IllustrationEXCESSIVE RUST ON THE FRAME AT KEY POINTS, SUCH AS FRONT SUSPENSION, ENGINE BLOCK. TOLD BY THE DEALER THE BODY HAS TO COME OFF TO FIX RUST PROBLEM. THE WERE OTHER CARS IN THE SHOP SAME YEAR, SAME MODEL. WAS TOLD IF I HIT A HARD BUMP OR WHOLE IN ROAD, THE FRONT END COULD COLLAPSE. LAND ROVER IS BEING NON RESPONSIVE. *JS
2004 Land Rover Discovery
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all Discovery years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
30–25K
525–50K
450–75K
675–100K
5100–150K
2150K+
25 reports with mileage · 4 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Engine. Review the 5 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes, Hydraulic. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Structure. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
4 crash reports2 fire reports1 injury reports
What owners actually said
29 reportsTL* THE CONTACT OWNS A 2004 LAND ROVER DISCOVERY. THE CONTACT STATED THAT THE VEHICLE WOULD NOT UNLOCK MANUALLY OR WHEN USING THE KEY FOB. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 82,000. *TR
DURING ROUTINE MAINTENANCE, THE MECHANIC NOTICED THAT THERE WAS A SIGNIFICANT AMOUNT OF RUST ON THE FRAME OF THE VEHICLE. THERE WERE SEVERAL PLACES WHERE THE RUST HAD LEFT HOLES IN THE METAL 6 INCHES IN LENGTH. THE MECHANIC INDICATED THAT THE VEHICLE WOULD LIKELY NOT PASS A VEHICLE SAFETY INSPECTION. THE MECHANIC STATED THAT …
Read full complaint
DURING ROUTINE MAINTENANCE, THE MECHANIC NOTICED THAT THERE WAS A SIGNIFICANT AMOUNT OF RUST ON THE FRAME OF THE VEHICLE. THERE WERE SEVERAL PLACES WHERE THE RUST HAD LEFT HOLES IN THE METAL 6 INCHES IN LENGTH. THE MECHANIC INDICATED THAT THE VEHICLE WOULD LIKELY NOT PASS A VEHICLE SAFETY INSPECTION. THE MECHANIC STATED THAT HE HAD NOT SEEN A FRAME RUSTED THIS BADLY ON A VEHICLE THAT WAS ONLY 7 YEARS OLD. *TR
AT 45 MPH HAD TO APPLY HARD BRAKING , THE TRUCK'S BRAKING SYSTEM RESPONDED POORLY CAUSING EXTRA LONG BRAKING DISTANCE. THE ABS , HILL DESCEND & TRACTION CONTROL WARNING LIGHTS CAME ON JUST BEFORE THE INCIDENT.
2004 LAND ROVER DISCOVERY HSE. CONSUMER EXPRESSES DISCONTENT REGARDING WARRANTY AND NEEDED REPAIRS *TGW THE CONSUMER STATED HE PURCHASED AN EXTENDED WARRANTY PLAN. THE WARRANTY COMPANY REFUSED TO AUTHORIZED THE REPLACEMENT OF A DEFECTIVE PUMP WITH NEW LAND ROVER REPLACEMENT PARTS. INSTEAD, THEY AUTHORIZED THE REPAIR FOR USED P…
Read full complaint
2004 LAND ROVER DISCOVERY HSE. CONSUMER EXPRESSES DISCONTENT REGARDING WARRANTY AND NEEDED REPAIRS *TGW THE CONSUMER STATED HE PURCHASED AN EXTENDED WARRANTY PLAN. THE WARRANTY COMPANY REFUSED TO AUTHORIZED THE REPLACEMENT OF A DEFECTIVE PUMP WITH NEW LAND ROVER REPLACEMENT PARTS. INSTEAD, THEY AUTHORIZED THE REPAIR FOR USED PARTS. AS A RESULT, THE SHOP WAITED WEEKS UNTIL THE PARTS WERE LOCATED. THE FIRST USED STEERING PUMP THAT WAS INSTALLED MALFUNCTIONED AND THE VEHICLE COULD NOT BE STEERED. A SECOND USED PUMP HAD TO BE LOCATED AND INSTALLED. THE CONSUMER STATED HE WAS WITHOUT HIS VEHICLE FOR TWO MONTHS. SHORTLY AFTER PICKING UP THE VEHICLE, IT BECAME APPARENT THAT THE SECOND USED REPLACEMENT WAS ALSO DEFECTIVE. *JB
