NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
226 reports70,000 miles · Sep 12, 2008
Engine And Engine Cooling
MY 2002 LANDROVER FREELANDER'S ENGINE FAILED AT AROUND 70,000 MILES WITHOUT ANY WARNING FROM THE VEHICLES WARNING LIGHT SYSTEM AND JUST AS THE VEHICLE'S ORIGINAL 5 YEAR WARRANTY ENDED. THE DEALERS REPAIR SHOP ATTRIBUTED THE ENGINE FAILURE TO OVERHEATING. DUE TO THE MANUFACTURE DISCONTINUING MANUFACTURING THIS ENGINE'S THE DEALE…
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MY 2002 LANDROVER FREELANDER'S ENGINE FAILED AT AROUND 70,000 MILES WITHOUT ANY WARNING FROM THE VEHICLES WARNING LIGHT SYSTEM AND JUST AS THE VEHICLE'S ORIGINAL 5 YEAR WARRANTY ENDED. THE DEALERS REPAIR SHOP ATTRIBUTED THE ENGINE FAILURE TO OVERHEATING. DUE TO THE MANUFACTURE DISCONTINUING MANUFACTURING THIS ENGINE'S THE DEALER HAD TO LOCATE A "REBUILT" ENGINE AS A REPLACEMENT. THE TOTAL COST OF THE "REBUILT ENGINE AND LABOR WAS AN ASTOUNDING $7,500.00. DUE TO THE HIGH INCIDENT OF THIS PARTICULAR ENGINE FAILING AND THE MANUFACTURER NOT MAKING THE ENGINE ANY LONGER IT TOOK AROUND 3 MONTHS TO PROCURE A REPLACEMENT "REBUILT" ENGINE AND INSTALL IT. ALSO, THE SUNROOF MOTOR AND THE REAR PASSENGER WINDOW MOTOR BOTH FAILED AND HAD TO BE REPLACED AT A COST OF AROUND $1,200.00. MY DEALER RECOMMENDED THAT I JOIN A CLASS ACTION LAW SUITE IF I COULD FIND ONE DEALING WITH THIS VEHICLE'S CLEAR LEMON QUALITIES. I UNDERSTAND FROM OTHER FREELANDER OWNERS THE NEXT THING TO GO WILL LIKELY BE THE TRANSMISSION. ALL OF THIS LEAVES ME WITH VERY LITTLE CONFIDENCE IN THE VEHICLE'S SAFETY OR RELIABILITY. I FEEL THE OUT OF POCKET EXPENSES FOR THIS ENGINE REPLACEMENT ARE UNWARRANTED AND SHOULD BE THE RESPONSIBILITY OF THE MANUFACTURE. ON BEHALF OF ALL FREELANDER OWNERS WHO HAVE HAD TO REPLACE THE ENGINE OF THIS CAR PLEASE ISSUE A RECALL OF THE ENGINE AND FORCE THE MANUFACTURE TO TAKE RESPONSIBILITY FOR THEIR FAILURE TO PRODUCE AND/OR USE A SOUND PIECE OF EQUIPMENT IN THIS VEHICLE. THANK YOU. *TR
NHTSA ODI #10242003
48,000 miles · Sep 3, 2008
Power TrainStructureVisibility
MECHANICAL PROBLEMS IMMEDIATELY AFTER PURCHASE REQUIRED 4-5 TRIPS TO DEALERSHIP BEFORE THEY FIXED IT. I DON'T' RECALL THE EXACT PROBLEM. SUNROOF MOTOR DIED & HAD TO BE REPLACED. LEFT REAR WINDOW REGULATOR DIED AND HAD TO BE REPLACED. RIGHT REAR WINDOW REGULATOR DIED AND HAD TO BE REPLACED. BROKEN LATCH ON HOOD HAD TO BE REPLACED…
