2003 Honda Pilot Suspension Problems

My 2003 Honda pilot rear subframe suspension is rusting and causing control issues. This is a common problem on the 2003-2008 Honda Pilots. In Honda TSB 21-019 Honda states " The subframe mounts may pull away from the body of the vehicle (see images below), but extensive testing has concluded that vehicle stability will be maintained." This is NOT true. Other Honda's have experienced similar issues and Honda has issued a safety recall. There should be a safety recall for the 2003-2008 Honda pilots for this subframe rust issue. Please see: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

REAR SUSPENSION MOUNTING LOCATIONS HAVE RUSTED THROUGH ALLOWING THE REAR SUSPENSION TO HANG DOWN. THE FRONT MOUNTING POINTS OF THE REAR SUSPENSION ARE NOT DAMAGED YET. WAS NOTICED AS A NOISE WHILE DRIVING AND FOUND DURING TIRE INSPECTION.

THE REAR SUB-FRAME ON THE DRIVER'S SIDE OF THIS 2003 HONDA PILOT IS EXTREMELY RUSTED EXPOSING THE SUSPENSION CROSS-MEMBER BOLT WHICH IS SIMILARLY RUSTED. AN INTERNET SEARCH INDICATES THIS IS A COMMON PROBLEM WITH HONDA PILOTS AND A POTENTIAL HIGH-RISK POINT OF FAILURE.

SUSPENSION IS COMPLETED RUSTED OUT FROM FRAME

USING 4 WHEEL DRIVE TO PULL MY BOAT THROUGH THE WOODS, 2 OF THE 4 REAR AXEL MOUNTS PULLED OUT OF THE UNIBODY FRAME AFTER A LOUD CLUNK. CAR WAS ALWAYS MAINTAINED AT THE DEALERSHIP. THE VEHICLE IS NOT REPAIRABLE, THIS SEEMS TO BE A DESIGN FLAW.

WE WERE DRIVING STRAIGHT ON THE HIGHWAY AT ~65 MPH, FULLY LOADED FOR A WEEK-LONG CAMPING TRIP, AND HIT A LARGE POTHOLE. THE REAR WHEEL ASSEMBLY OF MY HONDA PILOT BROKE SO THAT IT WAS ONLY PARTIALLY ATTACHED TO THE FRAME BECAUSE THE FRAME OF THE CAR RUSTED THROUGH. THE 2 BACK BOLTS WERE STILL IN PLACE, BUT THE FRAME ITSELF WAS CRUMBLING APART; THE 2 FRONT BOLTS WERE THE ONLY THINGS HOLDING THE REAR WHEEL AND AXLE TO THE CAR. THE PHOTO SHOWS THE STEEP ANGLE OF THE WHEELS, AND HOW LOW TO THE GROUND THE BACK OF THE CAR WAS. I DROVE THE CAR TO OUR MECHANIC, THEY PUT IT UP ON THE LIFT, AND THEN SHOWED US. THEY TOLD US IT WAS UNFIXABLE. THE CAR IS 14 YEARS OLD AND OTHERWISE IN GOOD SHAPE. IT HAS RECEIVED REGULAR MAINTENANCE (I HAVE 9 YEARS OF MAINTENANCE RECORDS). THE MECHANIC HAD DONE BRAKE WORK 3 DAYS PRIOR, AND I HAD GOTTEN THE TIRES ROTATED THE PREVIOUS WEEK. NONE OF THE PEOPLE WHO WORKED ON THE CAR NOTICED OR SAID ANYTHING WAS MAJORLY WRONG WITH THE CAR. WE WERE LUCKY WE DIDN'T HAVE A SERIOUS ACCIDENT WHEN THE CAR BROKE ON THE HIGHWAY.

THE TRUCK HESITATES IN ORDER TO GET IT TO MOVE YOU HAVE TO TAKE FOOT OFF THE GAS PEDAL.HAPPENS A LOT WHEN DRIVING.SOMETIMES IT STALLS....DRIVER SIDE REAR BODY MOUNT IS RUSTED OUT

LAST MONTH WHILE DRIVING VEHICLE SEEMED A LITTLE LOOSE WHILE GOING DOWN THE ROAD, LOOKED OVER FRONT END AND COULD FIND NO PROBLEMS. DAUGHTER (WHO HAD DRIVEN DAILY) COMPLAINED THAT PROBLEM WAS GETTING WORSE. WHILE BACKING UP SLOWLY MONDAY (3/20/17) , VEHICLE BECAME UNCONTROLLABLE AND SHIFTED LANES. UPON INSPECTION IT HAS BEEN FOUND BOTH REAR SUSPENSION MOUNTING POINTS (REAR MOST 2 OF 4) HAVE RUSTED LOOSE FROM UNIBODY ( COMPLETELY DETACHED). BOUGHT THIS PILOT NEW IN 2003, ALWAYS KEPT UP ON ALL SERVICE AND MAINTENANCE.

