The passenger side front directional signal went inoperative with about 3,000 miles on the odometer. I went into the owner manual to see what kind of bulb it takes, thinking I might replace it myself to save a trip to the dealership. All the manual said was "LED" for the light. No number, just LED. Curious, I thought, then went on the internet to learn more, and what I learned really torqued my lug nuts. There's no replacing a bulb. The entire headlight assembly must be replaced. List price is almost $2,000 for the assembly, and who knows how much labor would be. I am pissed. Why would a manufacturer design like this? I had a 2009 Dodge minivan that blew only a few bulbs in over 13 years, but each was easily replaced for under five bucks, in my own garage, by me. Is Kia, and from what I've heard, other manufacturers, padding their profits by selling headlight and taillight assemblies in the post-warranty market? (Side view mirrors, too.)
Yes, this will be covered by warranty, but in a few years it won't. Take heed, all.
I can certainly understand your frustration. The experience you're having with the Kia EV9's lighting system is a perfect example of a significant and often upsetting trend in the automotive industry.
You are correct in your assessment. The move to sealed, non-serviceable LED lighting assemblies is a widespread practice among many manufacturers, not just Kia. While LED lights offer several advantages—they're brighter, more energy-efficient, and have a much longer lifespan than traditional halogen or even HID bulbs—the downside is that when a single component fails, the entire, expensive assembly must be replaced.
Here's why manufacturers are designing vehicles this way and what you can do about it:
The Manufacturer's Perspective
The trend toward sealed assemblies is driven by a few key factors:
- Styling and Aerodynamics: LED lights are small and can be arranged in complex, unique patterns, which allows designers to create more distinctive and aerodynamic headlight and taillight shapes. These are often integrated into the body panels in ways that don't allow for simple bulb replacement.
- Durability and Reliability: A sealed unit is better protected from the elements, like moisture and dust, which can reduce the risk of corrosion and failure. The hope is that the LEDs will last the lifetime of the vehicle, so the lack of a replaceable bulb won't matter. Your early failure is an unfortunate exception.
- Profit and Service: As you suspected, there is a profit incentive. While it's not the sole reason for the design, selling complete assemblies after the warranty has expired is a significant revenue stream for both the manufacturer and their dealerships.
The Problem You're Facing
The core issue is that the long-life promise of LEDs doesn't mean they never fail. A single LED or a component in the circuit board that powers it can go bad, and because the unit is sealed, the entire housing becomes a costly piece of plastic and electronics. This is a very different scenario from your old minivan, where the bulb was a cheap and easily accessible component.
Your Warranty and the Future
You are correct that your current issue will be covered under Kia's warranty, likely under the 5-year/60,000-mile "New Vehicle Limited Warranty" since it's a defect in materials or workmanship.
The concern for the future is valid. The cost for a new EV9 headlight assembly is very high, and labor to replace it can be significant. This is a tough pill to swallow for consumers who are used to cheap and easy light bulb changes.
Unfortunately, there isn't much you can do about this design trend. It's the new standard for nearly all new vehicles with premium lighting packages. Your best course of action is to have the dealership replace the assembly under warranty and hope that the replacement unit lasts for many years to come.
