2004 Honda Pilot Suspension Problems

Your 2004 Honda Pilot has developed severe rust damage to the frame and rear-end structure, particularly in Florida's climate. Multiple mechanics have refused to repair it due to safety concerns — the frame is corroded to the point where it's no longer securely attached, and rust damage has made it unsafe to work on. The air conditioning compressor also failed, but shops won't repair it because of the underlying rust and structural damage. Addressing this issue would require significant structural repair or frame replacement, which may involve welding, rust treatment, and professional frame realignment.

Your car's undercarriage and suspension components may experience significant rust within five years of ownership. This rust can weaken structural parts and compromise suspension integrity over time. You should have your suspension inspected regularly and consider rust treatment or replacement of affected components.

Your car's rear sub-frame cross member has severe rust damage and needs to be replaced right away for safety reasons. A mechanic has confirmed this is a structural issue that requires immediate attention. The repair will involve removing and replacing the rusted cross member component.

DRIVERS REAR STRUT METAL FATIGUE FAILURE AT KNUCKLE CAUSED SHOCK ABSORBER TO DROP AND SLICE WHEEL.

2004 HONDA PILOT DRIVER SIDE REAR SUBFRAME CROSSMEMBER RUSTED AND FALLING APART. STARTED TO RUST AROUND 2010 THEN WORST AT 2019. ONLY THE DRIVER SIDE IS RUSTED AND BAD. THE PASSENGER SIDE HAS NO ISSUES.

RINSING WITH WATER OF THE UNDERCARRIAGE AFTER EXPOSURE TO SALTED ROADS AFTER SNOWFALL (ROUTINE PRACTICE) I NOTICED FLAKES OF RUST BENEATH THE REAR OF THE VEHICLE. I CRAWLED UNDER THE VEHICLE TO OBSERVE EXTENSIVE CORROSION OF THE CROSS MEMBER THAT THE REAR SUSPENSION STRUTS ARE ATTACHED TO. THE REAR DRIVER SIDE AREA WHERE THE STRUT IS CONNECTED IS CORRODED TO THE EXTENT WHERE THE MOUNT IS PARTIALLY EATEN AWAY AND A LARGE HOLE HAS FORMED. THE OTHER STRUT MOUNTING AREA IS CHARTING THE SAME COURSE AND IS SUBSTANTIALLY CORRODED. SHOULD A STRUT DISCONNECT FROM THE VEHICLE A LOSS OF CONTROL WOULD OCCUR. THE APPROXIMATE MILEAGE OF THE VEHICLE IS 107000. NO OTHER PARTS OF VEHICLE APPEAR TO BE CORRODED TO A LEVEL APPROACHING THE REAR. I WILL LOOK AT THE FRONT END TO INSPECT MORE CLOSELY FOR CORROSION DAMAGE AND TO TAKE PICTURES. VEHICLE WAS PARKED (STATIONARY) WHEN THE CORROSION WAS OBSERVED.

REAR SUSPENSION CROSS MEMBER SUPPORT RUSTS OUT DUE TO DESIGN. OVER TIME WATER IS THROWN FROM TIRE AND RESTS IN THE SUPPORT NUT AREA. OVER TIME RUST BUILDS UP AND THE SUPPORT BREAKS THROUGH THE REAR CROSS MEMBER. NO WAY FOR THE WATER TO ESCAPE. I AM SUPPLYING ONE PICTURE OF MY CAR SHOWING WHERE RUST HAS STARTED. TWO ADDITIONAL PICTURES ARE FROM THE SHOP FIXING MY CAR FOR ANOTHER ISSUE SHOWING ANOTHER CUSTOMER WITH THE SAME ISSUE, BUT MUCH WORSE. YOU CANNOT BUY THE CROSS MEMBER DUE TO HOW THE CAR IS MADE. SO THE FIX IS TO CUT OUT THE RUST AND WELD IN A NEW SUPPORT. THE CAR SHOP WILL RUST PROOF AND PUT A WATER RESISTANT FOAM OVER THE NEW SUPPORT NUT ENSURING THE RUST WILL NOT RETURN. MY COST OF THIS REPAIR FOR BOTH SIDES IS JUST SHY OF $2000. MY OPINION IS THIS IS A FACTORY DESIGN FLAW THAT SHOULD BE ADDRESSED BY HONDA. NO RECALLS FOR THIS ISSUE EXIST, AND YOU ARE TALKING ABOUT THE BACK END SUPPORT POTENTIALLY COLLAPSING AS YOU ARE DRIVING. THE ISSUE WAS CAUGHT BY THE TRANSMISSION SHOP DOING OTHER WORK ON 12/18/2018. THEY JUST FIXED THE OTHER CUSTOMER'S PILOT (2004) WITH THE SAME ISSUE (PICTURES I ATTACHED) AND HAD THE FORESIGHT TO LOOK AT MY 2004 PILOT. SO FOR SAFETY REASONS I HAVE NO CHOICE BUT TO HAVE THEM APPLY THE SAME FIX.

