NHTSA complaint #11735838

Owner complaint summary

The fuel tank protective shield underneath my vehicle has severely rusted and corroded, with visible perforations forming through the metal (photos attached). This shield protects the fuel tank from road debris and also helps secure the tank to the vehicle. The corrosion appears to be caused by galvanic corrosion: the steel fuel tank shield is bolted directly to an aluminum heat shield, and the contact between these dissimilar metals accelerates corrosion of the steel component. This is a known issue affecting numerous vehicles of this make and model, suggesting a design defect. Safety concerns: The shield is structural — it helps hold the fuel tank in place. Continued deterioration could compromise the tank's mounting and lead to the tank dropping or shifting. As the shield fails, the fuel tank itself becomes exposed to road debris that could puncture it, creating a fuel leak and fire hazard. There were no warning lights, messages, or symptoms inside the vehicle. The damage was only discovered during a visual inspection underneath the vehicle. The component is available for inspection upon request. UNKNOWN whether the manufacturer has issued any formal acknowledgment, but the failure pattern is consistent across many owner reports.