2002 Isuzu Rodeo

On April 10, 2018, NHTSA received a petition from Mr. Kevin Byrne (the Petitioner) requesting that the Agency ?undertake a defects investigation? of ?rust-related detachment of Isuzu Rodeo fuel tanks? (NHTSA ID 11091788). The Petitioner experienced a partial fuel tank detachment in his model year (MY) 2004 Isuzu Rodeo in July 2017. On May 23, 2018, ODI opened DP18-001 to evaluate the Petitioner?s request for a defect investigation. ODI sent information request letters to Isuzu and Honda requesting production, design history and field data related to fuel tank retention failures in MY 2001-2004 Isuzu Rodeo, MY 2002-2004 Isuzu Axiom and MY 2001-2002 Honda Passport vehicles equipped with the same fuel tank shield part number as the Petitioner?s vehicle (the ?subject vehicles?). ODI notes that Isuzu manufactured the subject Passport vehicles for Honda. Isuzu implemented a change to the tank shield corrosion protection system as a running change in early MY 2002 production. Isuzu and Honda sold approximately 172,000 subject vehicles in the United States. Fifty-eight (58) percent of the subject vehicles were produced prior to the shield change (99,000) and 42 percent after the change (73,000).ODI?s analysis of field data identified 19 incidents of partial fuel tank detachments in the subject vehicles. The incidents all occurred in states with high road salt usage in winter months (Salt States) and involved older vehicles beyond 10-years in service. On average, the failures occurred in the vehicle?s 13th year-in-service. Evidence of severe general corrosion in multiple undercarriage components was also noted in 13 of the 19 vehicles that experienced partial fuel tank detachments. None of the incidents resulted in fuel leakage or fire. Aside from the petitioner?s vehicle, ODI has not identified any other incidents of complete or partial fuel tank detachment in the MY 2002-2004 subject vehicles equipped with the modified retention shield.In addition, ODI reviewed 24 NHTSA complaints alleging corrosion concerns with the fuel tank retention system in the subject vehicles that did not result in fuel tank detachment. Twenty-three (23) of these complaints involve subject vehicles built prior to the shield change. Like the vehicles reporting fuel tank detachments, these vehicles are also all from Salt States and, in most cases (20 of the 24 complaints), the vehicles also experienced severe corrosion concerns in other undercarriage components. Half (12 of the 24 complaints) of the vehicles show prior accident damage in their service histories.Based on these analyses, ODI has not identified evidence of a defect trend for premature corrosion-related fuel tank detachments in the MY 2004 Isuzu Rodeo or similarly equipped vehicles. The damage that may result in tank retention concerns appears to occur progressively over many years with ample opportunity for detection and repair. Furthermore, ODI has not identified any crashes, fires, injuries, or fuel leaks associated with fuel tank retention failures in a population of vehicles that currently range from 16 to 19 years old.Accordingly, the Agency is denying the petition.A summary of ODI?s analysis of this petition will be published in the Federal Register and is also available in the investigative file for this action.The NHTSA consumer complaints counted in the closing resume for DP18-001 can be reviewed at www.nhtsa.gov under the following ODI identification numbers (VOQs in parentheses denote duplicate records): Allegations of fuel tank retention failure: 11084098 (11091788), 10532845, 10486109. Allegations of fuel tank retention component corrosion: 11138931, 10992150, 10845523,

On September 22, 2010, Isuzu Manufacturing Services of America, Inc (Isuzu) submitted a Defect Information Report (NHTSA Recall 10V-436) to the National Highway Traffic Safety Administration affecting approximately 120,000 model year (MY) 1998-2002 Isuzu Rodeo and Honda Passport vehicles and MY 2002 Isuzu Axiom vehicles originally sold, or currently operated, in the following states:Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin. All vehicle owners will receive the recall notification.Vehicles 10 years of age or younger will be provided with a free remedy.For vehicles older than 10 years, Isuzu will offer a free remedy provided the vehicle is presented to an Isuzu service facility or a Honda dealer (as applicable) no later than twelve (12) months after the date of mailing of the notification letter to the owner.The report describes a condition where vehicles operated in states using certain road deicing materials may exhibit excessive corrosion which may result in the left or right rear suspension lower link bracket becoming detached from the frame.According to Isuzu a detached lower link may affect vehicle handling and potentially cause a crash.The Office of Defects Investigation (ODI) analyzed complaint data and found that 114 of the 115 (99%) alleged complete lower link separations from the frame occurred in vehicles originally sold or operated in a state covered by the recall. Of these complaints 2 involved alleged crashes and 21 involved alleged loss of control incidents.The alleged crashes and loss of control incidents all occurred in vehicles operated in a state covered by the safety recall.Isuzu's recall instructs dealers to inspect the rear suspension lower link bracket area to determine if corrosion is present.For vehicles in which corrosion has damaged the lower link bracket area and affected its connection to the vehicle frame, a reinforcement bracket will be installed.For vehicles with no visible signs of corrosion, dealers with apply anti-corrosion material to reduce the likelihood of corrosion developing in the future. Based on Isuzu's safety recall, this Engineering Analysis is closed.A copy of the recall may be assessed on NHTSA's website using the reference number above.