TL*THE CONTACT OWNS A 2004 LAND ROVER DISCOVERY. THE REAR PASSENGER MIDDLE SEAT BACK REST HOOK FAILED. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING AND STATED THAT THE HOOK ASSEMBLY COULD NOT BE REPAIRED; THEREFORE, THE ENTIRE SEAT NEEDED TO BE REPLACED. THE MANUFACTURER FILED REPORT 7451000 AND STATED THAT THEY AD…
Read full complaint
TL*THE CONTACT OWNS A 2004 LAND ROVER DISCOVERY. THE REAR PASSENGER MIDDLE SEAT BACK REST HOOK FAILED. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING AND STATED THAT THE HOOK ASSEMBLY COULD NOT BE REPAIRED; THEREFORE, THE ENTIRE SEAT NEEDED TO BE REPLACED. THE MANUFACTURER FILED REPORT 7451000 AND STATED THAT THEY ADVISED THE VEHICLE WAS OUT OF WARRANTY; THEREFORE, THEY WOULD NOT ASSIST WITH THE REPAIRS. THE FAILURE AND THE CURRENT MILEAGES WERE 81,700.
TL* THE CONTACT OWNS A 2004 LAND ROVER DISCOVERY. WHILE DRIVING AT APPROXIMATELY 2 MPH, THE VEHICLE SURGED FORWARD BEFORE INDEPENDENTLY STOPPING. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER TO BE EXAMINED FOR THE CAUSE OF FAILURE. THE VEHICLE WAS NOT SERVICED. THE FAILURE AND CURRENT MILEAGES WERE 105,000.
TL*THE CONTACT OWNS A 2004 LAND ROVER DISCOVERY. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 2 MPH, THE VEHICLE SUDDENLY ACCELERATED. THE CONTACT APPLIED THE BRAKES BUT THE VEHICLE CONTINUED ACCELERATING OVER A CURB AND THEN FLIPPED OVER. THE CONTACT DID NOT REPORT ANY INJURIES. THE VEHICLE WAS TOWED TO A REPAIR SHOP.…
Read full complaint
TL*THE CONTACT OWNS A 2004 LAND ROVER DISCOVERY. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 2 MPH, THE VEHICLE SUDDENLY ACCELERATED. THE CONTACT APPLIED THE BRAKES BUT THE VEHICLE CONTINUED ACCELERATING OVER A CURB AND THEN FLIPPED OVER. THE CONTACT DID NOT REPORT ANY INJURIES. THE VEHICLE WAS TOWED TO A REPAIR SHOP. THE VIN WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 37,000.
TL*THE CONTACT OWNS A 2004 LAND ROVER DISCOVERY. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 35 MPH ON NORMAL ROAD CONDITIONS. THERE WAS A LOUD KNOCKING NOISE COMING FROM THE ENGINE. THE OIL PRESSURE WARNING LIGHT INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE WARNING INDICATOR REMAINED ILLUMINATED UNTIL THE ENGINE W…
Read full complaint
TL*THE CONTACT OWNS A 2004 LAND ROVER DISCOVERY. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 35 MPH ON NORMAL ROAD CONDITIONS. THERE WAS A LOUD KNOCKING NOISE COMING FROM THE ENGINE. THE OIL PRESSURE WARNING LIGHT INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE WARNING INDICATOR REMAINED ILLUMINATED UNTIL THE ENGINE WAS TURNED OFF. THE VEHICLE STALLED WHILE ATTEMPTING TO PULL OVER TO THE SIDE OF THE ROAD. ROADSIDE ASSISTANCE WAS CALLED TO THE SCENE. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER FOR INSPECTION. THE TECHNICIAN STATED THE ENGINE REQUIRED REPLACEMENT. THE VEHICLE HAS NOT BEEN REPAIRED FOR THE FAILURE. THE FAILURE AND CURRENT MILEAGES WERE 46,842.
