PC933 – Missing Internal Bushing in Brake Calipers – 2021 Nissan Rogue

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NISSAN
“–…/
November 22, 2023
Dr. Cem Hatipoglu
Acting Associate Administrator for Enforcement
National Highway Traffic Safety Administration
Attn: Recall Management Division (NVS-215)
Room W48-302
1200 New Jersey Avenue, SE
Washington, D.C. 20590
Dear Dr. Hatipoglu:
Nissan North America, Inc.
One Nissan Way
Franklin, TN 37067
Mailing Address:
PO Box 685001
Franklin, TN 37068
We are transmitting the enclosed Defect Information Report in accordance with 49 CFR Part
573. This Defect Information Report concerns two (2) MY 2021 Rogue vehicles recalled to
inspect and replace the left and right rear brake calipers. The two specific Rogue vehicles in
scope of this recall were previously recalled and inspected under Recall 21V-286; however, they
were released without replacing the rear brake calipers.
Very truly,
Will Swindell
Manager,
Technical Compliance
Encl.
DEFECT INFORMATION REPORT
1. Manufacturer:
Nissan North America, Inc., Smyrna Plant
2. Vehicles Potentially Involved:
The vehicles subject to this report were previously recalled vehicles that were judged not to
need a rear brake caliper replacement. The production period for the previously inspected
vehicles includes certain Model Year 2021 Nissan Rogue vehicles manufactured from
January 9, 2021 to February 24, 2021 at the Smyrna, TN plant.
Certain Model Year 2021 Nissan Rogue vehicles that were released without replacing the
rear brake calipers were produced from January 22, 2021 to January 29, 2021 at the Smyrna,
TN plant.
Based on production records, this issue (as described in Section 5 below) is unique to Model
Year 2021 Nissan Rogue vehicles manufactured during the timeframe that the technician
error occurred. No other Nissan or INFINITI vehicles are affected.
The name, description and part number of the subject components are below:
Part Name Part Descri~tion
Caliper Assy Disc Brake W/EPB (RH) Right Hand Brake Caliper Assembly
Caliper Assy Disc Brake W/EPB (LH) Left Hand Brake Caliper Assembly
Manufacturer of the subject equipment:
ADVICS Manufacturing
1784003 Avenida Cazcanes 2210
Parque Industrial Colinas de Lagos
Zip Code: 47515, Lagos de Moreno, Jalisco, Mexico
Ron Bogan
Director of Operation
Email: Ron.Bogan@advics.com
Phone: +1 (812)244-9695
3. Total Number of Vehicles Potentially Involved:
Part Number
44000-6RA0C
44010-6RA0C
Approximately two (2) MY 2021 Nissan Rogue vehicles total.
4. Percentage of Vehicles Estimated to Actually Contain the Defect:
100%.
5. Description of the Defect:
Due to a manufacturing error at the supplier (ADVICS}, certain Rogue vehicles may be
missing an internal bushing in the rear left and/or right brake caliper assembly. A
technician at the supplier did not initiate the automatic cycle for inserting the bushing in
production. The Programmable Logic Controller (PLC) did not detect the missing bushing
because the process verification logic had been inadvertently deleted due to a 4M change.
As a result, the brake caliper parts continued through the production line without the
bushing inserted.
The brake caliper bushing serves as a guide for the bolt nut shaft and keeps the 0-ring seal
in place. Without the bushing in place, the 0-ring seal can move and become deformed inbetween
the cast surface and the bolt nut, resulting in a brake fluid leak path. Normal
application of the brakes can lead to an external brake fluid leak that may cause an
electrical short of the Motor Gear Unit components, resulting in a dash warning light. The
brake fluid leak can cause reduced braking performance without warning, which could
increase the risk of crash.
6. Chronology of Principal Events:
February 18, 2021 – Nissan received notification from ADVICS about a brake caliper leak
during high pressure testing. Subsequent investigation of the part by ADVICS revealed that
a bushing was missing on the bolt nut shaft.
Nissan worked with the ADVICS to identify the cause and consequence of the issue. As a
precaution, Nissan initiated a yard hold on all potentially affected vehicles at the Smyrna, TN
plant while- ADVICS conducted their investigation.
