Reference:

Date:

NTB11-066g

December 20, 2013

VOLUNTARY SERVICE CAMPAIGN
1996-2004 PATHFINDER IN NON SALT STATES
FRONT STRUT HOUSING CORROSION
The PARTS INFORMATION section has been amended. Additional chemicals are to be ordered
through the Nissan Maintenance Advantage program. No other changes were made to
this bulletin. Please discard all previous versions of this bulletin.

CAMPAIGN ID #:
R1108
11V-244
NHTSA #:
APPLIED VEHICLES: 1996 – 2004 Pathfinder (R50)
Check Service COMM to confirm campaign eligibility.
INTRODUCTION
Nissan is conducting a voluntary service campaign on certain model year 1996 - 2004
Pathfinder vehicles that are currently registered in Salt States to inspect for corrosion, and
if necessary repair the front strut housing panels. The Salt States are listed below. For
vehicles currently registered in these States, please refer to NTB11-064.
Non-Salt States (This bulletin applies.)
Salt States (Refer to NTB11-064.)
Maine, New Hampshire, Vermont, Massachusetts, Rhode Island, Connecticut, New
York, New Jersey, Pennsylvania, Delaware, Maryland, West Virginia, Ohio, Indiana,
Michigan, Illinois, Wisconsin, Minnesota, Iowa, and Missouri and the District of
Columbia.
In addition to the recall campaign, in the interest of customer satisfaction, owners of similar
vehicles that are not subject to the recall because they were originally sold in and are
registered in States where corrosion is unlikely to occur will receive a courtesy notification
and will be offered an opportunity to have their vehicles inspected at no charge. If
necessary, the vehicles will also be remedied free of charge.
IDENTIFICATION NUMBER
Nissan has assigned identification number R1108 to this campaign. This number must
appear on all communications and documentation of any nature dealing with this campaign.
DEALER RESPONSIBILITY
Dealers are to repair vehicles falling within range of this campaign that enter the service
department. This includes vehicles purchased from private parties, vehicles presented by
transient (tourists) owners, and vehicles in a dealer’s inventory.

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TABLE OF CONTENTS
REPAIR OVERVIEW ………………………………………………………………..……...

Page
3

SERVICE PROCEDURE …………………………………………………………………... 4
Inspect for Corrosion in the Driver Side AND Passenger Side Front Wheel House
Areas

4

Determine if Vehicle is Repairable ……………………………………………………..

6

Repair Chart (to determine repair level on each side)

11

Level 1 Repair (driver side and passenger side)

11

Level 2 Repair (driver side AND passenger side)……………………………...
Strut Removal ………..…………………………………………………………………
Repair Bracket Installation …………………………………………………………….
Patching Perforated Areas …………………………………………………………….

11
14
17
33

STEERING SHAFT REPLACEMENT …………………………………………………….

43

EXAMPLE PHOTOS (perforation and scab corrosion)………………………………….

47

REQUIRED SPECIAL TOOLS …………………………………………………………….

49

PARTS INFORMATION ……………………………………………………………………. 50
CLAIMS INFORMATION …………………………………………………………………...

51

OWNER LETTER …………………………………………………………………………… 55
NON REPAIRABLE REPORT .…………………………………………………………….

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56

REPAIR OVERVIEW
Use Service Comm (campaign ID # R1108) to confirm
the vehicle you’re working on is affected by this campaign
Inspect for Corrosion in the Driver Side AND Passenger Side
Front Wheel House Areas (page 4)
Significant rust
is found in ONE OR BOTH wheel house areas

No significant rust
in BOTH wheel
house areas

Determine if Vehicle is Repairable (page 6)
(Inspect for perforation Area 1 and scab corrosion Area 2)
ON BOTH SIDES:

ON EITHER SIDE:

NO perforation in Area 1
AND
NO scab corrosion in
Area 2
Vehicle is repairable

Perforation in Area 1
OR
Scab corrosion in
Area 2

END

Vehicle is not repairable

(Perform repairs for the
driver side first.)
1. Retain the
vehicle at the
dealer
2. Supply the
customer with a
rental car
3. Fax a completed
Non-Repairable
Report to Morley
(see page 56)

Scenario

A

B

C

Vehicle side

Significant
rust

Driver Side

X

No more
than
surface
rust
--

Passenger Side

--

X

Driver Side

--

X

Passenger Side

X

--

Driver Side

X

--

Passenger Side

X

--

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Repairs to be performed:
Repair Level 2 on Driver Side
AND
Repair Level 1 on Passenger Side
Repair Level 1 on Driver Side
AND
Repair Level 2 on Passenger Side
Repair Level 2 on BOTH sides

NTB11-066g

NOTE:
•

Inspect both sides to determine if the vehicle is repairable.

•

If the vehicle is repairable, perform repairs for the driver side first.

SERVICE PROCEDURE
NOTE: This campaign does not cover any repairs beyond those specifically mentioned
in this Service Procedure.

Inspect for Corrosion in the Driver Side AND Passenger Side Front Wheel House
Areas

1. Turn the ignition OFF.

2. Set the parking brake.

3. Look behind both front tires (see Figure A).
NOTE: Turning the tires left and then right will allow a better view.

Look in
here

Look in
here

Figure A

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4. Visually inspect for corrosion and rust on the wheel housing panels and the strut
housing panels.
•

Inspect for corrosion and rust on the panels only.
NOTE: Corrosion or Rust on the struts or other suspension components is not
covered by this campaign.

Figure B

No significant rust found on the panels ON BOTH SIDES.
• Inspection end.
• Return the vehicle to the customer.

