2006 Honda Pilot Body & structure Problems

Rear suspension cradle attachment points at the frame corrode. This is common on all pilots in northern climates. Honda has recalled both the Ridgeline and CRV models for corrosion issues related to suspension attachment point corrosion but refuses to recall the pilot. While they claim you will not lose control when the suspension disconnects from the frame the vehicle cannot pass inspection and thus becomes disposable. When vehicles are otherwise perfect this is not acceptable from both safety and fiscal aspects. Please investigate this further as Honda has a repair kit and guidelines but charges thousands for the work .

NHTSA ID

11653782

Incident

Apr 1, 2025

The contact owns a 2006 Honda Pilot. The contact stated that following a State Safety Inspection, the vehicle failed due to extensive corrosion to the rear suspension and to the rear trailing arm. The contact was advised by the State Inspector not to drive the vehicle due to the advanced state of corrosion. The contact had researched online and related the failure to NHTSA Campaign Number: 23V228000 (Structure). The contact had called the manufacturer and was informed that the vehicle was not included in the recall. The vehicle was not taken to a dealer or independent mechanic. The vehicle was not diagnosed and was not repaired. The failure mileage was approximately 175,000.

NHTSA ID

11607352

Incident

Jul 29, 2024

Mileage

175,000 mi

Hi Honda pallet is completely rusted out and corroded on the back underneath. My mechanic said it is dangerous. The left-hand side could literally fall out while driving and this is not something normally seen even with the car being older

NHTSA ID

11577961

Incident

Mar 18, 2024

2006 Honda Pilot Subframe rust which is causing the subframe to pull away from the body of the vehicle. Known issue with a patch kit, but no dealership or auto body shop willing to fix it. Honda has recalled the Ridgeline and CRV for the same issue, but not the Honda Pilot. Vehicle is in perfect running condition except for this design flaw. Would like to get it repaired instead of junking a perfectly drivable vehicle.

NHTSA ID

11577232

Incident

Sep 13, 2023

The car's rear subframe has rusted to the point where the suspension no longer correctly mounts to the frame causing an unstable ride and handling issues. Yes, the car can be inspected. This is a safety issue because other parts of the suspension system or brake system could become loose or break off or otherwise be negatively affected by this corrosion. It could also cause me to be unable to control the vehicle properly if it gets worse. Yes, the problem has been confirmed by both a dealer and an independent mechanic. The Honda dealership has inspected it. There is a very similar problem with some of Honda's other models from this era including the Ridgeline and the CRV that have recently been recalled and I think this vehicle should be recalled for this issue as well.

NHTSA ID

11524539

Incident

Sep 5, 2022

The left rear frame of the vehicle is rusted out where the rear drive line bolts to the body or frame. Causing the rear drive line to have the ability of failing to stay attached to the vehicle. The rear suspension also connects at the same area. Just a huge rotted out hole at the moment.

NHTSA ID

11501383

Incident

Dec 17, 2022

WHILE MOVING SLOWLY IN A PRIVATE DRIVE AND TURNING STEERING WHEEL TO THE RIGHT THE CAR SUDDENLY ACCELERATED TO FULL THROTTLE CAUSING THE CAR TO CRASH INTO ANOTHER PARKED CAR AND A SUPPORT POST OF A CARPORT

