Recall - Rear Suspension
00-030March 20, 2000
Applies To: 1998-99 Passport - ALL
Safety Recall: Passport Rear Suspension
BACKGROUND
Excessive paint thickness on certain rear suspension components may cause the lower link bolts and nuts to loosen and make noise. Over time, the nut and bolt could fall out, allowing the lower link to separate from the axle.
Additionally, the rear stabilizer shackles, lateral link, and rear damper mounting nuts and bolts could loosen, causing abnormal noise.
CUSTOMER NOTIFICATION
All owners of affected vehicles will be mailed a notification of this recall. An example of the customer notification is at the end of this service bulletin.
Some of the affected vehicles may still be in dealer inventory. By Federal law, these vehicles cannot be sold or leased until they are repaired.
CORRECTIVE ACTION
Replace and torque the bolts in the lower links and the stabilizer bar links. Torque the mounts for the lateral rod, dampers, and upper links. Make all torque measurements on the nuts; measuring torque on the bolt heads will give incorrect readings.
PARTS INFORMATION
Stabilizer Bar Bolt Kit:
P/N 2-90000-960-0, H/C 6422158
Lower Link Bolt Kit:
P/N 2-90000-950-0, H/C 6422141
REQUIRED MATERIALS
Brite-Mark: Allocated with initial parts allocation.
(One Brite-Mark will mark approximately 575 vehicles.)
WARRANTY CLAIM INFORMATION
Operation Number: 417119
Flat Rate Time: 0.4 hour
Failed Part: P/N 8-97134-705-0
H/C 5648472
Defect Code: 00A
Contention Code: K81
Template ID: 00-030A
Skill Level: Repair Technician
REPAIR PROCEDURE
1. Park the vehicle on level ground. If you need more room underneath, park the vehicle on a wheel alignment rack. Do not raise the vehicle on a hoist, the full weight of the vehicle must be sitting on the suspension during this procedure.
2. Replace the nut and bolt mounting the right lower link to the rear axle. Torque the new nut to 137 N.m (101 lb-ft). Mark the nut and bolt with the Brite-Mark.
3. Repeat step 2 on the left side.
4. Replace the four nuts and bolts connecting the ends of the stabilizer bar to the frame. Torque the nuts to 20 Nm (15 lb-ft). Mark the nuts and bolts with Brite-Mark.
5. Torque the damper lower mounting nuts to 93 Nm (69 lb-ft). Mark the nuts and bolts with the Brite-Mark.
6. Torque the lateral rod-to-axle mounting nut to 93 Nm (69 lb-ft). Mark the nut and bolt with the Brite-Mark.
7. Torque the upper links-to-axle mounting nuts and bolts to 186 Nm (137 lb-ft). Mark the nuts and bolts with the Brite-Mark.
8. Fill out the information on a campaign completion label. Affix this label to the back edge of the driver's door lust above the door latch.
Example of Customer Letter
March 2000
Safety Recall: Passport Rear Suspension
Dear Passport Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
What is the reason for this notice?
lsuzu Motors Ltd., the manufacturer, has determined that a defect relating to motor vehicle safety exists in certain 1998 and 1999 Passports. Too much paint was applied to the rear axles of some vehicles while they were being manufactured. On those vehicles, there may not have been enough time for the paint to dry before the rear axle lower link bracket bolt and nut were tightened to the specified torque. The result is that the bolt and nut that connect the lower link to the rear axle may become loose. Initially, this loosening will usually produce an abnormal noise coming from the rear of the vehicle. If not corrected, however, the bolt could fully detach and the lower link could separate from the rear axle. That condition could then result in loss of vehicle control and a possible vehicle crash.
What should you do?
Call any authorized Honda dealer and make an appointment to have your vehicle repaired. They will replace some nuts and bolts in the rear suspension, and retighten others. This repair will be done free of charge. Please plan to leave your Passport for half a day to allow the dealer flexibility in scheduling.
Who to contact if you experience problems.
If you are not satisfied with the service you receive from your Honda dealer, you may write to
American Honda Motor Co., Inc.
Honda Consumer Affairs Dept.
Mail Stop 500-2N-7D
1919 Torrance Blvd.
Torrance, CA 90501-2746
If you believe that American Honda or the dealer has failed or is unable to remedy the defect in your vehicle, without charge, within a reasonable period of time (60 days from the date you first contact the dealer for a repair appointment), you may submit a complaint to
Administrator
National Highway Traffic Safety Administration
400 Seventh St., S.W.
Washington, D.C. 20590
Or call the toll-free Auto Safety Hotline at (800)424-9393. Residents of Washington D.C. should call (202)366-0123.
What to do if you feel this notice is in error.
This notice was mailed to you according to our latest information. If you no longer own this vehicle, or some information in this notice is incorrect, please fill out and return the enclosed, postage-paid Information Change Card. This will help us update our records.
If you have questions
If you have questions about this notice, or need assistance with contacting a Honda dealer, please call the Honda Consumer Affairs Department at (800)999-1009.
We regret any inconvenience this may cause you.
Disclaimer