Over 95% Of 2024 Nissan Frontiers Recalled Due To An Oversized Ball Joint

A faulty front ball joint has prompted Nissan to recall 2024 Frontier models in the United States, and the company believes approximately 95.7% of Frontiers have the issue.

Nissan says the front right-hand lower link may have been manufactured by a supplier with an oversized ball joint. This means the ball joint press fit on the front right-hand lower link could be below the minimum pushout specification, potentially causing it to separate over time. This can impact the vehicle’s driveability and increase the risk of a crash.

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Nissan notes that if the ball joint does disengage from the lower link, a snap ring will ensure it remains connected to the link. However, the vertical movement of the ball joint could slowly corrode the lower link, causing it to separate.

The faulty front right-hand lower link was manufactured by Yorozu Automotive in Jasper, Alabama. Nissan is recalling 5,929 Frontiers, all built at its Canton plant between January 29, 2024, and March 4, 2024.

The supplier first became aware of a potential problem on March 1, 2024, when the lower link failed a routine part evaluation. Yorozu soon discovered the ball joint used in the faulty part was oversized. It then determined that 10,036 suspect parts were produced on an incorrect stamping die, and these parts were installed on 9,664 assemblies shipped to Nissan’s plant.

Of the vehicles involved in the recall, five were trial units owned by Nissan itself, while a further 208 were destined for export. Nissan is not aware of any accidents or injuries related to the fault, nor has it received any market reports related to it.

U.S. dealerships were alerted to the recall on June 28, 2024, while owners will be notified from August 15. Dealers have been instructed to replace the front right-hand lower link. The repair should take approximately 2.5 hours and will be performed free of charge.