NHTSA ID

11377225

Incident

Nov 22, 2020

Mileage

190,000 mi

WE WERE LEAVING THE DRIVEWAY ON CHRISTMAS EVE, WE SUDDENLY HEARD A LOUD THUNK FOLLOWED BY A GRINDING NOISE FROM BENEATH THE VEHICLE. WE STOPPED IMMEDIATELY AND EXITED THE VEHICLE TO SEE WHAT HAD HAPPENED. I EXPECTED TO FIND THAT WE HAD RUN OVER A BICYCLE BUT INSTEAD FOUND THE ENTIRE REAR AXLE HANGING FROM THE SPRINGS. BOTH REAR SUSPENSION MOUNTS HAD CATASTROPHICALLY FAILED PULLING COMPLETELY OUT OF THE SUBFRAME. THE SUBFRAME CROSSMEMBER AND A NUMBER OF COMPONENTS WERE FOUND TO BE HEAVILY RUSTED AND SEVERELY STRUCTURALLY COMPROMISED. WE HAD PLANNED TO DRIVE ABOUT 80 (PREDOMINANTLY FREEWAY) MILES EACH WAY THAT DAY TO VISIT FAMILY FOR THE HOLIDAY. IT IS A SMALL MIRACLE THAT THESE FAILED IN THE DRIVEWAY AND NOT ON THE FREEWAY AT 70 MILES PER HOUR. A CATASTROPHIC FAILURE LIKE THIS AT FREEWAY SPEEDS COULD BE DEADLY! A QUICK GOOGLE SEARCH REVEALED THIS TO BE A RELATIVELY COMMON PROBLEM WITH THIS VEHICLE AND SHOULD WARRANT A RECALL. PLEASE DON'T WAIT UNTIL SOMEONE IS KILLED BY THIS OBVIOUS DESIGN FLAW.

NHTSA ID

11291676

Incident

Dec 24, 2019

Mileage

190,000 mi

2006 HONDA PILOT EX MILEAGE: 144,309 I WAS ACCELERATING FROM A STOP WHEN I FELT A JOLT COMING FROM THE REAR OF THE CAR. SEVERAL WARNING LIGHTS LIT UP IN THE DASHBOARD, THERE WAS A LOUD EXHAUST LEAK, AND THE CAR WAS NO LONGER ACCELERATING. THERE WAS AN AUTO CARE CENTER 50 YARDS AWAY SO I SLOWLY DROVE IT THERE FOR AN INSPECTION. THE MECHANIC LIFTED THE VEHICLE AND SHOWED ME THAT THE BACK TWO REAR SUBFRAME MOUNTS WERE DETACHED FROM THE BODY WHICH MADE THE CAR INOPERABLE. THERE WAS NO VISIBLE RUST ON THE UNDERCARRIAGE; THE SUBFRAME MOUNTS RUSTED FROM THE INSIDE OUT. MY INSURANCE COMPANY WOULD NOT COVER THE DAMAGE AS IT WAS A RUST ISSUE. THE CAR WAS IRREPARABLE SO I HAD TO TOTAL THE CAR AND RECEIVED 10% OF WHAT THE CAR WAS WORTH RUNNING FROM THE JUNK YARD. I PURCHASED THE PILOT NEW IN FEB. 2006 AND PERFORMED ALL THE RECOMMENDED HONDA MAINTENANCE. I PERSONAL PERFORMED ALL OIL AND BREAK JOBS SO I WAS FAMILIAR WITH THE UNDERCARRIAGE OF THE CAR. I DID NOT SEE ANY RUST UNDER THE CAR THAT WOULD HAVE ALERTED ME THERE WAS A POTENTIALLY DANGEROUS ISSUE WITH THE REAR SUBFRAME. A GOOGLE SEARCH TURNED UP SEVERAL OTHER HONDA PILOTS OF THIS GENERATION HAVING THE SAME SUBFRAME RUST AS MINE WITH THE SAME CATASTROPHIC FAILURE OF THE REAR MOUNTS. I BELIEVE THAT THIS IS A MANUFACTURING DEFECT IN THAT WATER WAS ALLOWED TO POOL BETWEEN THE LAYERS OF STEEL IN THE UNIBODY. THE CAR HAD 144,309 MILES ON IT AND WAS MECHANICALLY IN GREAT CONDITION UNTIL I HAD THIS ISSUE.