TL*THE CONTACT OWNS A 2004 LAND ROVER DISCOVERY. IN HEAVY RAIN CONDITIONS, WATER BEGAN LEAKING ONTO THE DASHBOARD, STEERING WHEEL, MIDDLE CONSOLE, AND THE GEAR SHIFT. IF THE VEHICLE IS NOT BEING DRIVEN AT THE TIME OF THE WET CONDITIONS, MOLD BEGINS TO BUILD UP INSIDE THE VEHICLE. THE VEHICLE HAS BEEN IN AND OUT OF THE DEALER …
Read full complaint
TL*THE CONTACT OWNS A 2004 LAND ROVER DISCOVERY. IN HEAVY RAIN CONDITIONS, WATER BEGAN LEAKING ONTO THE DASHBOARD, STEERING WHEEL, MIDDLE CONSOLE, AND THE GEAR SHIFT. IF THE VEHICLE IS NOT BEING DRIVEN AT THE TIME OF THE WET CONDITIONS, MOLD BEGINS TO BUILD UP INSIDE THE VEHICLE. THE VEHICLE HAS BEEN IN AND OUT OF THE DEALER NUMEROUS TIMES. THE FIRST TIME THE FAILURE OCCURRED, THE MECHANIC STATED THAT IT WAS DUE TO A CLOGGED DRAIN. THE MECHANIC BLEW OUT THE DRAIN, BUT IT DID NOT CORRECT THE ISSUE. DURING THE SECOND FAILURE, THE MECHANIC COULD NOT DETERMINE HOW THE WATER WAS ENTERING THE VEHICLE. DURING THE THIRD VISIT, THE MECHANIC STATED THAT THE FAILURE WAS DUE TO WEAR AND TEAR. THE FURTHER STATED THAT THERE WAS AN AREA ON THE DRIVER'S SIDE THAT MAY HAVE BEEN THE POINT OF ENTRY FOR THE WATER. DURING THE FOURTH AND FIFTH VISITS, THE MECHANIC UNCLOGGED THE DRAIN AND STATED THAT IT WAS DUE TO THE LEAVES FROM THE TREES. THE FAILURE STILL PERSISTS AND THE CONTACT BELIEVES THAT THE MANUFACTURER SHOULD BE RESPONSIBLE. SHE STATED THAT THERE WAS A TSB FOR THE DEFECT AND WAS CONCERNED THAT THE VEHICLE WOULD BEGIN TO RUST. THE FAILURE MILEAGE WAS 34,436 AND CURRENT MILEAGE WAS 38,000.
Official recalls
0No recalls in this snapshot.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1EA05016 · Brake Light Switch Failure
Opened Oct 14, 2005 · Closed Feb 22, 2007
Status: closed (inferred from source dates) · Exterior Lighting:brake Lights; Exterior Lighting:brake Lights:switch
ON JUNE 16, 2005, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE05-034) TO INVESTIGATE ALLEGED STOP LAMP (BRAKE) SWITCH FAILURES IN CERTAIN MODEL YEAR (MY) 2004 LAND ROVER DISCOVERY SERIES II VEHICLES.ON OCTOBER 14, 2005, THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS AND THE SCOPE EXPANDED TO INCLUDE CERTAIN MY 2002 THROUGH 2005 FREELANDER VEHICLES THAT USE A SUBSTANTIALLY SIMILAR SELF-ADJUSTING STOP LAMP SWITCH FURNISHED BY THE SAME SUPPLIER, METHODE ELECTRONICS MALTA, LTD. (METHODE).IN SEPTEMBER 2003, METHODE MOVED THE PRODUCTION OF AN INTERNAL SWITCH COMPONENT, KNOWN AS THE SLIDER MECHANISM, FROM A VALIDATED PLASTIC INJECTION-MOLDING TOOL (?CAVITY 1?) TO ANOTHER TOOL (?CAVITY 2?) THAT HAD NOT BEEN USED BEFORE