NHTSA Complaint #11546964 — 2014 KIA SORENTO

Had been getting “BSD” disabled messages while driving on expressway for several months, dealer inspected twice and found nothing. On May 30, 2023 while driving on street rear differential locked not allowing rear wheel rotation for short period ( 2 street blocks ), then resumed operation but with a high pitch squealing. On May 31, 2023 l took vehicle to dealer requesting a full inspection of the differential, mileage at 133367. I was immediately told that the differential is a sealed unit and could not be inspected, but they recommended a transmission force flush, a complete fuel system flush, plus an oil and filter change. I agreed to service, but insisted they needed to test drive vehicle. Dealer called me back same day indicating vehicle ready. We picked up vehicle, $600.93 cost. We were told everything checked out fine. On way home upon entering expressway just a mile away from dealer, rear differential locked up again!! We immediately pulled over to shoulder, Had we been on expressway, our vehicle would have been rear ended ! I called dealer to come pick up vehicle, they sent a tow truck & vehicle was brought back to dealer. Dealer confirmed rear differential was seazed and would have to be replaced. A week later they called to inform us that the front differential/transfer case had also failed and also needed to be replaced. Two weeks later, on June 17, 2023 vehicle repairs were finally completed at cost this time of $7292.60, totaling $7893.53 including initial repair costs. Mileage is now at 138320, and vehicle has once again begun to display “BSD” disabled messages. Differential has been making engagement/disengagement clicking sounds as if their is a lot of backlash/slop between gears.