NHTSA complaint #11753493

Owner complaint summary

The vehicle is experiencing severe, premature galvanic corrosion on the doors, hinges, and hood due to a documented factory defect where aluminum panels press directly against steel hinges without proper isolation (acknowledged by the manufacturer in TSB 31-001-24).This is a critical structural and safety hazard covered under Federal Motor Vehicle Safety Standard (FMVSS) 206, which regulates door locks and door retention components. The advanced sub-surface corrosion is causing the metal surrounding the door hinges to degrade and oxidize, causing the paint to blister, bubble, and flake off. Over time, this structural failure poses an imminent safety risk of causing the door hinges to seize or bind, potentially jamming the doors shut during an emergency and trapping occupants inside the vehicle. Furthermore, the degradation of these hinge components creates a severe risk of the doors failing and opening unexpectedly while the vehicle is in motion at highway speeds.The manufacturer is refusing to address this structural defect because the vehicle passed its 5-year calendar warranty window, ignoring the fact that this sub-surface chemical reaction takes years to visibly manifest. This defect requires a formal safety investigation and an expanded recall to protect drivers from door-retention failures.