NHTSA Complaint #11696684 — 2024 HONDA PILOT

Crackling/clicking noises coming from steering rack after the vehicle has warmed up and driven for 10-20 mins. Noises are more noticeable when driving at slow speeds and when pulling in/out of parking spaces. The electric steering rack in my vehicle has been replaced twice under warranty and these noises have reappeared approximately 1-2 months after each repair/replacement event which suggests a design/manufacturing defect with this part. There is no known technical service bulletin of this issue. The short and long-term effects of this defect are not publicly known and may pose a safety hazard. From research and discussions in online forums, this appears to be common problem with 4th generation honda pilots which started in model year 2023.