2003 Land Rover New Range Rover

SUMMARY:IN A LETTER DATED DECEMBER 2, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED NHTSA THAT LAND ROVER IS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 2003 THROUGH 2005 RANGE ROVER VEHICLES BUILT AT THE SOLIHULL (UK) ASSEMBLY PLANT FROM JANUARY 3, 2002 THROUGH FEBRUARY 22, 2005, TO REPLACE THE FRONT DRIVESHAFT JOINT (NHTSA RECALL NO. 08V-635, LAND ROVER RECALL NO. P041). THE FRONT DIFFERENTIAL COUPLING SLEEVE AND THE PROPELLER SHAFT MAY BE MISALIGNED RESULTING IN SPLINE WEAR OVER TIME, WHICH MAY EVENTUALLY RESULT IN THE SPLINES SHEARING.THE DEFECT CONDITION CAN RESULT IN A LOSS OF PROPULSION AND SUBSEQUENT VEHICLE DISABLEMENT IN THE ROADWAY OR ON THE SHOULDER OF THE ROADWAY. FURTHERMORE, THE DEFECT CONDITION CAN ALSO CAUSE LOSS OF THE TRANSMISSION LOCK FUNCTION WHEN THE VEHICLE IS SHIFTED INTO THE PARK POSITION.THE LOSS OF THE TRANSMISSION LOCK FUNCTION CAN CAUSE A VEHICLE ROLLAWAY CONDITION IF THE EMERGENCY BRAKE IS NOT APPLIED AND THE VEHICLE IS UNATTENDED BY THE DRIVER. IN JULY 2008, LAND ROVER INITIATED A SERVICE ACTION (Q041) INSTRUCTING DEALERS TO INSTALL A REDESIGNED FRONT PROPELLER SHAFT, FRONT DIFFERENTIAL COUPLING AND HEAT SHIELD KIT TO ADDRESS THE MISALIGNMENT AND SUBSEQUENT SPLINE WEAR.THIS IS THE SAME REPAIR PROCEDURE THAT WILL BE USED IN SAFETY RECALL 08V-635.APPROXIMATELY 48 PERCENT OF THE SUBJECT VEHICLES (18,000) HAVE HAD THE REMEDY PERFORMED UNDER SERVICE ACTION Q041 AS OF DECEMBER 2, 2008. ODI BELIEVES THAT SUDDEN LOSS OF MOTIVE POWER WITHOUT WARNING AND FAILURE OF THE TRANSMISSION LOCK FUNCTION ARE SAFETY CONSEQUENCES THAT, PARTICULARLY IN THE CONTEXT OF THE HIGH FAILURE RATE OF THE SUBJECT COMPONENTS, REPRESENT AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY AS STATED IN A RECALL REQUEST LETTER SENT TO FORD AND LAND ROVER ON NOVEMBER 6, 2008.LAND ROVER DOES NOT AGREE, BUT IS CHANGING ITS CUSTOMER SATISFACTION PROGRAM TO A SAFETY RECALL AS ODI REQUESTED. LAND ROVER NOTED THAT IT WAS AWARE OF ONE ALLEGED ACCIDENT; HOWEVER, IT WAS UNAWARE OF ANY INJURY OR VEHICLE DAMAGE ASSOCIATED WITH THE ALLEGED ACCIDENT.LAND ROVER'S RECALL RESOLVES THE SAFETY DEFECT CONCERNS PURSUED BY THIS INVESTIGATION. THIS ENGINEERING ANALYSIS IS CLOSED.

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED THAT THE PRIMARY CAUSE FOR THE MAJORITY OF THE REPORTED FRONT DIFFERENTIAL/DRIVE SHAFT FAILURES IS A MISALIGNMENT OF THE JOINT BETWEEN THE TWO COMPONENTS.CERTAIN LEVELS OF MISALIGNMENT MAY OVER TIME CAUSE AN UNEVEN WEAR OF THE SPLINES.CONTINUED WEAR OF THE SPLINES MAY RESULT IN A SHEARING OF THE SPLINES AND THE INABILITY OF THE DRIVESHAFT TO TRANSFER TORQUE TO THE FRONT DIFFERENTIAL. TO ADDRESS THE ISSUE IN THE FIELD, FORD INITIATED A SERVICE CAMPAIGN IN JUNE 2003 TO CORRECT THE MISALIGNMENT ISSUE AND, IF NECESSARY, REPLACE THE FRONT DRIVE SHAFT AND/OR DIFFERENTIAL.THE SERVICE CAMPAIGN COVERED MODEL YEAR (MY) 2003 AND MY 2004 VEHICLES BUILT FROM APRIL 18, 2002 THROUGH JULY 3, 2003.IN PRODUCTION, FORD INTRODUCED A CHANGE TO THE LUBRICATING GREASE OF THE JOINT IN FEBRUARY 2003 AND A CHANGE TO THE ASSEMBLY PLANT ALIGNMENT PROCESS IN JULY 2003 TO ADDRESS THE MISALIGNMENT AND WEAR ISSUE. ODI IDENTIFIED ONE CRASH RELATED TO THE ALLEGED DEFECT.THE CRASH INVOLVED A SUBJECT VEHICLE BEING STRUCK IN THE REAR AFTER BECOMING DISABLED BY A FRONT DIFFERENTIAL/DRIVESHAFT FAILURE AND PULLING TO THE SIDE OF THE ROAD. THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-012) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND SAFETY CONSEQUENCES OF FRONT DIFFERENTIAL/DRIVESHAFT FAILURES IN THE SUBJECT VEHICLE POPULATION.