REAR STRUT MOUNT ON FRAME IS TORN, WHEN DRIVING AND HIT SMALL BUMPS MAKES A CLUNK NOISE.

TL* THE CONTACT OWNS A 2004 HONDA PILOT. WHILE DRIVING AT AN UNKNOWN SPEED, THE CONTACT HEARD AN ABNORMAL POPPING NOISE. UPON INSPECTING UNDERNEATH THE VEHICLE, THE CONTACT NOTICED THAT THE REAR AXLE WAS DETACHED. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE LOCAL DEALER WAS NOT CONTACTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED AND OPENED CASE NUMBER: 08790702. THE MANUFACTURER REFERRED THE CONTACT TO THE LOCAL DEALER. THE FAILURE MILEAGE WAS APPROXIMATELY 300,000.

DRIVING ON OVER RAILROAD TRACKS AND HEARD LOUD CLUNK . CONTROL WAS A MAJOR ISSUE AFTER. WHEN I STOPPED THE VEHICLE TO INSPECT , I SAW THE FOLLOWING. BOTH REAR WHEELS TILTED INWARD AT THE TOP. I INSPECTED UNDERNEATH TO FIND THE REAR SUB-FRAME ANCHORS HAD PULLED THROUGH THE UNI-BODY. CALLED THE MANUFACTURE AND NO ASSISTANCE DUE TO MILEAGE AND AGE AND LIVING IN A SALT BELT STATE. OTHER MANUFACTURERS ARE RECALLING VEHICLES FOR FRAME RUST ISSUES . THIS IS BASICALLY THE FRAME OF THIS VEHICLE.....AND THE OVERALL CONDITION OTHERWISE IS GREAT. THIS SHOULD NOT HAPPEN!

REAR END SUPORTS TOTALLY FELL OUT FROM RUST

WHILE DRIVING OVER A BRIDGE EXPANSION JOINT I HEARD A LOUD BANG, THE ABS AND VTM 4 LIGHTS CAME ON ,AND IT STARTED HAVING A SEVERE VIBRATION . THE REAR UNI BODY FRAME ,FOR THE REAR SUB FRAME, MOUNTING POINTS PULLED OUT OF THE FRAME. THE REARWARD SUB FRAME HAD DROPPED DOWN ABOUT 6 - 8 INCHES. THE INSIDE OF THE FRAME HAS RUSTED AWAY, ON THE INSIDE.

TL* THE CONTACT OWNS A 2004 HONDA PILOT. WHILE THE VEHICLE WAS STATIONARY, THE REAR SUSPENSION BECAME SEVERELY RUSTED AND CORRODED. AN INDEPENDENT MECHANIC WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER AND DEALER WERE NOT CONTACTED. THE FAILURE MILEAGE WAS APPROXIMATELY 101,000.

REAR MOUNTING POINTS FOR REAR SUSPENSION SUBFRAME RUSTED OUT, ALLOWING THE SUBFRAME TO BECOME DETACHED AT TWO OF FOUR MOUNTING POINTS. SUBFRAME ROTATED DOWN UNTIL STOPPED BY EXHAUST SYSTEM, DETACHING WIRING FOR ANTI LOCK BRAKING SYSTEM. FAILURE OCCURRED WHILE DRIVING ON SECONDARY ROAD AT 40-50 MPH.

