Totally disappears once you let off the accelerator. It's not always constant. On a recent 2.5 hour drive, it didn't happen too often. But on the way back, it was near continuous. between 60 and 85.

We're going in to the dealership for diagnosis. We've had good luck with this dealership, so I'm hoping this doesn't turn into a nightmare. Hopefully it's the TSB in play or something that falls within the powertrain warranty.