Nissan Recalls 2024 Frontier Over Ball Joint That May Separate From Lower Link

Back on March 1, a routine part evaluation at the supplier of the front right-side lower link revealed the recall condition. Yorozu Automotive Alabama is the supplier in question, whereas the condition became clear following a failed test result for the link's push-out evaluation.

Three days later, the subsequent investigation determined that an oversized ball joint was used in the suspect lower link. The supplier had used the incorrect die in the production of said link, prompting a thorough review of production records to identify other potentially oversized ball joints. Yorozu determined that 10,036 suspect links had been produced, of which 9,664 were shipped to the Nissan Frontier-making Canton assembly plant in the state of Mississippi.

What about the remaining 372 parts? 248 of them were scrapped by the supplier, while 124 service parts were quarantined. Of the 9,664 affected pickup trucks, 4,056 were held at the production facility in Canton for inspection. Separately, 208 were destined for export and five affected vehicles are trial units within the automaker's control. This, in turn, means that 5,929 vehicles had potentially outflowed to customers.

From April to the month of May, bench testing conducted by Yorozu to simulate the recall condition showed vertical displacement of the ball joint. Even so, the ball joint remained engaged, for the snap ring kept it connected to the lower link. On the other hand, vertical movement over time may result in corrosion of the right-side lower link, leading to ball joint separation.

It goes without saying that a disengaged ball joint affects drivability, thus increasing the risk of a crash. Nissan isn't aware of any such incidents in the US market, which is hardly a surprise because the oldest trucks in the recall population rolled off the assembly line in late January 2024.

545009CD0C is the part number for the 2024 model year Nissan Frontier's front right-hand lower link, which takes an estimated 2.5 hours to replace. That's the estimate for Nissan service technicians, which are to replace suspect links at no charge to the customers. Affected owners will be notified by mail beginning August 15, 2024.

Retailing at $30,510 in base specification, the V6-engined Frontier was the second best-selling midsizer in the first quarter of 2024 due to the Tacoma's generational changeover. The Yokohama-based automaker moved 19,744 units compared to 21,558 for the Toyota Tacoma (versus 53,583 in the first quarter of 2023).

Gifted with 310 ponies, 281 pound-feet ( Nm) of twist, and 6,640 pounds (3,012 kilograms) for maximum towing capacity, Frontier comes in either King Cab or Crew Cab flavors. The most affordable crew-cabbed trim is the S at $31,810, whose 4x4 specification kicks off at $33,710.