PD109 – Ball Joint May Separate from Lower Link – 2024 Nissan Frontier

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June 26, 2024 NHTSA CAMPAIGN NUMBER: 24V479000

Ball Joint May Separate from Lower Link

Ball joint separation can cause a loss of steering control, increasing the risk of a crash.

 

NHTSA Campaign Number: 24V479

Manufacturer Nissan North America, Inc.

Components SUSPENSION, STEERING

Potential Number of Units Affected 5,929

 

Summary

Nissan North America, Inc. (Nissan) is recalling certain 2024 Frontier vehicles. The front right-side lower link may have been manufactured with an oversized ball joint, which can result in corrosion and ball joint separation from the front right-side lower link.

 

Remedy

Dealers will replace the front right-side lower link, free of charge. Owner notification letters are expected to be mailed August 15, 2024. Owners may contact Nissan’s customer service at 1-800-867-7669. Nissan’s number for this recall is PD109.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Nissan has a Recall

 


Description of the Defect:

Due to a supplier production issue that has since been corrected, the front right hand lower link may have been manufactured with an oversized ball joint. As a result, the ball joint press fit on the front right hand lower link may be below the minimum pushout specification, potentially leading to ball joint disengagement from the front right hand lower link.

While the disengagement of the ball joint will not lead to an immediate separation, it may create a higher risk of corrosion over time and a subsequent separation of the ball joint from the lower link. If this separation occurs, the vehicle’s drivability may be affected, increasing the risk of a crash.

 

Chronology of Principal Events:

On March 1, 2024, during a routine part evaluation at the supplier, a technician reported a failed test result for the push out evaluation on a front right hand lower link. The supplier quarantined the part and initiated an investigation.

On March 4, 2024, the supplier identified an oversized diameter of the ball joint in the incident test part. The supplier’s investigation found the incorrect die was used in the production of the front right hand lower link.

March 2024 -The supplier was able to determine a total of 10,036 suspect parts were produced on the incorrect stamping die based on production and maintenance records. The suspect parts were installed on 9,664 assemblies and shipped to the Canton, MS plant. These assemblies containing a suspect part may have been installed on 10,198 vehicles. Of the remaining parts, 248 were found at the supplier and scrapped, while 124 were identified as service parts and quarantined. Out of the total affected vehicles, 4,056 were held at Canton plant for inspection. Separately, five of the vehicles are trial units within Nissan’s control, 208 were destined for export and the remaining 5,929 vehicles potentially outflowed to the U.S. market.

April 2024 through May 2024 – The supplier conducted bench testing to simulate the subject condition. The initial testing showed vertical displacement of the balljoint. This result confirmed that the ball joint press fit was less than the minimum push out force of the joint. However, the ball joint remained engaged as the snap ring retained the ball joint.

Nissan coordinated vehicle level evaluations with two front right hand lower link assemblies to measure both lateral and longitudinal displacement. During this evaluation, Nissan assessed what effect excess movement would have on the front right hand ball joint durability and corrosion resistance.

June 2024 – Nissan concluded testing and finalized its assessment. As a result of the testing, Nissan confirmed that if the ball joint disengages from the front right hand lower link the snap ring will retain the ball joint connection to the lower link. However, vertical movement of the ball joint over time may lead to corrosion of the lower link which could result in separation of the balljoint. If this occurs, the vehicle’s drivability may be affected; increasing the risk of a crash.

June 18, 2024 – Nissan decided to conduct a Voluntary Safety Recall for all potentially affected vehicles.

Nissan has confirmed there are no market reports related to the subject condition. Nissan is also not aware of any accident or injuries related to the subject condition.

 

Description of Corrective Action:

Dealers will be notified of the recall on June 28, 2024. Beginning August 15, 2024, owners of all potentially affected vehicles will be notified to bring their Frontier to a Nissan dealer for replacement of the front right hand lower link. All repairs will be performed free of charge for parts and labor and may take up to two and a half (2.5) 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 because the subject vehicles are under warranty.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
NISSAN FRONTIER 2024

 


3 Associated Documents

Recall Acknowledgement

RCAK-24V479-9839.pdf 645.4KB

 


Recall 573 Report

RCLRPT-24V479-3174.PDF 213.596KB

 


Miscellaneous Document June 26, 2024 – Defect Information Report

RMISC-24V479-7760.pdf 947.993KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V479&docType=RCL

 


 

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