March 2021 through April 2021 – ADVICS determined that the issue was due to a technician
error. The technician did not initiate the automatic cycle for inserting the bushing in
production. The PLC did not detect the missing bushing because the process verification
logic was inadvertently deleted due to a 4M change.
Based on the suspect window information provided by ADVICS, Nissan conducted a plant
audit to inspect 80 units and found 28 brake caliper assemblies with missing bushings.
April 75, 2021 – Nissan decided to conduct a safety recall to remedy the issue.
September 2023 – During a routine test drive on a pre-production trial vehicle, Nissan
identified a small brake fluid leak from the right rear brake caliper on a MY 2027 Rogue
vehicle. Nissan launched an investigation, together with the supplier, into the cause of the
leak.
October 2023 – The supplier investigation revealed that an internal bushing was missing on
the bolt nut shaft, which appeared to be similar to the defect from the previous recall (21V-
286). The supplier reviewed the serial numbers from the inspected parts against the serial
numbers for Recall 21V-286 and determined that three (3) additional suspect serial
numbers had not been included as part of the previous recall.
November 2023 – Nissan reviewed the additional serial numbers the supplier provided and
investigated the impact of these missing serial numbers on the rear brake caliper
inspection procedure for Recall 27V-286. Based on internal records, Nissan was able to
trace the serial numbers to the Nissan pre-production trial vehicle and two (2) potentially
affected vehicles which had been inspected under Recall 27V-286.
November 75, 2023 – Out of abundance of caution, Nissan decided to conduct a Voluntary
Safety Recall to replace the left and right rear brake calipers on the two (2) vehicles that
were previously inspected and judged not to need a brake caliper replacement under
Recall 21V-286.
Nissan is not aware of any warranty claims, accident or injuries related to the subject
condition.
7. Description of Corrective Action:
Dealers will be notified of the new recall beginning November 28, 2023. The two (2) owners
of the previously inspected vehicles that were judged not to need a rear brake caliper
replacement will be notified beginning on January 70, 2024 to bring their Rogue to a Nissan
dealer for repair. Dealers will be instructed to replace both left and right rear brake calipers.
All repairs will be performed free of charge for parts and labor and may take up to two (2)
hours to complete.
Nissan will not include a statement in the Part 577 owner notification concerning
reimbursement for the cost of obtaining a pre-notification remedy since the subject
vehicles are under warranty.
8. Copy of Notices:
Copies of all notices will be provided to NHTSA as they become available.

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-791
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Nissan North America, Inc.
Submission Date : NOV 22, 2023
NHTSA Recall No. : 23V-791
Manufacturer Recall No. : PC933
Manufacturer Information :
Manufacturer Name : Nissan North America, Inc.
Address : P. O. BOX 685001
Franklin TN 37068-5009
Company phone : 800-647-7261
Population :
Number of potentially involved : 2
Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2021-2021 Nissan Rogue
Vehicle Type : LIGHT VEHICLES
Body Style : SUV
Power Train : GAS
Descriptive Information : Based on production records, this issue is unique to Model Year 2021 Nissan Rogue
vehicles manufactured during the timeframe that the technician error occurred. No
other Nissan or INFINITI vehicles are affected.
Production Dates : JAN 22, 2021 – JAN 29, 2021
VIN Range 1 : Begin : NR End : NR Not sequential
Description of Defect :
Description of the Defect : Due to a manufacturing error at the supplier (ADVICS), certain Rogue vehicles
may be missing an internal bushing in the rear left and/or right brake caliper
assembly. A technician at the supplier did not initiate the automatic cycle for
inserting the bushing in production. The Programmable Logic Controller (PLC)
did not detect the missing bushing because the process verification logic had
been inadvertently deleted due to a 4M change. As a result, the brake caliper
parts continued through the production line without the bushing inserted.
The brake caliper bushing serves as a guide for the bolt nut shaft and keeps the
O-ring seal in place. Without the bushing in place, the O-ring seal can move and
become deformed in-between the cast surface and the bolt nut, resulting in a
brake fluid leak path.
FMVSS 1 : NR
FMVSS 2 : NR
Description of the Safety Risk : Normal application of the brakes can lead to an external brake fluid leak that
may cause an electrical short of the Motor Gear Unit components, resulting in
a dash warning light. The brake fluid leak can cause reduced braking
Part 573 Safety Recall Report 23V-791 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
performance without warning, which could increase the risk of crash.
