NHTSA Complaint #11709507 — 2023 HONDA PASSPORT

While driving at highway speeds, I experienced multiple loud, intermittent double-knocking noises within a short period of time, followed by an additional grinding/rotational noise at low speeds. These noises were abnormal and raised immediate safety concerns, prompting me to bring the vehicle to a dealer that day. During inspection and test driving, the noise condition was confirmed. Further inspection revealed that a front brake caliper (flange) bolt was missing, and the brake caliper had shifted out of position. This bolt is a critical fastener that secures the brake caliper to the brake assembly and is available for inspection through service records. This condition posed a serious safety risk, as a shifted or unsecured brake caliper could result in reduced braking performance, brake failure, or wheel lock-up, potentially endangering vehicle occupants and other road users. The issue was confirmed by an authorized Honda service center, and the vehicle was inspected by manufacturer-authorized personnel. The vehicle was repaired at no charge by reinstalling the correct hardware and restoring the brake caliper to its proper position. One week later, I have come to find out this is a known issue, and Honda has issued a Technical Service Bulletin (TSB) for 2023–2024 Honda Passport vehicles addressing loose or missing front brake caliper/flange bolts. I never received a recall notice or voluntary letter from Honda notifying me this might be an issue or to have it inspected. No warning lights or messages appeared prior to the incident; the only symptoms were the knocking noises at highway speeds and grinding noise at low speed.