DURING PRELIMINARY EVALUATION PE09-030, ISUZU MOTORS AMERICA, INC (ISUZU) NOTED TWO PRIMARY DIFFERENCES ONCE THE REAR SUSPENSION LOWER LINK SEPARATION OCCURS BETWEEN THE ALLEGED DEFECT (SEPARATION OF THE LOWER LINK FROM THE FRAME) OF THIS INVESTIGATION AND A SAFETY DEFECT INVOLVING LOWER LINK SEPARATION FROM THE REAR AXLE ADDRESSED BY ISUZU IN SAFETY RECALL 00V-058.IN THE CASE OF THE DEFECT CONDITION IDENTIFIED IN RECALL 00V-058, ISUZU STATED THAT THE ATTACHMENT BOLT COULD DETACH FULLY, CAUSING SEPARATION OF THE LOWER LINK FROM THE REAR AXLE POSSIBLY CREATING A LOSS OF VEHICLE CONTROL. ISUZU ALSO STATED THAT THIS CONDITION OCCURS EARLY IN THE SERVICE LIFE OF THE VEHICLE.IN THIS INVESTIGATION ISUZU NOTED LOWER LINK SEPARATION FROM THE FRAME IS A PROGRESSIVE CORROSION ISSUE WITH PRIOR WARNING TO CONSUMERS.ISUZU ALSO STATED THAT IN THE EVENT OF A LOWER LINK SEPARATION FROM THE FRAME, THE VEHICLE IS STILL CONTROLLABLE AND CAN BE SAFELY STOPPED. THE OFFICE OF DEFECT INVESTIGATION (ODI) ANALYZED COMPLAINT DATA PROVIDED BY ISUZU AND AMERICA HONDA MOTOR COMPANY, INC (HONDA), AS WELL AS VEHICLE OWNER QUESTIONNAIRES SUBMITTED TO ODI FROM CONSUMERS.IN TOTAL, THERE WERE 60 UNIQUE REPORTS OF LOWER LINK SEPARATIONS FROM THE FRAME INCLUDING 1 ALLEGED CRASH AND 7 LOSS OF VEHICLE CONTROL INCIDENTS THAT MAY BE RELATED TO THE ALLEGED DEFECT.MOST OF THESE COMPLAINTS INDICATED THAT THERE WAS NO WARNING PRIOR TO THE LINK SEPARATION.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA09-018) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND RISK TO MOTOR VEHICLE SAFETY OF THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.

The contact owns a 2002 Isuzu Rodeo. The contact recently became aware of severe corrosion on the frame of the vehicle. The contact stated that the vehicle was repaired under NHTSA Campaign Number: 10V436000 (Suspension) approximately 10 years ago. The contact believed that the recall repair should have covered more than just the rear suspension and that the entire subframe should have been included. The vehicle was taken to two independent Collision Centers and was advised that the cost of repair exceeded the value of the vehicle, and the vehicle was declined to be repaired. The manufacturer was informed of the failure. The failure mileage was 91,819.

NHTSA ID

11724093

Incident

Dec 2, 2025

Mileage

91,819 mi

The contact owns a 2002 Isuzu Rodeo. The contact stated that while driving at approximately 50 MPH, the vehicle stalled. The contact stated that as she was coasting to the right to stop on the shoulder, she observed that there was smoke in the cabin. The contact stated that after she stopped, she opened the driver's side passenger door and saw that smoke was emitting from under the passenger seat, which had been folded over in "cargo mode." The contact lifted the seat and saw that the seat back was melted, with a black spot in the center. The contact stated that she had a cooler in the back that was full of water, and she poured all of it behind and under the seat. The contact saw that the water evaporated. The contact then checked out outside of the vehicle to see if there was any heat source. The contact observed that flames had formed under the rear driver's side wheel well. The contact stated that a person who lived in the house near where she had stopped had observed what was happening and came out with a fire extinguisher and extinguished the fire. The fire department was not called. The contact had the vehicle towed to her residence. The vehicle was not diagnosed and was not repaired. The manufacturer was not informed of the failure. The contact had researched online and related the failure to NHTSA Campaign Number: 05V466000 (Fuel System, Gasoline) due to the location of the fuel tank, which was located on the driver's side rear, by the rear wheel well. The failure mileage was approximately 117,000.