Description of the Cause : NR
Identification of Any Warning
that can Occur :
There is no preceding warning for the customer.
Involved Components :
Component Name 1 : Caliper Assy Disc Brake W/EPB (RH)
Component Description : Right Hand Brake Caliper Assembly
Component Part Number : 44000-6RA0C
Component Name 2 : Caliper Assy Disc Brake W/EPB (LH)
Component Description : Left Hand Brake Caliper Assembly
Component Part Number : 44010-6RA0C
Supplier Identification :
Component Manufacturer
Name : ADVICS Manufacturing
Address : 1784003 Avenida Cazcanes 2210
Lagos de Moreno Foreign States 47515
Country : Mexico
Chronology :
See attached Part 573 for chronology.
Part 573 Safety Recall Report 23V-791 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Dealers will be instructed to replace both left and right rear brake calipers.
All repairs will be performed free of charge for parts and labor and may
take up to two (2) hours to complete.
Nissan will not include a statement in the Part 577 owner notification
concerning reimbursement for the cost of obtaining a pre-notification
remedy since the subject vehicles are under warranty.
How Remedy Component Differs
from Recalled Component :
NR
Identify How/When Recall Condition
was Corrected in Production :
NR
Recall Schedule :
Description of Recall Schedule : Dealers will be notified of the new recall beginning November 28, 2023.
The two (2) owners of the previously inspected vehicles that were judged
not to need a rear brake caliper replacement will be notified beginning on
January 10, 2024 to bring their Rogue to a Nissan dealer for repair.
Planned Dealer Notification Date : NOV 28, 2023 – NR
Planned Owner Notification Date : JAN 10, 2024 – NR
* NR – Not Reported

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CAMPAIGN
BULLETIN
Rear Brake Caliper Replacement
Voluntary Recall Campaign
Reference: PC993
Date: November 28, 2023
Attention: Dealer Principal, Sales, Service & Parts Managers
SAFETY RECALL
CAMPAIGN ID: PC993 | Original Document
***** Campaign Summary *****
Nissan is committed to the safety and security of our customers and their passengers. Nissan has notified the National Highway Traffic Safety Administration (NHTSA) that it is issuing a recall for two (2) vehicles previously inspected and released under campaign PC804. Nissan is conducting a Voluntary Safety Recall to replace the left and right rear brake calipers on the two (2) vehicles.
Due to a manufacturing error at the supplier, certain Rogue vehicles may be missing an internal bushing in the rear left and/or right brake caliper assembly. The brake caliper bushing serves as a guide for the bolt nut shaft and keeps the O-ring seal in place. Without the bushing in place, the O-ring seal can move and become deformed between the cast surface and the bolt nut, resulting in a brake fluid leak path. Normal application of the brakes can lead to an external brake fluid leak that may cause an electrical short of the Motor Gear Unit components, resulting in the illumination of the red brake warning light in the center of the dash meter. The brake fluid leak can cause reduced braking performance without warning, which could increase the risk of crash.
The two (2) owners of the affected vehicles will be notified beginning in January 2024 to bring their Rogue to a Nissan dealer for repair. Dealers will be instructed to replace both left and right rear brake calipers. All repairs will be performed free of charge for parts and labor and may take up to two (2) hours to complete.
***** What Dealers Should Do****
1. Verify if vehicles are affected by this Voluntary Recall using Service Comm or DBS National Service history – Open Campaign I.D. PC993
2. Dealers must not sell, lease, trade, rent or loan any vehicles in dealer inventory subject to this recall campaign until after the vehicle has been remedied.
3. If a retailed vehicle affected by this Campaign ID visits the dealer for service, the dealer should inform the customer about the recall and communicate that the remedy and parts are available.
IMPORTANT: It is a violation of Federal law for dealers to sell or deliver new vehicles in their inventory covered by this notification until the campaign’s remedy action is performed.):
Affected
Models/Years:
Affected Population:
Dealer Inventory:
SERVICE COMM Activation date:
Stop Sale
In Effect
MY2021 Rogue (T33)
2
NA
November 28, 2023
YES
CAMPAIGN ID: PC993 Page 2 of 4 | Original Document
4. Once repaired, dealers should submit the claim using the claims coding provided, and release the vehicle.
***** Release Schedule *****
Parts
Parts are available and can be ordered via the normal ordering process.