TO PRODUCE PARTS FOR LAND ROVER.SLIDERS FROM CAVITY 2 MAY BE CHARACTERIZED BY POOR FILL, LACK OF DEFINITION IN THE SLIDER TEETH AND DIMENSIONAL INSTABILITY.CONSEQUENTLY, THE SLIDER MAY BE UNABLE TO RESTRAIN IMPROPER MOVEMENT OF THE PLUNGER DURING NORMAL BRAKE PEDAL OPERATION.THIS MAY CAUSE THE SWITCH TO FALL OUT OF ADJUSTMENT, THUS SIGNIFICANTLY REDUCING THE EFFORT REQUIRED TO ENERGIZE THE SWITCH AND ILLUMINATE THE STOP LAMPS.?CAVITY 2? SWITCHES WERE INSTALLED IN APPROXIMATELY 8,763 DISCOVERY SUBJECT VEHICLES BUILT FROM DECEMBER 2003 THROUGH MAY 2004 AND APPROXIMATELY 3,915 FREELANDER SUBJECT VEHICLES BUILT FROM OCTOBER 2003 THROUGH MAY 2004.ADDITIONALLY, STOP LAMP SWITCHES IN CERTAIN MY 2002 THROUGH 2005 FREELANDER SUBJECT VEHICLES MAY SLIP OUT OF ADJUSTMENT AS A RESULT OF SWITCH DAMAGE DUE TO AN INCORRECT SETTING PROCEDURE DURING VEHICLE MANUFACTURE OR AS A RESULT OF SWITCH MOUNTING BRACKET FLEX.ANALYSIS OF ALL AVAILABLE DATA INDICATES THE PREDOMINANT FAILURE MODE IS CONSTANT STOP LAMP ILLUMINATION.OTHER REPORTED CONSEQUENCES OF STOP LAMP SWITCH MALADJUSTMENT INCLUDE INOPERATIVE AUTOMATIC TRANSMISSION GEAR SELECTOR/BRAKE PEDAL SHIFT INTERLOCK, INOPERATIVE SPEED (CRUISE) CONTROL, AND TELLTALE ILLUMINATION AS DESCRIBED IN TECHNICAL SERVICE BULLETIN (TSB) NO. LT206-001 DATED OCTOBER 28, 2004 ISSUED BY THE MANUFACTURER TO LAND ROVER DEALERS IN THE UNITED KINGDOM (UK).TO DATE, ODI IS AWARE OF 77 NON-DUPLICATIVE COMPLAINTS THAT ALLEGE STOP LAMP SWITCH FAILURE ON THE SUBJECT VEHICLES (10 COMPLAINTS ON MY 2004 DISCOVERY, 45 ON MY 2002 FREELANDER, 19 ON MY 2003 FREELANDER, AND 3 ON MY 2004 FREELANDER VEHICLES).ADDITIONALLY, 4,595 DISCOVERY AND 13,370 FREELANDER SUBJECT VEHICLES HAVE EXPERIENCED ONE OR MORE WARRANTY CLAIMS TO REPLACE THE STOP LAMP SWITCH.OF THE 5,170 WARRANTY CLAIMS PAID TO REPLACE STOP LAMP SWITCHES ON DISCOVERY SUBJECT VEHICLES, APPROXIMATELY 31% OCCURRED BEFORE THE VEHICLE WAS SOLD NEW AND APPROXIMATELY 88% OCCURRED WITHIN THE FIRST 12 MONTHS OF VEHICLE SERVICE.THE WARRANTY TREND ON DISCOVERY SUBJECT VEHICLES IS IN DECLINE WITH 3,545 CLAIMS PAID IN CALENDAR YEAR (CY) 2004, 1,303 CLAIMS PAID IN CY 2005, AND 322 CLAIMS PAID IN CY 2006 THROUGH SEPTEMBER 28, 2006 (WHICH IS WHEN ODI LAST RECEIVED UPDATED WARRANTY CLAIMS DATA FROM LAND ROVER), AND IT APPEARS THAT THE ALLEGED DEFECT ON DISCOVER SUBJECT VEHICLES HAS BEEN REMEDIED THROUGH WARRANTY REPAIRS.HOWEVER, ODI ANALYSIS OF THE MANUFACTURER?S WARRANTY AND COMPLAINT RECORDS INDICATES THE FAILURE TREND ON CERTAIN FREELANDER SUBJECT VEHICLES IS ONGOING.BY LETTER DATED FEBRUARY 2, 2007, LAND ROVER HAS NOTIFIED ODI THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA RECALL NO. 07V-041) TO REPLACE DEFECTIVE STOP LAMP SWITCHES IN APPROXIMATELY 33,247 MY 2002 THROUGH 2005 FREELANDER VEHICLES BUILT AT THE SOLIHULL, UK ASSEMBLY PLANT FROM SEPTEMBER 5, 2001 THROUGH MAY 19, 2005. ALTHOUGH ODI HAS CONCERN
