NHTSA Complaint #11162277 — 2004 HONDA PILOT

REAR SUSPENSION CROSS MEMBER SUPPORT RUSTS OUT DUE TO DESIGN. OVER TIME WATER IS THROWN FROM TIRE AND RESTS IN THE SUPPORT NUT AREA. OVER TIME RUST BUILDS UP AND THE SUPPORT BREAKS THROUGH THE REAR CROSS MEMBER. NO WAY FOR THE WATER TO ESCAPE. I AM SUPPLYING ONE PICTURE OF MY CAR SHOWING WHERE RUST HAS STARTED. TWO ADDITIONAL PICTURES ARE FROM THE SHOP FIXING MY CAR FOR ANOTHER ISSUE SHOWING ANOTHER CUSTOMER WITH THE SAME ISSUE, BUT MUCH WORSE. YOU CANNOT BUY THE CROSS MEMBER DUE TO HOW THE CAR IS MADE. SO THE FIX IS TO CUT OUT THE RUST AND WELD IN A NEW SUPPORT. THE CAR SHOP WILL RUST PROOF AND PUT A WATER RESISTANT FOAM OVER THE NEW SUPPORT NUT ENSURING THE RUST WILL NOT RETURN. MY COST OF THIS REPAIR FOR BOTH SIDES IS JUST SHY OF $2000. MY OPINION IS THIS IS A FACTORY DESIGN FLAW THAT SHOULD BE ADDRESSED BY HONDA. NO RECALLS FOR THIS ISSUE EXIST, AND YOU ARE TALKING ABOUT THE BACK END SUPPORT POTENTIALLY COLLAPSING AS YOU ARE DRIVING. THE ISSUE WAS CAUGHT BY THE TRANSMISSION SHOP DOING OTHER WORK ON 12/18/2018. THEY JUST FIXED THE OTHER CUSTOMER'S PILOT (2004) WITH THE SAME ISSUE (PICTURES I ATTACHED) AND HAD THE FORESIGHT TO LOOK AT MY 2004 PILOT. SO FOR SAFETY REASONS I HAVE NO CHOICE BUT TO HAVE THEM APPLY THE SAME FIX.