2002 Nissan Pathfinder

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

In their Defect Information Report (DIR) of April 20, 2011, Nissan North America, Inc. (Nissan) notified NHTSA that it would conduct a safety recall of certain 1996-2004 Nissan Pathfinder and 1997-2003 Infinity QX4 vehicles to repair corrosion damage to the driver's side front strut tower.The vehicles included in the recall are those that were originally sold, or are currently registered in salt belt states including Connecticut, Delaware, Iowa, Illinois, Indiana, Massachusetts, Maine, Maryland, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and the District of Columbia.The DIR states in part, ...the strut housing may crack and pull away from the inner hood ledge assembly.This could lead to the strut housing panel separating and contacting the steering column lower shaft.Contact with the steering column lower shaft can cause steering difficulties and may require an increase in steering effort by the driver.If the steering column lower shaft completely fractured it would result in a total loss of steering control.In some cases, the strut housing panel can contact or affect adjacent brake system components.Complainants reported experiencing either steering or brake system issues, and in some cases, both.Nissan dealer's will inspect the strut housing and, based on the level of corrosion found, make an assessment as to how to remedy the vehicle (see defect information report for additional details). Brake system components adjacent to, and in the area of, the strut tower (i.e., brake master cylinder, left front brake line, ABS wire harness, etc.) will also be inspected.

This relates to Campaign Number 11V244000 We are the original and only owners of the vehicle I originally brought the vehicle in for the recall and they simply sprayed some undercoating in the wheel wells. Less than a month later both strut towers separated from the body of the vehicle while my wife was driving home, she lost steering and could have had a serious or fatal accident. I towed to the dealer and they installed braces in both strut towers. I have always taken exceptional care of my vehicles, which includes multiple washes during winter months and extensive undercarriage washing every spring. This past Oct when I took the vehicle in for mandatory state inspection I was informed that the vehicle would not pass inspection next year. They told me this once before in relation to extensive rust to the passenger side rear frame next to the muffler. I was able to cut out the rust and weld a thicker plate of steel in there to repair the frame. I just changed my oil and looked for what the mechanic was referring too. This time the rust is between the braces they installed for the struts and the front of the wheel well. The mechanic saw the rust coming through the paint and poked at it with a screw driver, the screw driver went right though the body leaving significant holes in the structure that supports the struts. When the weather breaks I will further inspect to determine if there is enough good metal left for me to attempt a repair. I am doubtful a repair will be possible as the metal used to construct this vehicle is very poor quality. Despite my constant care, washing, rust conversion treatments, painting with rust blocking paint and using undercoating, every inch on the underside of the vehicle is rusted. Both rear quarters rotted behind the wheel flares and down into where the rear doors close and contact the rear quarters. Now due to Nissan's decision to use substandard metal I am forced to buy a new vehicle which is currently financially impossible

NHTSA ID

11577805

Incident

Oct 10, 2023

My complaint relates to Campaign Number 07V435000 We are the original and only owner of this vehicle. While driving the vehicle I started to notice a fuel smell, after several attempts to locate the source, one day I added fuel, I noticed a small puddle in my driveway the following morning. I removed the wheel and the fender well cover to find the fuel filler neck had rotted through and fuel had wet both the tire and the brakes. The above campaign number has a recall the ends in the prior manufacturing year even though the part in question was used by the manufacturer through the 2004 model year. I repaired the vehicle and am now dealing with a constant check engine light due to a manufacturing defect that creates a large vacuum leak at the fuel cap. The part arrived with a notice that the leak is common and recommends replacement of the fuel cap. I replaced the cap and am having the same problem. I have retained the defective part should you wish to inspect it. I think the recall should be expanded to the entirety of the use of the defective part by the manufacturer, model year 2004. It would also be nice if the replacement part manufacturer was fined for selling a product they know to have defective manufacturing. Leak discovered 20 August 2023 at 153,789 miles Replacement part# FN748 from Spectra Premium ordered through Amazon

NHTSA ID

11577797

Incident

Aug 20, 2023

The contact owns a 2002 Nissan Pathfinder. The contact stated that the vehicle was previously serviced at a local dealer under NHTSA Campaign Number: 11V244000 (Steering, Suspension); however, the mechanic diagnosed that there was no rust in the strut housing assembly. The contact then stated that when he replaced the front struts, excessive rust was seen in the strut housing assembly. The contact stated that the vehicle was taken to multiple independent mechanics, who diagnosed that the front axle needed to be replaced and confirmed there was excessive rust in the strut housing. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 147,477.

NHTSA ID

11520142

Incident

Dec 20, 2017

Mileage

147,477 mi

The contact's son owned a 2002 Nissan Pathfinder. The contact stated that she received notification of NHTSA recall campaigns and flyers and requested to be removed from the recall distribution list. The contact stated that the vehicle was sold. The local dealer and manufacturer were not contacted. The VIN was not available.

