NHTSA Complaint #11577805 — 2002 NISSAN PATHFINDER

This relates to Campaign Number 11V244000 We are the original and only owners of the vehicle I originally brought the vehicle in for the recall and they simply sprayed some undercoating in the wheel wells. Less than a month later both strut towers separated from the body of the vehicle while my wife was driving home, she lost steering and could have had a serious or fatal accident. I towed to the dealer and they installed braces in both strut towers. I have always taken exceptional care of my vehicles, which includes multiple washes during winter months and extensive undercarriage washing every spring. This past Oct when I took the vehicle in for mandatory state inspection I was informed that the vehicle would not pass inspection next year. They told me this once before in relation to extensive rust to the passenger side rear frame next to the muffler. I was able to cut out the rust and weld a thicker plate of steel in there to repair the frame. I just changed my oil and looked for what the mechanic was referring too. This time the rust is between the braces they installed for the struts and the front of the wheel well. The mechanic saw the rust coming through the paint and poked at it with a screw driver, the screw driver went right though the body leaving significant holes in the structure that supports the struts. When the weather breaks I will further inspect to determine if there is enough good metal left for me to attempt a repair. I am doubtful a repair will be possible as the metal used to construct this vehicle is very poor quality. Despite my constant care, washing, rust conversion treatments, painting with rust blocking paint and using undercoating, every inch on the underside of the vehicle is rusted. Both rear quarters rotted behind the wheel flares and down into where the rear doors close and contact the rear quarters. Now due to Nissan's decision to use substandard metal I am forced to buy a new vehicle which is currently financially impossible