I HAD A VERY SERIOUS MECHANICAL FAILURE AFTER HITTING A BUMP ON A DIRT ROAD ONLY GOING 25 MPH. ALL 4 OF THE REAR AXLE MOUNTS FAILED CAUSING THE REAR OF THE VEHICLE TO DROP AND THE TIRES TO SPREAD. THIS COULD HAVE BEEN VERY DANGEROUS IF I WAS GOING FASTER OR HIT THE BUMP ON THE HIGHWAY. WE HAD BEEN NOTICING A CLUNKING SOUND COMING FROM THE REAR OF THE VEHICLE BUT COULDN'T FIGURE OUT WHAT IT WAS. SO, PERHAPS ONE OR TWO FOR THE MOUNTS HAD ALL READY FAILED BEFORE THIS FINAL FAILURE. WE BOUGHT THIS VEHICLE NEW IN 2004 AND IT HAS NEVER BEEN IN ANY ACCIDENT NOR DRIVEN OFF ROAD. IT IS A MICHIGAN CAR SO IT HAS BEEN EXPOSED TO ROAD SALT PERHAPS CONTRIBUTING TO THE RUSTING OF THE MOUNTS. BUT, UNDER NO CIRCUMSTANCE SHOULD THIS OCCUR. AFTER DOING AN INTERNET SEARCH I WAS ONLY ABLE TO FIND TWO OTHER INSTANCES OF THIS HAPPENING. AS THESE VEHICLES GET OLDER MORE MAY HAPPEN IF IT IS A DESIGN FLAW.

ACCIDENT ON THE FREEWAY THE CAR SPED OUT OF CONTROL HIT THE CENTER DIVIDER. FRONT AND SIDE AIR BAGS WENT OFF! THE STEERING WHEEL AIRBAGS SCARRED THE INSIDE OD MY WRIST.

TL* THE CONTACT OWNS A 2004 HONDA PILOT. THE CONTACT STATED THAT WHILE DRIVING 20 TO 40 MPH THE FRONT OF THE VEHICLE SHUDDERS VIOLENTLY. THE VEHICLE WAS TAKEN TO THE DEALER MULTIPLE TIMES BUT THEY WERE NOT ABLE TO DIAGNOSE THE PROBLEM. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS NO LONGER UNDER WARRANTY AND ADVISED THE CONTACT TO TAKE THE VEHICLE BACK TO THE DEALER. THE FAILURE MILEAGE WAS 125,000.

STARTED AT APPROX. 70,000 MILES. CAR SHUTTERS/VIBRATES (AS THOUGH GOING OVER A SOFT RUMBLE STRIP) WHEN GOING APPROX. 45 MPH. STOPS ONCE I LET OFF GAS OR ACCELERATE. INITIALLY HAPPENED ONLY ONCE IN A WHILE. NOW IT HAPPENS CONSISTENTLY. *KB

INFORMED BY THE DEALER THAT THE MOTOR MOUNTS ON MY 2004 PILOT WERE CRACKED AND THAT I WOULD START TO NOTICE THIS IN VIBRATION OF THE VEHICLE. DEALER TOLD ME THAT THIS WAS SOMETHING SEEN QUITE OFTEN IN THE PILOT AND ODYSSEY. 2004 PILOT WITH 91K MILES. *TR

BROKEN FRONT ENGINE MOUNT DETECTED ON MY 2004 HONDA PILOT WITH 45000 MILES. NOTICED A VIBRATION WHEN STARTING OUT FROM A COMPLETE STOP. FIRST NOTICED PROBLEM ABOUT A YEAR AGO BUT DEALER SAID THEY COULD NOT DUPLICATE PROBLEM. HAD VEHICLE SERVICED RECENTLY AND WAS INFORMED OF PROBLEM. HAVE SINCE LEARNED THAT MANY OTHER OWNERS HAVE HAD SIMILAR PROBLEMS WITH THEIR PILOTS. ALSO HAD FRONT LOWER CONTROL ARM BUSHINGS REPLACED AT 40000 AT DEALERS ADVICE. VEHICLE IS USED STRICTLY ON PAVED ROADS AND THOUGHT IT WAS ODD THAT THEY WOULD GO OUT SO EARLY. *TR