NHTSA ID

11687710

Incident

Sep 13, 2025

Mileage

117,000 mi

The contact's son owns a 2002 Isuzu Rodeo. The contact stated while driving downhill at 40 MPH around a curve with a child sitting in the rear seat, the brake pedal was depressed but the vehicle failed to respond. Additionally, the contact stated that upon turning the steering wheel, the vehicle failed to respond as needed. The contact continued driving until the vehicle responded. The contact stated that the failure reoccurred while her son was driving the vehicle. The vehicle was towed to an independent mechanic where it was diagnosed that the subframe was severely fractured. An unknown dealer was notified of the failure. The manufacturer was notified of the failure and informed the contact that they could not assist as NHTSA Campaign Number: 10V436000 (Suspension) had previously been completed on the vehicle. The vehicle was not repaired. The failure mileage was approximately 105,370.

NHTSA ID

11488067

Incident

Feb 5, 2022

Mileage

105,370 mi

Frame rust condition which makes the SUV un repairable

NHTSA ID

11441833

Incident

Nov 10, 2021

TL* THE CONTACT OWNS A 2002 ISUZU RODEO. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 35 MPH, THE SPARE TIRE DETACHED FROM THE VEHICLE. THE CONTACT TOOK THE VEHICLE TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FRAME OF THE VEHICLE WAS RUSTED OUT. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT DID NOT OFFER ANY FURTHER ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 88,000. THE VIN WAS NOT AVAILABLE.

NHTSA ID

11006500

Incident

Jul 19, 2017

Mileage

88,000 mi

TL* THE CONTACT OWNS A 2002 ISUZU RODEO. THE CONTACT STATED THAT THERE HAD BEEN EXTENSIVE RUST AND CORROSION NEAR THE AXLES. THE VEHICLE WAS NOT INSPECTED AND DIAGNOSED BY AN AUTHORIZED DEALER. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INDICATED THAT THE VEHICLE WAS EXCLUDED FROM AN UNKNOWN RECALL CAMPAIGN BECAUSE NEBRASKA WAS NOT CONSIDERED A SALT BELT STATE. THE MANUFACTURER OFFERED NO SOLUTION. THE VEHICLE WAS UNABLE TO BE DRIVEN DUE TO THE FAILURE OF COMPONENTS POTENTIALLY FRACTURING. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 150,000. UPDATED 10/18/17*LJ *TR

NHTSA ID

11006348

Incident

Jun 1, 2017

Mileage

150,000 mi

TAKATA AIR BAG, MY 2002 RODEO AIRBAG LIGHT IS ON, ON THE DASHBOARD, I CALLED THE DEALER AND THEY SAID ITS NOT PART OF THE RECALLS, IT IS A VEHICLE MADE BY HONDA AND SHOULD BE COVERED UNDER THE RECALLS, ITS THE SAME VEHICLE AS THE HONDA PASSPORT JUST A DIFFERENT YR AND ITS A FLORIDA REGISTERED AUTOMOBILE, HOW CAN I GET HELP WITH THIS AIRBAG PROBLEM, I SHOULDNT HAVE TO PAY FOR THE REPAIRS DUE TO DEFECTS AND RECALLS.

NHTSA ID

10944627

Incident

Dec 1, 2016

Mileage

180,000 mi

I HAVE 110,000 MILES ON VEHICLE AND WAS JUST TOLD FRAME IS RUSTING OUT. NOT SAFE TO DRIVE THIS CAR HAS MANY MILES LEFT ON ENGINE, NOT HAPPY ABOUT RUSTED FRAME I HAVE HEARD ABOUT , ALSO ABS LIGHT GOES OFF AND ON.

NHTSA ID

10943961

Incident

Jan 5, 2017

Mileage

110,000 mi

This bulletin outlines the procedures for using the Alpine Exchange Program (the "Exchange Program"). The Exchange Program must be used when any Alpine radio or other component covered by this bulletin is repaired under warranty and may also be used for radio and component repairs not covered under warranty. Contact Alpine directly for pricing and payment methods applicable to radio and component repairs not covered under warranty.

Isuzu Commercial Truck of America, Inc. (ICTA) is providing the following procedural recommendations to improve dealer efficiency when submitting Parts Warranty claims. We strongly recommend dealers follow these procedures in order to avoid delays in Parts Warranty claim payments and/or claim chargeback. This bulletin was revised to add a Parts Warranty Form

Isuzu Commercial Truck of America, Inc. (ICTA) is providing the following procedural recommendations to improve dealer efficiency when submitting Parts Warranty claims. We strongly recommend dealers follow these procedures in order to avoid delays in Parts Warranty claim payments and/or claim chargeback.

The following is a list of the Isuzu-recommended Threebond product part numbers identified in the various Isuzu Workshop Manuals and bulletins. If a Threebond product is unavailable, we recommend that you utilize the chart below to find equivalent of similar products (when available) from Loctite and Permatex.

The Isuzu Commercial Truck of America (ICTA) Service Technical Assistance Center (TAC) provides diagnostic support to Isuzu dealer technicians repairing Isuzu vehicles in and out of vehicle warranty. A TAC case number will be issued solely for information tracking purposes and future contact reference.

This service bulletin provides service information on new torque specification and installation procedure for ACDelco Spin-On Oil Filters.