Additional source detail variants (2)
Exterior Lighting:brake Lights
ON JUNE 16, 2005, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE05-034) TO INVESTIGATE ALLEGED STOP LAMP (BRAKE) SWITCH FAILURES IN CERTAIN MODEL YEAR (MY) 2004 LAND ROVER DISCOVERY SERIES II VEHICLES.ON OCTOBER 14, 2005, THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS AND THE SCOPE EXPANDED TO INCLUDE CERTAIN MY 2002 THROUGH 2005 FREELANDER VEHICLES THAT USE A SUBSTANTIALLY SIMILAR SELF-ADJUSTING STOP LAMP SWITCH FURNISHED BY THE SAME SUPPLIER, METHODE ELECTRONICS MALTA, LTD. (METHODE).IN SEPTEMBER 2003, METHODE MOVED THE PRODUCTION OF AN INTERNAL SWITCH COMPONENT, KNOWN AS THE SLIDER MECHANISM, FROM A VALIDATED PLASTIC INJECTION-MOLDING TOOL (?CAVITY 1?) TO ANOTHER TOOL (?CAVITY 2?) THAT HAD NOT BEEN USED BEFORE TO PRODUCE PARTS FOR LAND ROVER.SLIDERS FROM CAVITY 2 MAY BE CHARACTERIZED BY POOR FILL, LACK OF DEFINITION IN THE SLIDER TEETH AND DIMENSIONAL INSTABILITY.CONSEQUENTLY, THE SLIDER MAY BE UNABLE TO RESTRAIN IMPROPER MOVEMENT OF THE PLUNGER DURING NORMAL BRAKE PEDAL OPERATION.THIS MAY CAUSE THE SWITCH TO FALL OUT OF ADJUSTMENT, THUS SIGNIFICANTLY REDUCING THE EFFORT REQUIRED TO ENERGIZE THE SWITCH AND ILLUMINATE THE STOP LAMPS.?CAVITY 2? SWITCHES WERE INSTALLED IN APPROXIMATELY 8,763 DISCOVERY SUBJECT VEHICLES BUILT FROM DECEMBER 2003 THROUGH MAY 2004 AND APPROXIMATELY 3,915 FREELANDER SUBJECT VEHICLES BUILT FROM OCTOBER 2003 THROUGH MAY 2004.ADDITIONALLY, STOP LAMP SWITCHES IN CERTAIN MY 2002 THROUGH 2005 FREELANDER SUBJECT VEHICLES MAY SLIP OUT OF ADJUSTMENT AS A RESULT OF SWITCH DAMAGE DUE TO AN INCORRECT SETTING PROCEDURE DURING VEHICLE MANUFACTURE OR AS A RESULT OF SWITCH MOUNTING BRACKET FLEX.ANALYSIS OF ALL AVAILABLE DATA INDICATES THE PREDOMINANT FAILURE MODE IS CONSTANT STOP LAMP ILLUMINATION.OTHER REPORTED CONSEQUENCES OF STOP LAMP SWITCH MALADJUSTMENT INCLUDE INOPERATIVE AUTOMATIC TRANSMISSION GEAR SELECTOR/BRAKE PEDAL SHIFT INTERLOCK, INOPERATIVE SPEED (CRUISE) CONTROL, AND TELLTALE ILLUMINATION AS DESCRIBED IN TECHNICAL SERVICE BULLETIN (TSB) NO. LT206-001 DATED OCTOBER 28, 2004 ISSUED BY THE MANUFACTURER TO LAND ROVER DEALERS IN THE UNITED KINGDOM (UK).TO DATE, ODI IS AWARE OF 77 NON-DUPLICATIVE COMPLAINTS