WHILE DRIVING ON THE NEW JERSEY TURNPIKE TRAVELING AT A SPEED OF APPROXIMATELY 65-70 MILES AN HOUR MY TRUCK SUDDENLY MADE A LOUD NOISE AND IT FELT LIKE THE BRAKES LOCKED UP AND MELT GRINDING SOUNDS. I HAD IT TOWED TO A REPAIR SHOP AND WAS TOLD IT WAS FRONT DIFFERENTIAL FAILURE.

NHTSA ID

11141695

Incident

Aug 13, 2018

Mileage

179,000 mi

DRIVING UP A HILL AND STARTED TO LOSE POWER. EVENTUALLY LOST ALL POWER ON HIGHWAY AND HAD TO PULL OVER AND WAIT FOR A TOW TRUCK TO COME.

NHTSA ID

10731618

Incident

Jul 1, 2015

Mileage

64,000 mi

IN OCTOBER 2013 WHILE I TOOK MY CAR TO A PRIVATE GARAGE FOR OIL CHANGE. THE MECHANIC NOTICED THAT THE FRAME ON MY VEHICLE WAS ROTTED OUT . HE CALLED ME INTO THE GARAGE AND SHOWED ME THE PROBLEM. I IMMEDIATELY CALLED THE LAND ROVER DEALERSHIP WERE THE CAR WAS PURCHASED NEW AND THEY HAVE BEEN DOING THE SERVICE ON THE VEHICLE SINCE IT WAS NEW . I INFORMED THE SERVICE MANAGER OF THE ISSUE AND I QUESTIONED THE FACT THAT NO ONE AT THE DEALERSHIP EVER MENTIONED THE RUST ISSUE ON MY VEHICLE. THE SERVICE MANAGER ASKED ME TO DRIVE UP TO THE DEALERSHIP SO THEY CAN TAKE A LOOK AT IT. ONCE AT THE DEALERSHIP THE SERVICE MANAGER PUT UP THE CAR ON THE LIFT AND WAS SHOCKED TO SEE HOW BAD THINGS WERE. HE TOOK PICTURES OF THE FRAME AND CONTACTED LAND ROVER MAIN OFFICE AND SENT THEM THE PICTURES. LAND ROVER MAIN OFFICE CONTACTED ME AND TOLD ME THAT THEY HAVE NEVER SEEN ANYTHING LIKE THIS BEFORE BUT THEY MADE THE DECISION NOT TO COVER FIXING THE PROBLEM ALTHOUGH IT IS A SAFETY ISSUE . MY CONCERN IS THAT ONE DAY THIS CAR IS GOING TO BREAK IN HALF AND A MAJOR ACCIDENT WOULD OCCUR BECAUSE OF IT. I REALLY NEED YOUR HELP. *TR

NHTSA ID

10568995

Incident

Oct 7, 2013

Mileage

127,000 mi

THE RANGE ROVER IS EQUIPPED WITH ELECTRONIC CROSS LINKED AIR SUSPENSION (WITH VARIABLE RIDE HEIGHT). VARIABLE HEIGHT SUSPENSION SYSTEM SWITCHES FROM LOW TO HIGH ON ITS OWN AND CREATES A GREATER RISK FOR ROLL OVER. WHEN THE CAR IS OPERATING ON THE HIGH MODE, WITHOUT THE DRIVER BEING AWARE BECAUSE IT SWITCHES ON IT'S OWN, IT MEANS THAT THE CAR IS IN GEAR FOR OFF ROAD AND PUTS ROAD TURNS MORE DANGEROUS, WITH HIGH POSSIBILITY OF A ROLL OVER. THE VEHICLE ON A NORMAL TURN AROUND 20 MILES AN HOUR SPEED ALMOST LOST CONTROL DUE TO SYSTEM SWITCHING TO HIGHER SUSPENSION SETTING ON ITS OWN WITHOUT MY CONTROL. *TR

