NHTSA complaint #11756507

Owner complaint summary

On the evening of [XXX], I started my vehicle while it was parked in my garage. Within approximately five minutes, the vehicle suddenly produced a violent and unusually loud mechanical noise, followed by visible smoke billowing from beneath the hood. Recognizing the immediate potential fire and safety hazard to both myself and my property, I immediately shut the vehicle down. The following morning, I took directly to Honda North, an authorized Honda dealership in Clovis, California, for a professional diagnostic inspection. The dealership's certified inspection determined that the A/C compressor had suffered a catastrophic internal mechanical failure and had completely seized. According to the dealership, the compressor's internal failure while the system was operating resulted in metallic debris being circulated throughout and contaminating the A/C system. This catastrophic seizure heavily strained the engine's drive belt system. The failure was a direct result of the factory compressor shaft seal leaking out all system refrigerant and lubricating oil, causing the unit to run dry and seize. As a result, the dealership determined that replacing only the failed compressor would not be sufficient to properly restore the system. The recommended repair requires a complete A/C system overhaul, including replacement of the compressor, condenser, expansion valve, and associated refrigerant lines/components. Honda has openly acknowledged this exact factory defect in Service Bulletin 23-040, extending the shaft seal warranty to 10 years. However, Honda Corporate Customer Service is refusing responsibility for the downstream consequential destruction caused by their own defective component, citing only general vehicle age and mileage, despite the vehicle having 55,782 miles and sitting well within the 10-year extended warranty window. They have refused to provide an engineering justification or written analysis for this safety-related coverage denial. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)