THAT ALLEGE STOP LAMP SWITCH FAILURE ON THE SUBJECT VEHICLES (10 COMPLAINTS ON MY 2004 DISCOVERY, 45 ON MY 2002 FREELANDER, 19 ON MY 2003 FREELANDER, AND 3 ON MY 2004 FREELANDER VEHICLES).ADDITIONALLY, 4,595 DISCOVERY AND 13,370 FREELANDER SUBJECT VEHICLES HAVE EXPERIENCED ONE OR MORE WARRANTY CLAIMS TO REPLACE THE STOP LAMP SWITCH.OF THE 5,170 WARRANTY CLAIMS PAID TO REPLACE STOP LAMP SWITCHES ON DISCOVERY SUBJECT VEHICLES, APPROXIMATELY 31% OCCURRED BEFORE THE VEHICLE WAS SOLD NEW AND APPROXIMATELY 88% OCCURRED WITHIN THE FIRST 12 MONTHS OF VEHICLE SERVICE.THE WARRANTY TREND ON DISCOVERY SUBJECT VEHICLES IS IN DECLINE WITH 3,545 CLAIMS PAID IN CALENDAR YEAR (CY) 2004, 1,303 CLAIMS PAID IN CY 2005, AND 322 CLAIMS PAID IN CY 2006 THROUGH SEPTEMBER 28, 2006 (WHICH IS WHEN ODI LAST RECEIVED UPDATED WARRANTY CLAIMS DATA FROM LAND ROVER), AND IT APPEARS THAT THE ALLEGED DEFECT ON DISCOVER SUBJECT VEHICLES HAS BEEN REMEDIED THROUGH WARRANTY REPAIRS.HOWEVER, ODI ANALYSIS OF THE MANUFACTURER?S WARRANTY AND COMPLAINT RECORDS INDICATES THE FAILURE TREND ON CERTAIN FREELANDER SUBJECT VEHICLES IS ONGOING.BY LETTER DATED FEBRUARY 2, 2007, LAND ROVER HAS NOTIFIED ODI THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA RECALL NO. 07V-041) TO REPLACE DEFECTIVE STOP LAMP SWITCHES IN APPROXIMATELY 33,247 MY 2002 THROUGH 2005 FREELANDER VEHICLES BUILT AT THE SOLIHULL, UK ASSEMBLY PLANT FROM SEPTEMBER 5, 2001 THROUGH MAY 19, 2005. ALTHOUGH ODI HAS CONCERN
Exterior Lighting:brake Lights:switch
ON JUNE 16, 2005, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE05-034) TO INVESTIGATE ALLEGED STOP LAMP (BRAKE) SWITCH FAILURES IN CERTAIN MODEL YEAR (MY) 2004 LAND ROVER DISCOVERY SERIES II VEHICLES.ON OCTOBER 14, 2005, THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS AND THE SCOPE EXPANDED TO INCLUDE CERTAIN MY 2002 THROUGH 2005 FREELANDER VEHICLES THAT USE A SUBSTANTIALLY SIMILAR SELF-ADJUSTING STOP LAMP SWITCH FURNISHED BY THE SAME SUPPLIER, METHODE ELECTRONICS MALTA, LTD. (METHODE).IN SEPTEMBER 2003, METHODE MOVED THE PRODUCTION OF AN INTERNAL SWITCH COMPONENT, KNOWN AS THE SLIDER MECHANISM, FROM A VALIDATED PLASTIC INJECTION-MOLDING TOOL (?CAVITY 1?) TO ANOTHER TOOL (?CAVITY 2?) THAT HAD NOT BEEN USED BEFORE TO PRODUCE PARTS FOR LAND ROVER.SLIDERS FROM CAVITY 2 MAY BE CHARACTERIZED BY POOR FILL, LACK OF DEFINITION IN THE SLIDER TEETH AND DIMENSIONAL INSTABILITY.CONSEQUENTLY, THE SLIDER MAY BE UNABLE TO RESTRAIN IMPROPER MOVEMENT OF THE PLUNGER DURING NORMAL BRAKE PEDAL OPERATION.THIS MAY CAUSE THE SWITCH TO FALL OUT OF ADJUSTMENT, THUS