NHTSA ID

11231743

Incident

Apr 14, 2019

Mileage

144,309 mi

MY WIFE WAS TURNING INTO OUR GARAGE WHEN THE ENGINE SUDDENLY REVED UP CAUSING HER TO CRASH INTO SEVERAL ITEMS IN THE GARAGE (AIR COMPRESSOR,GAS GRILL,SHOP VAC,SHELVING, AND OTHER THINGS)PUSHING THEM AGAINST THE BACK WALL BEFORE STOPPING AND ALLOWING HER TO TURN THE CAR OFF. SHE HAD THE BRAKE FULLY DEPRESSED AND THE STEERING WHEEL TURNED BUT HAD NO CONTROL. THE CAR IS A 2006 HONDA PILOT WITH ABOUT 170,000 MILES.

NHTSA ID

11229584

Incident

Jul 4, 2019

Mileage

170,000 mi

TOOK VEHICLE IN FOR NYS INSPECTION AND THE MECHANIC CALLED ME TO TELL ME HE CANNOT PASS THE INSPECTION. THE REAR SUB-FRAME HAS SEVERE CORROSION. THERE ARE LARGE SECTIONS COMPLETELY RUSTED OUT. HE SAID NO ONE WOULD PASS THIS VEHICLE'S INSPECTION. HE SAID THERE IS A HIGH RISK OF THE REAR SUSPENSION TOTALLY COLLAPSING RESULTING IN A LOSS OF CONTROL OF THE VEHICLE. HE SAID JUST HITTING A BUMP IN THE ROAD HARD ENOUGH WILL CAUSE THIS. SAID HE HAS NEVER SEEN CORROSION THIS BAD ON A 12 YEAR OLD VEHICLE, EVEN IN NYS.

NHTSA ID

11170552

Incident

Jan 14, 2019

Mileage

186,500 mi

WHILE PULLING INTO A PARKING LOT A LOUD BANG HAPPEND IN OUR 2006 HONDA PILOT. WE THOUGHT WE HAD BOTTOMED OUT. IT TURNS OUT THAT THE REAR SUBFRAME, SUSPENSION, AND DRIVE TRAIN HAD FALLEN OUT OF THE REAR CROSSMEMBER. THIS IS DUE TO PREMATURE RUST AND INADEQUATE METAL USED IN THE REAR SUBFRAME. THE REAR SUBFRAME AND SUSPENSION IS ONLY BEING HELD IN WITH 2 MORE RUSTY BOLTS. THIS VEHICLE IS NOT RUSTY ANYWHERE ELSE AND IS IN EXCELLENT CONDITION. IT DOES HAVE 165,000 MILES ON IT. THE VEHICLE IS NO LONGER SAFE TO DRIVE . I HATE TO THINK WHAT WOULD HAVE HAPPENED AT 70 MPH ON THE HIGHWAY WITH MY FAMILY. THIS IS A SERIOUS SAFETY ISSUE AND NEEDS TO BE ADDRESSED IMMEDIATELY. THE CERTIFIED HONDA DEALER THAT I TOOK IT TOO SAYS THEY CAN'T FIX IT, AND THE VEHICLE IS JUNK. THE VEHICLE IS IN EXCELLENT CONDITION IN EVERY OTHER ASPECT. THE FAILURE IS OBVIOUSLY A MANUFACTURE DEFECT. I HAVE E-MAILED HONDA, BUT THEY HAVE NOT RESPONDED TO ME EXCEPT FOR A AUTO RESPONSE E-MAIL. THIS VEHICLE IS WORTH ABOUT $6000 BEFORE THIS HAPPENED.

NHTSA ID

11138967

Incident

Sep 29, 2018

Mileage

165,000 mi

TL* THE CONTACT OWNS A 2006 HONDA PILOT. WHILE THE VEHICLE WAS BEING SERVICED AT BUERKLE HONDA (3360 HWY 61 N, ST PAUL, MN 55110, (651) 490-6600), THE TECHNICIAN NOTICED THAT THE PART LOCATED BETWEEN THE FRAME AND THE BODY WAS CORRODED. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS UNSAFE TO DRIVE AND COULD NOT BE REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 170,000. THE VIN WAS NOT AVAILABLE.