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MECHANICAL PROBLEMS IMMEDIATELY AFTER PURCHASE REQUIRED 4-5 TRIPS TO DEALERSHIP BEFORE THEY FIXED IT. I DON'T' RECALL THE EXACT PROBLEM. SUNROOF MOTOR DIED & HAD TO BE REPLACED. LEFT REAR WINDOW REGULATOR DIED AND HAD TO BE REPLACED. RIGHT REAR WINDOW REGULATOR DIED AND HAD TO BE REPLACED. BROKEN LATCH ON HOOD HAD TO BE REPLACED. CHECK ENGINE LIGHT AND EXCESSIVE CRANKING 6/1/02 AND 8/17/02 DEALERSHIP CLEARED CODES NO REPAIRS. SERVICE ENGINE SOON LIGHT AND EXCESSIVE CRANKING 9/17/02, DEALERSHIP REPLACED LEAKING FUEL PUMP. SERVICE ENGINE SOON LIGHT AND SHIFTING PROBLEMS 3/2006, DEALERSHIP SENT ME HOME NO REPAIRS. SERVICE ENGINE SOON LIGHT AND CAR LOST POWER WHILE DRIVING, THROTTLE BODY HAD A SHORT AND DEALERSHIP REPLACED. SERVICE ENGINE SOON LIGHT AND DELAY IN SHIFTING FROM 2ND TO 3RD 9/1/08. HAVE NOT HAD THIS DIAGNOSED YET. SUSPECT BAD SOLENOIDS OR TRANSMISSION FAILURE. *TR
NHTSA ODI #10240849
58,000 miles · Aug 29, 2008
Power Train
I HAVE A 2002 LANDROVER FREELANDER. RAN GREAT AT FIRST. ABOUT 2 WEEKS LATER, THE CHECK ENGINE LIGHTS CAME ON, THE DOWNHILL DECENT WARNING LIGHT, AND THE ODOMETER DISPLAY WAS FLASHING F AND 4. UPON DRIVING IN THIS CONDITION, WE FOUND THAT THE GEARS WERE SLIPPING AND MADE A LOUD CLUNKING SOUND. *TR
NHTSA ODI #10240273
55,000 miles · Aug 25, 2008
Engine And Engine CoolingPower Train
2002 LAND ROVER FREELANDER. TRANSMISSION FAILED AT 45,000 MILES. CATASTROPHIC ENGINE FAILURE AT 55,000 MILES. VEHICLES STOPPED DEAD IN THE MIDDLE OF RUSH HOUR TRAFFIC. MECHANICS AT THE LAND ROVER DEALERSHIP SAID THAT 100% OF THE FREELANDER MODEL HAD THE SAME TRANSMISSION & ENGINE FAILURES. *TR
NHTSA ODI #10239675
688,000 miles · Aug 23, 2008
Power Train
JUST BOUGHT THE 2002 LAND ROVER - FREELANDER 2 WEEKS AGO, IT HAS 68K MILES, THEN ITS TRANSMISSION TOTALLY FAILED, IT WILL NOT GO INTO REVERSE / BACKWARD. ALSO, WHEN IT IS SWITCHING GEAR, THE GEAR 2 & 3 ARE VERY VERY ROUGH. TODAY, THE MECHANIST TOLD ME THAT THE TRANSMISSION SHOULD BE REPLACED. *TR
NHTSA ODI #10239467
50,000 miles · Aug 18, 2008
Engine And Engine Cooling
2002 LAND ROVER FREELANDER - OVER A 2 YEAR PERIOD REPEATEDLY TOOK THE CAR TO LAND ROVER DEALER FOR MISSING COOLANT - CAR FAILS TO DRIVE APRIL 2006 - INFORMED ENGINE NEEDS TO BE REPLACED - REPLACED ENGINE JULY 2006 - ~8 DEALER SERVICING INCLUDING ~5 FOR ENGINE RELATED ISSUES OVER THE NEXT ONE AND HALF YEARS - CAR FAILS TO DRIVE T…