NHTSA ID

10515921

Incident

Jun 9, 2013

Mileage

123,000 mi

MY 2003 RANGE ROVER HSE SUFFERED A FAILURE OF THE FRONT DIFFERENTIAL AND DRIVESHAFT. A COMMON AND KNOWN ISSUE TO LAND ROVER. I WAS TRAVELING DOWN THE INTERSTATE AND SUDDENLY LOST ALL FORWARD MOMENTUM. I HAD TO IMMEDIATELY FIND A SAFE PLACE TO PULL OVER AND PUT ON THE HAND BRAKE TO KEEP THE VEHICLE FROM ROLLING. IT WOULD NOT MOVE. IT WAS TOWED TO A REPAIR FACILITY AND THE BROKEN PARTS WERE REPLACED. IT WAS FIXED WITH NEW PARTS, BUT THEY ARE THE SAME DESIGN OF THE ONES THAT FAILED. I WAS TOLD THERE IS NOT PERMANENT FIX PROVIDED BY LAND ROVER AND THIS WILL HAPPEN AGAIN. *TR

NHTSA ID

10230869

Incident

Jun 1, 2008

Mileage

75,965 mi

MY 2003 RANGE ROVER HSE DIFFERENTIAL DIED WITHOUT WARNING. I HAD TO BE TOWED HOME ($200) + $1500 TO FIX IT WITH AN AFTER MARKET DIFFERENTIAL. *TR

NHTSA ID

10225190

Incident

Apr 12, 2008

BOUGHT CAR JULY 2007 WITH 35,000 MILES; 3 DAYS AFTER I WAS DRIVING ON THE HIGHWAY WITH MY LITTLE GIRL IN THE CAR AND THE BRAKES LOCKED THEN THERE WAS A GRINNING NOISE, HAD TO CHANGE 4 LANES TO GET TO THE SHOULDER, NEARLY GOT RUN OVER BY A TRUCK..CAR WOULD NOT STOP WHEN I PUT IT ONTO PARK..IT WAS ROLLING DOWN THE SHOULDER HAD TO PULL UP HAND BRAKE. NEARLY DIED. CAR TOWED FOUND OUT IT WAS FRONT DIFF..PAID $4000 FROM MY POCKET. EIGHT MONTHS LATER SAME THING..FRONT DIFF WENT..COMPLAINED TO DEALER..THEY WERE RUDE AND ARROGANT..CALLED ROVER HEAD OFFICE..COMPLAINED TO THEM..THEY TOLD ME THEY WOULD GET BACK TO ME..THEY NEVER DID..WILL NEVER BUY A ROVER AGAIN..THE WORST CAR, THE WORST SERVICE EVER. *TR

NHTSA ID

10224423

Incident

Jul 1, 2007

Mileage

35,000 mi

WHILE DRIVING HOME FROM WORK LATE AT NIGHT MY 2003 RANGE ROVER STOP AND THE INDICATOR DIRECTED ME TO PUT MY CAR IN NEUTRAL. WHEN I STEPPED ON THE GAS I HEARD A LOUD GRINDING SOUND. I WAS STRANDED AT 1AM ON A WEEK NIGHT WAITING FOR A TOW TRUCK RANGE ROVER SHOULD RECALL THIS PROBLEM WITH THE DIFFERENTIAL ESPECIALLY IF SO MANY PEOPLE ARE HAVING THIS ISSUE AND WE PAID OVER 80,000 FOR OUR CARS. *TR

NHTSA ID

10221822

Incident

Mar 17, 2008

Mileage

80,200 mi

Presentation from Dealer Shop Foreman Conference Call

LAND ROVER: THE FRONT LEFT HAND CORNER, A NOISE OF RUBBING, SCRAPING, DRONE TYPE AND/OR A VIBRATION APPEARS DUE TO TRANSFER CASE CHAIN ON COAST/OVERRUN CHORDAL VIBRATION. MODEL RANGE ROVER. NO MODEL YEARS. *PE

LAND ROVER: GEARSHIFT REMAINS STUCK, EITHER UP, DOWN, IN NEUTRAL, PARK OR IS ERRATIC OR INTERMITTENT IN OPERATION OF SHIFTING, DUE TO POSSIBLE EARTH POINTS ARE LOOSE OR CORRODED. MODEL RANGE ROVER. NO MODEL YEAR. *PE

LAND ROVER: THE COMPRESSOR EXHAUST VALVE MAY BE CAUSE OF THE AIR SUSPENSION WARNING LAMP TO BE ILLUMINATED AND A POSSIBLE ELECTRICAL FAILURE. *PE

STEERING COLUMN REACH MOTOR NOISE. *EH UPDATED 07-25-07. *KB

POWER STEERING SQUEAK AT BULKHEAD. *TT