NHTSA ID

11130479

Incident

Aug 29, 2018

Mileage

170,000 mi

ON 8/18/18, WHILE DRIVING ON A HIGHWAY AT ABOUT 50 MPH, WE HEARD A LOUD THUD. THEN WHEN THE ACCELERATOR WAS PUSHED, THE CAR MADE A LOUD NOISE. I CALLED MY MECHANIC THINKING IT MIGHT BE THE EXHAUST. WHEN HE LOOKED AT IT ON 8/22/18, HE INFORMED ME THE REAR SUB FRAME WAS PULLING OUT OF THE BODY, AND THE CAR WAS NOT SAFE TO DRIVE. HE SAID THIS SHOULDN'T HAVE HAPPENED TO A CAR THAT IS 12 YEARS OLD, AND IN GOOD MECHANICAL CONDITION. HE SAID THE ONLY THING HOLDING THE REAR FRAME UP WAS MY EXHAUST PIPE.

NHTSA ID

11122153

Incident

Aug 18, 2018

Mileage

210,600 mi

REAR SUB-FRAME MOUNT HAS SEPARATED FROM FRAME OF THE VEHICLE - CAR HAS NEVER GONE OFF ROADING - ALL HIGHWAY MILES - CAR WAS WELL MAINTAINED - IT SHOULDN'T HAVE HAPPENED

NHTSA ID

11079676

Incident

Mar 14, 2018

Mileage

267,875 mi

TL* THE CONTACT OWNS A 2006 HONDA PILOT. THE CONTACT STATED THAT THE LIFTGATE FRACTURED. THE VEHICLE WAS TAKEN TO MARKLEY HONDA (3401 S COLLEGE AVE FORT COLLINS, CO) WHERE THE CONTACT WAS INFORMED THAT THE VEHICLE WAS OUT OF WARRANTY AND HE WOULD HAVE TO PAY OUT OF POCKET. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT DID NOT OFFER ANY ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 100,000. THE VIN WAS NOT AVAILABLE.

NHTSA ID

10994979

Incident

Jun 15, 2015

Mileage

100,000 mi

THE REAR DOOR/HATCH OF OUR 2006 HONDA PILOT HAS AN ISSUE WITH THE LATCHING MECHANISM. THE ACTUAL MECHANISM ON THE REAR HATCH HAS BECOME DISCONNECTED FROM THE FRAME AND IS ABLE TO MOVE FREELY ABOUT. THIS CAUSES THE REAR HATCH TO NOT LATCH, LATCH PARTIALLY, OR LATCH BUT STILL ALLOW THE REAR HATCH TO SLIGHTLY MOVE. THE LATCHING MECHANISM IS ONLY BEING HELD IN PLACE (IN A CONFINED AREA) BY THE PLASTIC PANELING OF THE CAR. SINCE THE LATCH IS NO LONGER ATTACHED TO THE FRAME, THE MOVEMENT OF THE MECHANISM DETERMINES IF THE REAR HATCH IS GOING TO LATCH OR NOT. WHEN IT IS LATCHED, THE ONLY ITEM SECURING THE MECHANISM IS THE PLASTIC PANELING. THE MECHANISM ITSELF IS NOT DEFECTIVE OR BROKEN HOWEVER; THE WAY THE MECHANISM HAS BEEN SECURED SEEMS TO BE THE ISSUE. THE MOST CONCERNING ASPECT IS HOW A DOOR LATCH MECHANISM COULD BECOME DISCONNECTED AND ALLOW FOR AN INCIDENT TO POSSIBLY OCCUR. *TR