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2002 LAND ROVER FREELANDER - OVER A 2 YEAR PERIOD REPEATEDLY TOOK THE CAR TO LAND ROVER DEALER FOR MISSING COOLANT - CAR FAILS TO DRIVE APRIL 2006 - INFORMED ENGINE NEEDS TO BE REPLACED - REPLACED ENGINE JULY 2006 - ~8 DEALER SERVICING INCLUDING ~5 FOR ENGINE RELATED ISSUES OVER THE NEXT ONE AND HALF YEARS - CAR FAILS TO DRIVE THREE TIMES IN 2 MONTHS - TAKEN TO LAND ROVER DEALER FOR DIAGNOSIS EACH TIME OF FAILURE - TOLD ENGINE NEEDS TO BE REPLACED JUNE 2008 - LAND ROVER CUSTOMER CARE CENTER / SERVICE CONTACTED REPEATEDLY WITH ESCALATION TO A SUPERVISOR - LAND ROVER WILL NOT TAKE ANY ACTION TO HELP RESOLVE CUSTOMER ISSUE AROUND DEFECTIVE ENGINES - STAND BY 12 MONTH WARRANTY - ONE CAR, 2 ENGINES FAILED/DEFECTIVE OVER 5 YEARS OWNERSHIP - MANUFACTURER REFUSING TO ACKNOWLEDGE PRODUCT DEFECTS, TAKE RESPONSIBILITY AND ASSIST CUSTOMER TO MAKE GOOD ON SUBSEQUENT PRODUCT LIABILITY. *TR
NHTSA ODI #10238803
72,000 miles · Aug 11, 2008
Latches/locks/linkages
TL*THE CONTACT OWNS A 2002 LAND ROVER FREELANDER. WHEN THE CONTACT ATTEMPTED TO OPEN THE TAILGATE, IT WOULD NOT UNLOCK, REGARDLESS IF SHE USED THE KEYLESS REMOTE OR MANUALLY ATTEMPTED TO OPEN THE DOOR. SHE ALSO NOTICED THAT THE FRONT PASSENGER AND REAR DRIVER SIDE DOORS WOULD NOT UNLOCK WITH THE KEYLESS REMOTE. THE DOORS WILL…
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TL*THE CONTACT OWNS A 2002 LAND ROVER FREELANDER. WHEN THE CONTACT ATTEMPTED TO OPEN THE TAILGATE, IT WOULD NOT UNLOCK, REGARDLESS IF SHE USED THE KEYLESS REMOTE OR MANUALLY ATTEMPTED TO OPEN THE DOOR. SHE ALSO NOTICED THAT THE FRONT PASSENGER AND REAR DRIVER SIDE DOORS WOULD NOT UNLOCK WITH THE KEYLESS REMOTE. THE DOORS WILL ONLY UNLOCK MANUALLY. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY STATED THAT ALL OF THE MALFUNCTIONING DOORS NEEDED THE DOOR LATCHES REPLACED. THE VEHICLE HAS NOT BEEN SERVICED FOR THE FAILURES. THE CURRENT MILEAGE WAS 84,000 AND FAILURE MILEAGE WAS 72,000.
NHTSA ODI #10237688
65,000 miles · Aug 6, 2008
Engine And Engine Cooling
I ONLY HAVE 65,XXX MILES ON MY 2002 FREELANDER AND IT NOW NEEDS A NEW ENGINE-SOMEHOW THERE IS OIL IN MY COOLANT TANK? THE DEALER TOLD ME THAT IT NEEDS TO GO AWAY. I STILL OWE ON THIS CAR-TALK ABOUT UPSIDE DOWN IN A LOAN. *TR
NHTSA ODI #10237274
59,000 miles · Aug 1, 2008
Service Brakes, Hydraulic
ABS FAILURE, LAND ROVER FREELANDER 2002, LAND ROVER HOUSTON REFUSED TO WORK ON VEHICLE EVEN THOUGH IT WAS PURCHASED THERE. SERVICE MANAGER BRUCE WATKINS ASKED TO TOW THE VEHICLE FROM HIS DEALERSHIP. *TR
NHTSA ODI #10236613
79,000 miles · Aug 1, 2008
Engine And Engine CoolingPower Train
2002 LAND ROVER FREELANDER S, ENGINE AND TRANSMISSION FAILURE,,,,,,,,,,, *TR
NHTSA ODI #10236600
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
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