Part Number
Description
Quantity
D4000-6RA0C
Brake Assy – RH Rear
1
D4010-6RA0C
Brake Assy – LH Rear
1
46237-AV601
Gasket-Brake Hose
4
Repair
• NTB23-084
Owner Notification
Nissan will notify the owners of potentially affected vehicles beginning January 2024.
***** Dealer Responsibility *****
It is the dealer’s responsibility to check Service Comm or DBS National Service History using the appropriate Campaign I.D. for the campaign status on each vehicle falling within the range of this voluntary recall campaign, which for any reason enters the service department. This includes vehicles purchased from private parties or presented by transient (tourist) owners and vehicles in new vehicle inventory. If a VIN subject to this recall campaign was part of a dealer trade, the letter associated with that VIN should be forwarded to the appropriate dealer for service completion.
NISSAN NORTH AMERICA, INC.
Total Customer Satisfaction
Q. Is this a recall?
A. Yes.
Q. Is this a Stop Sale?
A. Yes.
Q. What is the reason for the recall?
A. Due to a manufacturing error at the supplier, certain Rogue vehicles may be missing an internal bushing in the rear left and/or right brake caliper assembly.
Frequently Asked Questions (FAQ):
CAMPAIGN ID: PC993 Page 3 of 4 | Original Document
Q. What is the possible effect of the condition?
A. The brake caliper bushing serves as a guide for the bolt nut shaft and keeps the O-ring seal in place. Without the bushing in place, the O-ring seal can move and become deformed between the cast surface and the bolt nut, resulting in a brake fluid leak path. Normal application of the brakes can lead to an external brake fluid leak that may cause an electrical short of the Motor Gear Unit components, resulting in the illumination of the red brake warning light in the center of the dash meter. The brake fluid leak can cause reduced braking performance without warning, which could increase the risk of crash.
Q. What will be the corrective action for this voluntary recall campaign?
A. Dealers will replace both left and right rear brake calipers.
Q. How long will the corrective action take?
A. This service, which is conducted at no charge to you for parts and labor, could take up to two (2) hour to complete. However, your Nissan dealer may require your vehicle for a longer period of time based upon their work schedule.
Q. When will vehicle owners be notified?
A. Nissan will begin sending notifications to affected owners beginning January 2024, via U.S. Mail.
Q. Is my vehicle safe to drive?
A. If your vehicle is subject to this campaign, you will be contacted by Nissan Consumer Affairs or receive an Owner Notification letter from Nissan, which will instruct owners to bring their vehicles to a Nissan dealer to have their vehicles remedied as soon as possible.
Q. Is there anything owners can do to mitigate this condition?
A. No.
Q. Will a rental vehicle be provided while the dealer is servicing the vehicle?
A. Please consult your dealer for alternate transportation availability while your vehicle is being serviced. Rental is available upon customer request, while parts are on order.
EXPENSE CODE
DESCRIPTION
AMOUNT
502
Rental Expense
$156 (Max)
CAMPAIGN ID: PC993 Page 4 of 4 | Original Document
Contact the Warranty claims call center 1-800-258-7008 Option 7, if additional expense is required. Please refer to the Goodwill Rental Guidelines in the APRM for detailed information regarding application of rental reimbursement.
Q. Are parts readily available?
A. Yes
Q. Is there any charge for this service?
A. No. The remedy will be performed for the customer free of charge.
Q. Will I have to take my vehicle back to the selling dealer to have the service performed?
A. No, any authorized Nissan dealer is able to perform the recall campaign.
Q. I have lost confidence in the vehicle. Will Nissan replace or repurchase the vehicle?
A. The remedy will fully correct this condition. As the condition will be corrected, there is no basis for repurchasing or replacing your vehicle.
Q. What model year vehicles are involved?
A. Model year 2021 Nissan Rogue vehicles manufactured from January 9, 2021 to February 24, 2021.
Q. Are you experiencing this condition on any other Nissan (or INFINITI) models?
A. Yes. Certain Model Year 2021 Nissan Rogue vehicles manufactured in the Smyrna, TN plant from January 9, 2021 to February 24, 2021.
Revision History:
Date
Announcement
Purpose
November 28, 2023
Original Document
New campaign announcement

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