NHTSA Complaint #11710418 — 2018 ACURA TLX

While performing routine maintenance on my 2018 Acura TLX, I discovered a critical structural failure in the front right (passenger side) lower control arm. The factory weld connecting the stamped steel control arm to the compliance bushing housing has failed and separated. Visual inspection reveals a clear manufacturing defect: there is a significant crater and void in the weld bead, indicative of incomplete fusion or a "start/stop" error during the manufacturing process. This is a latent structural defect, not a stress fracture from mileage or impact. The weld has begun to separate from the housing, leaving a visible gap. Safety Risk: This failure compromises the suspension geometry and structural integrity of the vehicle. If the weld completes its separation while driving, it would result in the control arm detaching from the subframe, leading to immediate loss of steering control, wheel collapse, and a high probability of a collision. Status: No warning lights were illuminated prior to discovery. The vehicle has not been involved in any collisions that would affect this component. The defective part is currently on the vehicle but is available for inspection by NHTSA or manufacturer representatives upon request.