REAR SUSPENSION RUSTED OUT FROM THE FRAME. ONLY ONE SIDE AS OF RIGHT NOW.

OF THE FOUR POSTS WHERE THE COMPLETE REAR AXLE MOUNTS TO THE UNDER BODY OF THE CHASSIS, TWO OF THE POSTS HAVE RUSTED AWAY FROM THE FRAME, LEAVING THE REAR AXLE ONLY HALF ATTACHED TO THE MAIN BODY OF THE CAR. THE VEHICLE HAS VERY LIMITED RUST ANYWHERE, SO FOR THE UNDER BODY TO RUST TO A POINT OF SEPARATION FROM THE REAR WHEEL ASSEMBLY IS DISCONCERTING. WE HAD NO WARNING AND HAD THE VEHICLE PROPERLY/ROUTINELY MAINTAINED. IF THE REAR AXLE ASSEMBLY HAD COMPLETELY BROKEN AWAY, THE RESULTING CRASH WOULD HAVE BEEN DISASTROUS. CERTIFIED MECHANICS CONFIRM THAT THEY HAD NEVER SEEN SUCH A SERIOUS DETERIORATION OF A SIGNIFICANT STRUCTURAL COMPONENT.

WHILE MY WIFE WAS DRIVING MY 2003 HONDA PILOT SHE ALMOST LOST CONTROL WITHOUT ANY WARNING. SHE DRIVE IT THE FEW REMAINING MILES HOME AND ASKED ME TO EXAMINE IT FOR A POSSIBLE LOOSE WHEEL. UPON INSPECTION I FOUND THAT THE ENTIRE REAR SUSPENSION HAD SEPARATED FROM THE BODY AND THAT ONLY THE ABS BRAKE WIRES WAS HOLDING IT IN PLACE. THERE WAS NO APPARENT REASON FOR THIS. THERE WAS NOTHING TO EXPLAIN WHY THIS HAD OCCURED

TL* THE CONTACT OWNS A 2003 HONDA PILOT. WHILE MAKING A LEFT TURN AT VARIOUS SPEEDS, THE CONTACT HEARD A NOISE COMING FROM THE REAR OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE BOLT CONNECTING THE SUSPENSION TO THE FRAME HAD CORRODED AND THAT THE SUSPENSION NEEDED TO BE WELDED TO THE FRAME OF THE VEHICLE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 160,000.

I AM THE ORIGINAL OWNER OF A 2003 HONDA PILOT. I AM AN OLDER, CAUTIOUS DRIVER AND HAVE BABIED THIS VEHICLE, DOING ALL REGULAR SERVICE AT THE DEALER'S, SO IT WOULD RUN IN TOP SHAPE FOR MANY YEARS TO COME. AROUND SIX MONTHS AGO I NOTICED AT LOWER SPEEDS (20-30 M.P.H.) THE VEHICLE SHUDDERS. TO COUNTER THE PROBLEM I HAVE TO ACCELERATE AND THEN IT GOES AWAY. I HAVE HAD THE DEALER CHECK IT THREE TIMES AND EACH TIME THEY SAY THEY CANNOT REPLICATE THE PROBLEM, WHICH IS HARD TO BELIEVE. LAST WEEK THE D LIGHT STARTED TO FLASH. I TOOK IT INTO THE DEALER RIGHT AWAY AND THEY SAID IT WAS A SENSOR. I ASKED IF THAT COULD BE MAKING THE CAR SHUDDER AND THEY SAID PROBABLY. I HAD THEM CHANGE IT AND THE SHUDDER HAS NOT GONE AWAY. THIS MORNING IT WAS PARTICULARLY HEAVY SO I CALLED THE DEALER AGAIN AND THEY GAVE ME THE AMERICAN HONDA NUMBER. I CALLED THEM AND THEY SAID THE DEALER SHOULD LOOK AT IT. I'VE SEEN SO MANY OTHER PEOPLE HAVE THE SAME COMPLAINT AND I'M VERY CONCERNED THIS IS A SAFETY ISSUE THAT HONDA IS CHOOSING TO IGNORE; A LITTLE LIKE OTHER AUTO COMPANIES HAVE DONE OVER THE PAST FEW YEARS UNTIL A FATALITY HAPPENS. AS I CARRY MY FAMILY IN THIS VEHICLE AND I AM PARTICULARLY CONCERNED. *TR