NHTSA ID

11478436

Incident

Aug 9, 2022

I WROTE A LETTER AND FILED A COMPLAINT ABOUT A PERFORATED RUST FRAME ON MY 2002 NISSAN PATHFINDER WITH 118,000 MILES. I HAD PROBLEMS WITH THE FRONT END BROUGHT TO WHERE I PURCHASED 18 YEARS AGO TO HAVE A RECALLED PERFORMED ON THE AIR BAG FOR SAFETY BUT MY RUSTED FRAME IS NOT RECALLED. THE SMITHTOWN DEALERSHIP OWNED BY JOSEPH O RUBIO THAT I PURCHASED AND JUST BROUGHT MY TO CAR TO GET IT SERVICED. THE SERVICE TECH ANDREW LISSKE TOLD ME NOT TO DRIVE MY NISSAN PATHFINDER FOR SAFETY REASONS BECAUSE THE FRAME IS ROTTED BUT CHNAGED MY AIR BAG FOR A RECALL THEN HE SAID MY VEHICLE IT IS OLD AND THEY DON'T MAKE CARS LIKE THEY USED TO . ATTACHESIS THE SERVICE TICKET. I WAS DRIVING AND THE FRONT PASSENGER END WAS HOPING WHILE GOING OVER 40 MILES AN HOUR. I WROTE AND SPOKE TO SOMEONE NOT I HAVE DOCUMATATION.

NHTSA ID

11316447

Incident

Dec 17, 2019

Mileage

118,000 mi

TL* THE CONTACT OWNS A 2002 NISSAN PATHFINDER. THE CONTACT STATED WHILE DRIVING 40 MPH, THE FRONT PASSENGER'S SIDE TIRE VIBRATED ABNORMALLY. THE CONTACT STATED THAT IT WAS DIFFICULT TO CONTROL THE VEHICLE. THERE WAS NO WARNING LIGHTS ILLUMINATED. THE CONTACT STATED HE PARKED THE VEHICLE ON THE SIDE OF THE ROAD FOR APPROXIMATELY 30 MINUTES, RESTARTED THE VEHICLE AND DROVE TO THE RESIDENCE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT SUBFRAME NEEDED TO BE WELDED PRIOR TO REPLACING THE LOWER CONTROL ARM ON THE FRONT PASSENGER'S SIDE OF THE VEHICLE. THE VEHICLE WAS NOT REPAIRED. A DEALER WAS NOT CONTACTED OR NOTIFIED OF THE FAILURE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND COMPLAINT WAS FILED. THE FAILURE MILEAGE WAS 118,000.

NHTSA ID

11315925

Incident

Dec 19, 2019

Mileage

118,000 mi

I BROUGHT IT TO MY MECHANIC WE LOOKED AT THE FRAME UNDER THE CARS FRONT END IT IS CLUCKING THERE IS EXCESSIVE RUST, PERFORATED STEEL AND DISCONNECTED FROM OTHER PARTS VERY DANGEROUS. I BOUGHT THIS CAR NEW FROM SMITHTOWN NISSIAN IN 2002 I AM THE ORIGINAL OWNER. I CALLED SMITHTOWN NISSAN THEY SAID THEY HAVE RECALLS FOR THIS BUT MY VIN# CAR IS NOT AFFECTED I READ THE RECALL NOTICE R1107 IT STATES IM HIGH SALT AREAS AND NEW YORK IS ONE OF THEM FOR THIS TYPE OF PROBLEM . THE MANUFACTURER SHOULD BE LIABLE.