NHTSA ID

10648776

Incident

Oct 20, 2014

Mileage

120,000 mi

NOTICED CLEAR COAT NON EXISTENT ON MOST OF VEHICLE. VEHICLE IS WHITE AND YOU CAN WIPE YOUR HAND OVER MOST ANY AREA (WET OR DRY) AND YOU WILL HAVE WHITE PAINT ON YOUR HAND. *TR

NHTSA ID

10522776

Incident

Jul 1, 2012

Mileage

155,000 mi

PAINT IS SHOT ON HOOD,CLEAR COAT IS DEFECTIVE. *TR

NHTSA ID

10521310

Incident

Oct 17, 2012

DRIVING ON THE CITY STREETS ABOUT 15 MPH AROUND A CORNER THE SPARE TIRE FELL OFF FROM THE BOTTOM OF THE VEHICLE. UPON FURTHER INVESTIGATION THE CABLE THAT HOLDS THE SPARE TIRE WAS FRAYED. THE END OF THE CABLE WAS FOUND ON THE STREET ALONG WITH THE SPARE TIRE. THIS EVENT CAUSED NO DAMAGE TO MY VEHICLE OR ANY OTHER VEHICLE OR PEDESTRIANS(HAPPENED IN FRONT OF AN ELEMENTARY SCHOOL AFTER DROPPING OFF MY KIDS). IF THIS INCIDENT WOULD HAVE HAPPENED ON THE FREEWAY, IT MIGHT HAVE HAD A DIFFERENT OUTCOME. *TR

NHTSA ID

10475401

Incident

Sep 14, 2012

Mileage

85,000 mi

WET FLOORS IN FOOTWELL AREA. COMMON PROBLEMS ON MANY YEARS OF PILOT/RIDGELINE VEHICLES. HONDA REFUSES TO ADDRESS THIS ISSUE UNDER FACTORY BUMPER-BUMPER WARRANTY AND HONDACARE EXTENDED WARRANTY, YET HONDA IS AWARE AND ISSUED A TSB SURROUNDING FOOTWELL LEAKS. *JS

NHTSA ID

10453514

Incident

Mar 29, 2012

Mileage

97,914 mi

THE REAR DOOR/HATCH OF OUR 2006 HONDA PILOT HAS AN ISSUE WITH THE LATCHING MECHANISM. THE ACTUAL MECHANISM ON THE REAR HATCH HAS BECOME DISCONNECTED FROM THE FRAME AND IS ABLE TO MOVE FREELY ABOUT. THIS CAUSES THE REAR HATCH TO NOT LATCH, LATCH PARTIALLY, OR LATCH BUT STILL ALLOW THE REAR HATCH TO SLIGHTLY MOVE. THE LATCHING MECHANISM IS ONLY BEING HELD IN PLACE (IN A CONFINED AREA) BY THE PLASTIC PANELING OF THE CAR. SINCE THE LATCH IS NO LONGER ATTACHED TO THE FRAME, THE MOVEMENT OF THE MECHANISM DETERMINES IF THE REAR HATCH IS GOING TO LATCH OR NOT. WHEN IT IS LATCHED, THE ONLY ITEM SECURING THE MECHANISM IS THE PLASTIC PANELING. THE MECHANISM ITSELF IS NOT DEFECTIVE OR BROKEN HOWEVER; THE WAY THE MECHANISM HAS BEEN SECURED SEEMS TO BE THE ISSUE. THE MOST CONCERNING ASPECT IS HOW A DOOR LATCH MECHANISM COULD BECOME DISCONNECTED AND ALLOW FOR AN INCIDENT TO POSSIBLY OCCUR. *TR

NHTSA ID

10441048

Incident

Dec 16, 2011

Mileage

85,800 mi

TL* THE CONTACT OWNS A 2006 HONDA PILOT. THE CONTACT STATED THAT AFTER ROLLING DOWN THE REAR DRIVERS SIDE WINDOW, IT WOULD NOT ROLL BACK UP. A POPPING NOISE COULD BE HEARD COMING FROM THE WINDOW WHILE THE CONTACT ATTEMPTED TO ROLL IT BACK UP. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND WAS TOLD THAT THE ACTUATOR FOR THE WINDOW FAILED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE AND CURRENT MILEAGES WERE 86,912.