I TOOK MY PILOT IN FOR A SLIPPING TRANSMISSION. I WAS TOLD I HAD BAD MOTOR MOUNTS AND THAT WAS ALLOWING THE TRANSMISSION TO SLIP. I SPENT APPROX. $3600.00 TO HAVE THE MOTOR MOUNTS FIXED, TIMING BELT AND WATER PUMP, FRONT STRUTS, ETC. FIXED. THE PROBLEM STARTED AGAIN, THIS TIME, GETTING A FLASHING "D" LIGHT. TOOK IT BACK IN FOR FAILURE TO FIX THE PROBLEM. HAD 4TH GEAR PRESSURE GEAR REPLACED FOR COST. I NOW HAVE A CHECK ENGINE LIGHT ON POSTING A CODE OF P0730, "INCORRECT GEAR RATIO". I HAVE BEEN INTO HONDA 4 TIMES FOR THIS ISSUE INCLUDING TODAY, AND I WAS TOLD I NEED A NEW TRANSMISSION. I AM OUT OF WARRANTY OF COURSE, BUT I KNOW THERE ARE MANY, MANY COMPLAINTS REGARDING THIS PARTICULAR ISSUE. I DO NOT HAVE THE MONEY TO REPLACE A FAULTY TRANSMISSION THAT WAS BUILT POORLY. I AM WORRIED I MIGHT GET INTO A CRASH BECAUSE OF THIS. I AM CONTEMPLATING HIRING A LAWYER TO RESOLVE THIS ISSUE. *TR

FIRST, DOOR LOCKS AUTOMATIC NOW HAVE TO UNLOCK MYSELF, ALONG WITS THE OUTSIDE DOORS.ALARM BUTTON NO LONGER WORKS TO UNLOCK. DOOR HANDLES INSIDE HAVE BEEN PEELING AND ACTUALLY CUT YOUR FINGERS WHEN OPENING THE DOOR, I HAVE MASWING TAPE IN THEM AND IT'S UGLY, FINALLY..LIGHTS INSIDE ARE GOING OUT ON RADIO, DIMMING ON INTERIOR ALSO.

OUR 2003 HONDA PILOT LOCKED UP ON THE HIGHWAY DUE TO TRANSMISSION FAILURE OF THE 2ND GEAR. WE WERE TRAVELING IN THE 3RD LANE OVER 60 MPH WHEN BOTH FRONT TIRES LOCKED AND WE SKIDDED TO A HALT IN LESS THAN 200 YARDS ON THE HIGHWAY. PRIOR TO OUR VEHICLE BREAKING DOWN, THERE WERE NO SIGNS OF DANGER, NO UNUSUAL SOUNDS, NO BLINKING LIGHTS OR ANY HESITATION WITH THE CAR. OUR VEHICLE HAD 138,400+ MILES AND HAS BEEN SERVICED REGULARLY ACCORDING TO HONDA'S RECOMMENDED MAINTENANCE SCHEDULES, INCLUDING ALL TRANSMISSION FLUID CHANGES. ON MAY 7, 2004 WITH 36,384 MILES, OUR VEHICLE HAD RECEIVED A RETROFIT OF THE A/T OIL JET KIT DUE TO HONDA'S 04-021B SAFETY RECALL ON THE AUTOMATIC TRANSMISSION SECOND GEAR. LUCKILY NO ONE WAS INJURED AND THERE WERE NO OTHER VEHICLES INVOLVED IN THE INCIDENT. THE CAR BEHIND US STOPPED JUST IN TIME TO AVOID A COLLISION. OUR CAR COULD NOT BE ROLLED INTO THE BREAKDOWN LANE AS BOTH FRONT WHEELS WERE LOCKED AND WE WERE STRANDED IN THE 3RD LANE. A POLICE OFFICER WAS CALLED TO THE SCENE AND LOGGED THE INCIDENT AS A DISABLED VEHICLE. THE OFFICER REQUESTED FOR IMMEDIATE TOWING SINCE WE WERE IN A DANGEROUS LOCATION. THE CAR WAS TOWED TO A HONDA DEALER, WHO PROVIDED THE FOLLOWING DIAGNOSIS AND ESTIMATE: "TRANSMISSION INTERNAL FAILURE BOTH FRONT AXLES TWISTED NEEDS 2 TIRES - FLAT SPOTS ALIGNMENT $5,199.14 PLUS TAX" WE OPTED NOT TO REPAIR THE HONDA AND INSTEAD PURCHASED A NEW NON-HONDA VEHICLE AND RECEIVED A TRADE-IN VALUE FOR 'AS-IS' CONDITION. *TR