Significant rust is found on the panels ON ONE OR BOTH SIDES:
•

Go to Determine if Vehicle is Repairable on the next page.

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Determine if Vehicle is Repairable (driver side AND passenger side inspection)
NOTE: The following pictures in this section are of the driver side. The passenger side
is the same regarding inspection and location of rust.
1. Lift the vehicle on a hoist.

2. Remove both front wheels.

3. Inspect for corrosion ON BOTH SIDES in the strut housing Area 1 and wheel house
Area 2 (see Figures 1 through 6).

Area 2
Area 2 is behind the strut
spring. It is visible with
the strut in place but
difficult to show in a
photo. See Figure 2 on
the next page for a photo
with the strut removed.

Area 1
On panel
behind strut

Figure 1

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Strut has been
removed to show the
areas of inspection.
NOTE: Strut does not
need to be removed to
perform inspection.
Area 2

Area 1
Figure 2
This example photo shows the inspection areas in relation to the repair bracket installation.

Area 2

Area 1
Figure 3
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Area 1

Example of no perforation (no
holes) within the outlined area

Area 1

Figure 4
Area 1: Look for perforation (holes) in the metal only in the area outlined above.
NOTE: If needed, refer to examples (additional photos) of Area 1 perforation inspection
on pages 47 and 48.

If there is perforation (holes) in the metal in Area 1 on the driver side OR passenger side:
a. Retain the vehicle at the dealer. (The vehicle is not repairable.)
b. Supply the customer with a rental car.
c. Fax a completed Non-Repairable Report to Morley (see page 56).

If there is no perforation (no holes) in the metal in Area 1 on the driver side AND
passenger side:
•

Go to Area 2 on the next page.

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Area 2
Example of no “scab corrosion” (no flaking
rust or raised rust) within the outlined area

Area 2

Figure 5
Area 2: Look for “scab corrosion” (flaking rust or raised rust) only in the area outlined
above.
NOTE: If needed, refer to example (additional photo) of Area 2 scab corrosion
inspection on page 48.

Figure 5 is an example of “scab corrosion” (flaking and
raised rust).

Figure 6

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If there is scab corrosion (flaking or raised rust) in Area 2 on the driver side OR passenger
side:
a. Retain the vehicle at the dealer. (The vehicle is not repairable.)
b. Supply the customer with a rental car.
c. Fax a completed Non-Repairable Report to Morley (see page 56).

If there is no scab corrosion (no flaking or raised rust) in Area 2 on the driver side AND
passenger side:
•

If there is no perforation in Area 1 and no scab corrosion in Area 2, the vehicle is
“repairable”.

•

To determine the repair level on each side, go to the Repair Chart on the next page.
NOTE: Corrosion or rust on the strut or other suspension components is not covered
by this campaign.

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Repair Chart (determine repair level on each side)

Scenario

Vehicle side

Significant
rust

--

Driver Side
Passenger Side

---

No more
than
surface
rust
---

Driver Side

X

--

Passenger Side

--

X

Driver Side

--

X

Passenger Side

X

--

Driver Side

X

--

Passenger Side

X

--

A

B

Repairs to be performed:

No repairs to be performed
Repair Level 2 on Driver Side
AND
Repair Level 1 on Passenger Side
Repair Level 1 on Driver Side
AND
Repair Level 2 on Passenger Side
Repair Level 2 on BOTH sides

C

Summary of Repair Levels

Driver Side AND Passenger Side
Level 1 – No visible rust or only surface rust
• Use an abrasive tool to remove surface rust
• Clean wheel housing and strut housing area
• Apply self etching primer

Page 12

• Apply rubberized undercoating
Level 2 – Any scab corrosion or perforation
• Remove the strut
• Use an abrasive tool to remove loose
corrosion and rust
• Apply self etching primer

Page 14

• Install the repair bracket
• Patch perforated areas – if needed
• Apply rubberized undercoating

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LEVEL 1 REPAIR (driver side AND passenger side)
For driver side AND passenger side - no visible rust or only surface rust

WARNING: Perform repairs in a well ventilated area.
NOTE:
• Plastic covers (fender protectors) in the wheel house area do not need to be
removed.
• Photos in this section are of the passenger side, driver side is similar.
• For 4WD vehicles: If the drive shaft boot is ripped, it should be covered to
prevent debris from entering the drive shaft joint.

1. Use a wire brush to remove loose rust in
the area shown with dashed line.

2. Clean dust, dirt, or other debris from the
wheel housing and strut housing area.
Figure 7
3. Cover the strut so it is protected from
overspray.
4. Completely and liberally coat the strut
housing and wheel house area with self
etching primer.
• Use DuPont Etch Primer
(P/N A-4119S™) or equivalent.
• Follow all product instructions.
• Coat all of the exposed metal areas
on the strut housing and wheel house
panels.

Figure 8

• A second coat may be needed for heavy rust spots.
• Let each coat dry for 5 minutes.
NOTE: Refer to the Parts Information for additional product details.

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5. Completely and liberally coat the wheel
house and strut housing area with
rubberized undercoat.
• Use 3M™ Rubberized Undercoating
(P/N 051135 – 08883) or equivalent.
• Follow all product instructions.
• Coat all of the exposed metal areas
on the strut housing and wheel house
panels.
• Use a spray nozzle to spray the
areas behind the strut and other hard
to reach areas.

Figure 9

NOTE: Refer to the Parts Information
for additional product details.

6. Let the undercoat dry for about 1 hour before removing the strut cover.