NHTSA Complaint #10235706 — 2003 HONDA PILOT

THE FRONT LOWER BALL JOINT ON MY 2003 HONDA PILOT SEPARATED WHILE BEING DRIVEN OUT OF A PARKING LOT. THE FRONT RIGHT SUSPENSION COLLAPSED. UPON INSPECTION, THE JOINT HAD NEVER BEEN LUBRICATED WHEN THE CAR WAS ASSEMBLED. THIS JOINT IS A "LUBED-FOR-LIFE" JOINT THAT CANNOT BE INSPECTED OR LUBRICATED ONCE ASSEMBLED. THE PROTECTIVE BOOT AND RETAINING CLIP WERE IN PERFECT CONDITION WHEN THE JOINT FAILED. I AM A MECHANICAL ENGINEER (TENNESSEE LICENSE # 110751) AND HAVE BEEN INVOLVED IN SEVERAL METAL FAILURE INVESTIGATIONS. I AM CERTAIN THAT THIS JOINT FAILED DUE TO HAVING NOT BEEN LUBRICATED AT THE FACTORY. THIS CAR HAD BEEN INSPECTED BY A HONDA DEALERSHIP AS A CERTIFIED USED CAR AND HAD ALSO BEEN SERVICED AT THE HONDA DEALERSHIP WHERE IT HAD PASSED THEIR SUSPENSION CHECK. IF THIS FAILURE HAD OCCURRED 10 MINUTES EARLIER OR LATER WE WOULD HAVE LOST CONTROL OF THE VEHICLE ON THE INTERSTATE AT 70MPH. THE CAR HAS NEVER BEEN IN AN ACCIDENT OR ABUSED IN ANY WAY. NEITHER HONDA USA NOR THE TWO DEALERSHIPS INVOLVED WOULD RECOGNIZE THE SERIOUSNESS OF THIS FAILURE. THE LOWER CONTROL ARM, HUB ASSEMBLY, AND STEERING KNUCKLE WERE REPLACED AT MY EXPENSE. *TR