HAD TO REPLACE FRONT AND SIDE MOTOR MOUNTS ON MY 2003 HONDA PILOT. THIS WAS AFTER ONLY 67,118 MILES. MECHANIC SAID THIS IS A COMMON PROBLEM WITH THE ORIGINAL MOTOR MOUNTS. THIS COULD BE VERY DANGEROUS. *TR

THE FRONT LOWER BALL JOINT ON MY 2003 HONDA PILOT SEPARATED WHILE BEING DRIVEN OUT OF A PARKING LOT. THE FRONT RIGHT SUSPENSION COLLAPSED. UPON INSPECTION, THE JOINT HAD NEVER BEEN LUBRICATED WHEN THE CAR WAS ASSEMBLED. THIS JOINT IS A "LUBED-FOR-LIFE" JOINT THAT CANNOT BE INSPECTED OR LUBRICATED ONCE ASSEMBLED. THE PROTECTIVE BOOT AND RETAINING CLIP WERE IN PERFECT CONDITION WHEN THE JOINT FAILED. I AM A MECHANICAL ENGINEER (TENNESSEE LICENSE # 110751) AND HAVE BEEN INVOLVED IN SEVERAL METAL FAILURE INVESTIGATIONS. I AM CERTAIN THAT THIS JOINT FAILED DUE TO HAVING NOT BEEN LUBRICATED AT THE FACTORY. THIS CAR HAD BEEN INSPECTED BY A HONDA DEALERSHIP AS A CERTIFIED USED CAR AND HAD ALSO BEEN SERVICED AT THE HONDA DEALERSHIP WHERE IT HAD PASSED THEIR SUSPENSION CHECK. IF THIS FAILURE HAD OCCURRED 10 MINUTES EARLIER OR LATER WE WOULD HAVE LOST CONTROL OF THE VEHICLE ON THE INTERSTATE AT 70MPH. THE CAR HAS NEVER BEEN IN AN ACCIDENT OR ABUSED IN ANY WAY. NEITHER HONDA USA NOR THE TWO DEALERSHIPS INVOLVED WOULD RECOGNIZE THE SERIOUSNESS OF THIS FAILURE. THE LOWER CONTROL ARM, HUB ASSEMBLY, AND STEERING KNUCKLE WERE REPLACED AT MY EXPENSE. *TR

NOTICEABLE CABIN VIBRATION WHEN CAR APPROACHES 70MPH, VERY NOTICEABLE. NO MODIFICATIONS OR REPAIRS AS OF YET. *TR

MY VEHICLE VIBRATES AT HIGHWAY SPEEDS BETWEEN 70-80 MPH. I HAVE TAKEN THE CAR INTO THE DEALER NO LESS THAN 5 TIMES FOR THE PROBLEM AND JUST RECENTLY WAS TOLD THAT HONDA IS AWARE OF THE PROBLEM AND THAT THE VIBRATION IS A CHARACTERISTIC OF THE VEHICLE. UP TO THIS POINT THE DEALER HAS RE-BALANCED THE TIRES OVER AND OVER AND REDONE THE ALIGNMENT. I EVEN PURCHASED BRAND NEW TIRES AND STILL THERE IS THE VIBRATION. THE DEALER ROAD FORCE BALANCED THE TIRES AND STILL THE VIBRATION PROBLEM. THERE ARE MANY PEOPLE COMPLAINING ABOUT THIS PROBLEM ON THE HONDAPILOT.ORG WEBSITE AND THERE APPEARS TO BE NO RESOLUTION. *JB