IN APPROXIMATELY EARLY 2006, I NOTICED THE FRONT WHEELS WOULD SHIMMY WHEN I APPLIED THE BRAKES AT HIGHER SPEEDS. TYPICALLY IT WOULD OCCUR AS I WAS DRIVING DOWN STEEPER GRADES IN THE MOUNTAINS. I BROUGHT THIS TO THE ATTENTION OF THE HONDA DEALER IN APRIL 2006 WHEN THE VEHICLE HAD 35,418 MILES. THE HONDA DEALER DISMISSED IT AND SAID IT WAS PROBABLY DUE TO THE FRONT WHEEL STILL WANTING TO PROVIDE POWER WHILE THE BRAKES WERE APPLIED. CONSEQUENTLY, THE BRAKE SYSTEM CHECKED OUT FINE DURING THEIR INSPECTION. UNFORTUNATELY, THE PROBLEM STILL PERSISTS AND IS GETTING WORSE. I'VE ALSO NOW NOTICED THE PROBLEM WHEN I DRIVE ON FLATTER SURFACES AS WELL. THE PROBLEM IS MOST NOTICEABLE WHEN STOPPING AT SPEEDS OVER 50 MPH AND IS EVEN MORE PRONOUNCED WHEN DRIVING DOWN HILLS. MY CONCERN AT THIS POINT IS THAT THE VEHICLE WILL BECOME UNSTABLE BECAUSE OF THE EXCESSIVE SHIMMY THAT OCCURS IN THE FRONT WHEELS WHILE BRAKING AT HIGHER SPEEDS OR ON AN INCLINE. *TR

MY 2004 HONDA PILOT HAS A CONTINUOUS VIBRATING PROBLEM AT 75 MPH. SEVERAL SOLUTIONS HAVE BEEN ATTEMPTED, BUT NOTHING FIXES THIS PROBLEM. *NM

THIS VEHICLE FROM ORIGINAL PURCHASE HAS HAD A WHEEL VIBRATION THAT SEEMS TO BE INCORRECTABLE BY DEALER. I BELIEVE IT IS A DEFECT FROM THE MANUFACTURE HONDA. THE VEHICLE HAS ALSO NEEDED BRAKE ROTORS RESURFACED AT LESS THAN 20,000 MILES AND IS CURRENTLY WAITING FOR PARTS TO HAVE TWO TIE RODS REPLACED.

WHEN EVER I HIT THE BRAKES ON MY 2004 HONDA PILOT EXL THERE IS A THUMPPING NOISE. I HAVE COMPLAINED TO THE DEALER ABOUT IT AND HE SAYS THAT IS NORMAL. I HAVE RESEARCHED ON THE WEB AND THERE ARE SEVERRAL PEOPLE COMPLAINING ABOUT THE SAME PROBLEM.*AK

AT SPEEDS EXCEEDING 70 MPH THERE IS A VIBRATION WHICH CAN BE FELT THROUGH THE STEERING WHEEL, GAS PEDAL, AND AT TIMES THE FLOOR OF THE WHOLE VEHICLE. THIS USUALLY OCCURS AT 73-74MPH. AFTER REPEATED SERVICES AND BALANCING OF TIRES THE DEALERSHIP TOOK THE TIRES TO PERFORM A ROAD FORCE TEST. THIS RULED OUT THE TIRES CAUSING THE PROBLEM. AFTER THE 4TH ATTEMPT TO CORRECT THE VIBRATION A HONDA CASE MANAGER SAID THAT IT COULD BE A "CHARACTERISTIC OF THE VEHICLE". THIS WAS NOT MENTIONED BY THE SALES PERSON AT THE TIME OF PURCHASE AND I BELIEVE IT IS A DEFECT IN THE SUSPENSION OR DRIVETRAIN. I FOUND MANY OTHERS HAVE HAD THIS COMPLAINT. SEE WWW.HONDA-PILOT.ORG UNDER FORUMS THEN SUSTAINED VIBRATIONS AT SPEEDS OVER 70MPH. THE SERVICE PERSON SAID THIS WAS NOT A SAFETY ISSUE BUT I WOULD DISAGREE. *AK