NHTSA ID

10411551

Incident

Jul 8, 2011

Mileage

86,912 mi

2006 HONDA PILOT-SEVERE INTERIOR LEAK IN FRONT PASSENGER SIDE FLOORBOARD, EXTENDING TO DRIVER'S SIDE FLOORBOARD. UNKNOWN HOW LONG THIS HAS BEEN OCCURRING. THE CARPET IS SATURATED. THE CARPET PAD UNDERNEATH IS ALSO SATURATED. MILDEW, MOLD AND BODY RUST WILL DEVELOP. HONDA ISSUED SERVICE BULLETIN (07-010) FOR THIS PROBLEM ON FEB. 8, 2007. DEALER DISCLAIMS ANY RESPONSIBILITY FOR SERVICE BULLETIN WORK, DUE TO OUTSIDE OF THEIR 3 YEAR WINDOW. NO ACCIDENTS/ VEHICLE DAMAGE PRIOR TO FINDING SOAKED CARPET. REGULAR MAINTENANCE DONE PER MANUFACTURER'S SCHEDULE. VEHICLE STILL UNDER EXTENDED WARRANTY. LACK OF NOTICE ABOUT SERVICE BULLETIN CAN LEAD TO MOLD ISSUES, BY EXTENSION TO RESPIRATORY ISSUES. HONDA CAN PREVENT THIS POTENTIAL PROBLEM BY NOTIFYING OWNERS, NOT WAITING FOR THEM TO DISCOVER SATURATED, SOAKED, AND IN SOME INSTANCES FROZEN CARPET INSIDE THE CAR. *TR

NHTSA ID

10390029

Incident

Feb 23, 2011

BEGAN NOTICING A MUSTY SMELL IN THE VEHICLE, FOLLOWED SEVERAL MONTHS LATER BY A SLOSHING SOUND THAT EVENTUALLY MANIFESTED ITSELF INTO A ROLLING WAVE OF WATER THAT SWEPT OVER MY FLOOR MATS. WATER IS SATURATING THE CARPETS (THINK OF A WET SPONGE) AFTER ENTERING THE VEHICLE PASSENGER COMPARTMENT THROUGH UNDETERMINED POINTS AT OR NEAR THE FIREWALL. THIS DEFINITELY OCCURS WHENEVER THE VEHICLE IS DRIVEN IN RAIN, WHEN DRIVEN OVER WET AND SNOW-COVERED ROADS, AND WHEN SITTING IN A CAR WASH. I HAVE NOT DETERMINED IF IT OCCURS WHILE THE VEHICLE SITS UNUSED IN THE DRIVEWAY. THE DEALER HAS REMOVED, CLEANED, REINSTALLED, AND RESEALED A "BODY PLUG" THAT WAS SUPPOSEDLY IMPROPERLY SEALED AT THE FACTORY; YET, EVEN AFTER THIS SERVICE WORK, THE PROBLEM PERSISTS. SEARCHING THE WEB, I'VE NOTICED OTHER HONDA PILOT AND RIDGELINE OWNERS EXPERIENCING THE SAME TYPE OF WATER LEAKAGE PROBLEM; AND, WITH VARYING DEGREES OF SUCCESS, DEALERS SEEM TO BE PUTTING "BAND AIDS" (CAULK) ON A VARIETY OF NOTED AND POTENTIAL ENTRY POINTS THROUGH THE FIREWALL, WHEEL WELLS, AND WELDED METAL JOINTS. *TR

NHTSA ID

10274712

Incident

Aug 1, 2008

Mileage

15,500 mi