SIGNIFICANTLY REDUCING THE EFFORT REQUIRED TO ENERGIZE THE SWITCH AND ILLUMINATE THE STOP LAMPS.?CAVITY 2? SWITCHES WERE INSTALLED IN APPROXIMATELY 8,763 DISCOVERY SUBJECT VEHICLES BUILT FROM DECEMBER 2003 THROUGH MAY 2004 AND APPROXIMATELY 3,915 FREELANDER SUBJECT VEHICLES BUILT FROM OCTOBER 2003 THROUGH MAY 2004.ADDITIONALLY, STOP LAMP SWITCHES IN CERTAIN MY 2002 THROUGH 2005 FREELANDER SUBJECT VEHICLES MAY SLIP OUT OF ADJUSTMENT AS A RESULT OF SWITCH DAMAGE DUE TO AN INCORRECT SETTING PROCEDURE DURING VEHICLE MANUFACTURE OR AS A RESULT OF SWITCH MOUNTING BRACKET FLEX.ANALYSIS OF ALL AVAILABLE DATA INDICATES THE PREDOMINANT FAILURE MODE IS CONSTANT STOP LAMP ILLUMINATION.OTHER REPORTED CONSEQUENCES OF STOP LAMP SWITCH MALADJUSTMENT INCLUDE INOPERATIVE AUTOMATIC TRANSMISSION GEAR SELECTOR/BRAKE PEDAL SHIFT INTERLOCK, INOPERATIVE SPEED (CRUISE) CONTROL, AND TELLTALE ILLUMINATION AS DESCRIBED IN TECHNICAL SERVICE BULLETIN (TSB) NO. LT206-001 DATED OCTOBER 28, 2004 ISSUED BY THE MANUFACTURER TO LAND ROVER DEALERS IN THE UNITED KINGDOM (UK).TO DATE, ODI IS AWARE OF 77 NON-DUPLICATIVE COMPLAINTS THAT ALLEGE STOP LAMP SWITCH FAILURE ON THE SUBJECT VEHICLES (10 COMPLAINTS ON MY 2004 DISCOVERY, 45 ON MY 2002 FREELANDER, 19 ON MY 2003 FREELANDER, AND 3 ON MY 2004 FREELANDER VEHICLES).ADDITIONALLY, 4,595 DISCOVERY AND 13,370 FREELANDER SUBJECT VEHICLES HAVE EXPERIENCED ONE OR MORE WARRANTY CLAIMS TO REPLACE THE STOP LAMP SWITCH.OF THE 5,170 WARRANTY CLAIMS PAID TO REPLACE STOP LAMP SWITCHES ON DISCOVERY SUBJECT VEHICLES, APPROXIMATELY 31% OCCURRED BEFORE THE VEHICLE WAS SOLD NEW AND APPROXIMATELY 88% OCCURRED WITHIN THE FIRST 12 MONTHS OF VEHICLE SERVICE.THE WARRANTY TREND ON DISCOVERY SUBJECT VEHICLES IS IN DECLINE WITH 3,545 CLAIMS PAID IN CALENDAR YEAR (CY) 2004, 1,303 CLAIMS PAID IN CY 2005, AND 322 CLAIMS PAID IN CY 2006 THROUGH SEPTEMBER 28, 2006 (WHICH IS WHEN ODI LAST RECEIVED UPDATED WARRANTY CLAIMS DATA FROM LAND ROVER), AND IT APPEARS THAT THE ALLEGED DEFECT ON DISCOVER SUBJECT VEHICLES HAS BEEN REMEDIED THROUGH WARRANTY REPAIRS.HOWEVER, ODI ANALYSIS OF THE MANUFACTURER?S WARRANTY AND COMPLAINT RECORDS INDICATES THE FAILURE TREND ON CERTAIN FREELANDER SUBJECT VEHICLES IS ONGOING.BY LETTER DATED FEBRUARY 2, 2007, LAND ROVER HAS NOTIFIED ODI THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA RECALL NO. 07V-041) TO REPLACE DEFECTIVE STOP LAMP SWITCHES IN APPROXIMATELY 33,247 MY 2002 THROUGH 2005 FREELANDER VEHICLES BUILT AT THE SOLIHULL, UK ASSEMBLY PLANT FROM SEPTEMBER 5, 2001 THROUGH MAY 19, 2005. ALTHOUGH ODI HAS CONCERN