NHTSA ID

11291453

Incident

Dec 15, 2019

Mileage

118,000 mi

I WAS DRIVING MY 2002 PATHFINDER TO WORK ON MONDAY OF THIS WEEK WHEN I STARTED TO FEEL A SLIGHT SHAKING IN MY STEERING WHEEL AND CHATTER IN MY BRAKE PEDAL WHILE DRIVING AT 55MPH ON THE HIGHWAY. AFTER I GOT OFF THE HIGHWAY I COULD BARELY MAKE A RIGHT TURN AS THE STEERING WHEEL WAS VERY STIFF. I CHECKED MY FRONT END AND WHAT I FOUND WAS FRIGHTENING. THE DRIVERS SIDE STRUT TOWER HAD TORN FROM THE FRAME AND BODY AND WAS NOW PUSHING AGAINST BOTH THE STEERING SHAFT AND MASTER CYLINDER WHICH WAS BENT UP AT AN ANGLE. MY MASTER BRAKE CYLINDER IS NOW SUPPORTING THE RIGHT FRONT WHEEL! THANK GOD THE STRUT DID NOT SNAP THE STEERING SHAFT OR MASTER CYLINDER WHILE AT HIGHWAY SPEED. I MIGHT BE IN A HOSPITAL BED OR DEAD. I HAD THE CAR TOWED TO A NISSAN DEALERSHIP WHO TOLD ME THAT IT RECEIVED A LEVEL 1 REPAIR BY THE PREVIOUS OWNER (I AM THE SECOND OWNER) IN 2011 AND NOTHING COULD BE DONE EXCEPT TO CALL CORPORATE. I DID SOME RESEARCH AND FOUND THAT THE RECALL HAS TWO LEVELS: 1 AND 2. LEVEL 1 IS A SIMPLE INSPECTION, CLEANING AND COATING. LEVEL 2 REQUIRES A BOLTED IN METAL BRACE BE INSTALLED TO REINFORCE THE STRUT TOWER. NISSAN CORPORATE TOLD ME THE LEVEL 1 REPAIR WAS ALREADY COMPLETED AND NOTHING FURTHER COULD BE DONE EVEN THOUGH THE REPAIR DID NOTHING TO REMEDY THE PROBLEM AND NOW I AM IN NEED OF A LEVEL 2 REPAIR. I CANNOT BELIEVE THAT NISSAN CAN WALK AWAY FROM THIS AFTER THEIR LEVEL 1 FIX FAILS TO REMEDY THE PROBLEM. THE LEVEL 1 REPAIR IS A TICKING TIME BOMB AS THE SO CALLED "FIX" DOES NOTHING TO STOP THE TOWER FROM FAILING. I HONESTLY FEEL THAT NISSAN HAS NOT DONE ENOUGH TO REMEDY THE ISSUE AND THERE COULD STILL BE HUNDREDS OR THOUSANDS OF PATHFINDERS WITH BOGUS LEVEL 1 REPAIRS ON OUR ROADS RIGHT THIS MINUTE. NISSAN SHOULD PROVIDE THE LEVEL 2 RECALL EVEN IF LEVEL 1 HAS ALREADY BEEN COMPLETED.

NHTSA ID

11256630

Incident

Sep 16, 2019

Mileage

165,000 mi

CERTIFICATION LABEL AND VIN PLATE REPLACEMENT SERVICE INFORMATION Because of collision damage or other vehicle repair, a replacement “Certification Label” or “VIN Plate/Label” may be needed. HINT: Certification Label = FMVSS (Federal Motor Vehicle Safety Standards) label. These items may be available from Infiniti by request if certain criteria are met. This bulletin lists the criteria and provides an application form for such replacements. · The “VIN Plate/Label” (metal plate or vinyl label) is attached to the instrument panel or body on the driver side at the base of the windshield (see Figure 1). · The “Certification Label” (vinyl adhesive label) is located on the lower area of the driver side B-Pillar (see Figure 1).

CERTIFICATION LABEL AND VIN PLATE REPLACEMENT SERVICE INFORMATION Because of collision damage or other vehicle repair, a replacement “Certification Label” or “VIN Plate/Label” may be needed. HINT: Certification Label = FMVSS (Federal Motor Vehicle Safety Standards) label. These items may be available from Nissan by request if certain criteria are met. This bulletin lists the criteria and provides an application form for such replacements. · The “VIN Plate/Label” (metal plate or vinyl label) is attached to the instrument panel or body on the driver side at the base of the windshield (see Figure 1). · The “Certification Label” (vinyl adhesive label) is located on the lower area of the driver side B-Pillar (see Figure 1).

CERTIFICATION LABEL AND VIN PLATE REPLACEMENT SERVICE INFORMATION Because of collision damage or other vehicle repair, a replacement “Certification Label” or “VIN Plate/Label” may be needed. HINT: Certification Label = FMVSS (Federal Motor Vehicle Safety Standards) label. These items may be available from Nissan by request if certain criteria are met. This bulletin lists the criteria and provides an application form for such replacements. · The “VIN Plate/Label” (metal plate or vinyl label) is attached to the instrument panel or body on the driver side at the base of the windshield (see Figure 1). · The “Certification Label” (vinyl adhesive label) is located on the lower area of the driver side B-Pillar (see Figure 1).

VEHICLE KEY NOT DETECTED / AUTHENTICATED, ENGINE WILL NOT START This bulletin has been amended. See AMENDMENT HISTORY on the last page. Please discard previous versions of this bulletin.

REMOVING FOREIGN MATERIAL FROM THE WINDOW GLASS This bulletin has been amended. See AMENDMENT HISTORY on the last page. Please discard previous versions of this bulletin.

WINDSHIELD CRACKING This bulletin has been amended. See AMENDMENT HISTORY on the last page. Please discard previous versions of this bulletin.