NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
226 reports66,000 miles · Dec 17, 2007
Engine And Engine CoolingPower Train
WE HAD JUST HAD OUR CAR IN FOR SERVICING PRIOR TO A LONGER DRIVE. WHILE WE WERE DRIVING AT HIGHWAY SPEEDS, OUR CAR ACCELERATED WITHOUT WARNING. THE ENGINE "REVVED" WITHOUT ANY INCREASE IN SPEED. ONCE HOME, CONTACTED OUR DEALERSHIP WHERE THEY PROCEEDED TO TELL US THAT WE WOULD REQUIRE A NEW TRANSMISSION WHEN WE WERE ONLY JUST OUT…
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WE HAD JUST HAD OUR CAR IN FOR SERVICING PRIOR TO A LONGER DRIVE. WHILE WE WERE DRIVING AT HIGHWAY SPEEDS, OUR CAR ACCELERATED WITHOUT WARNING. THE ENGINE "REVVED" WITHOUT ANY INCREASE IN SPEED. ONCE HOME, CONTACTED OUR DEALERSHIP WHERE THEY PROCEEDED TO TELL US THAT WE WOULD REQUIRE A NEW TRANSMISSION WHEN WE WERE ONLY JUST OUT OF WARRANTY. THEY COULD NOT TELL US WHAT THE CAUSE OF THE PROBLEM WAS - ONLY THAT IT WOULD COST UPWARDS OF $6000 TO FIX IT BY REPLACING THE TRANSMISSION. PRIOR TO THIS, OUR DEALERSHIP HAD OUR LAND ROVER FREELANDER FOR 4 WEEKS FIXING OTHER KNOWN PROBLEMS SUCH AS THE COOLANT SYSTEM, AGAIN, JUST OUT OF WARRANTY FOR A FIX OF OVER $3000; ONCE IT WAS RETURNED, THE ENGINE LIGHT CAME BACK ON IMMEDIATELY (I.E. ON OUR WAY HOME FROM PICKING THE CAR UP) - I RETURNED IMMEDIATELY WITH THE VEHICLE AND WAS TOLD THAT THE ENGINE BLOCK HAD BEEN CRACKED WHICH WOULD REQUIRE AN ADDITIONAL $2000 PLUS IN REPAIRS (ALTHOUGH THEY DID DISCOUNT US ON THIS REPAIR - MORE THAN LIKELY BECAUSE THEY HAD CAUSED IT). WE HAVE HAD NOTHING BUT DIFFICULTY WITH THIS VEHICLE. THE ISSUES BEGAN ALMOST IMMEDIATELY FROM THE DATE OF PURCHASE. ADDITIONALLY, THE LAND ROVER SERVICE PEOPLE ARE LESS THAN HELPFUL. I BELIEVE THEY ARE DECEPTIVE, ARROGANT, AND LACK THE KNOWLEDGE AND SKILL REQUIRED TO FULLY SERVICE A VEHICLE. I HAVE GONE THROUGH THREE DIFFERENT DEALERSHIPS TO LOCATE SOMEONE WHOM I TRUST TO SERVICE THIS VEHICLE; FINALLY, NOW THAT THE CARE IS OUT OF WARRANTY WE WILL BE GOING TO A LOCAL REPAIR SHOP WHERE THEY WERE ABLE TO WALK ME THROUGH WHAT WAS WRONG WITH THE VEHICLE AND FIX THE PROBLEM. *TR
NHTSA ODI #10212079
65,000 miles · Dec 2, 2007
Engine And Engine CoolingPower TrainVisibility
2002 LAND ROVER FREELANDER WITH ONLY 65,000 MILES HAS HAD REPAIRS THAT ARE BEYOND WHAT SHOULD BE NORMAL, INCLUDING A NEW TRANSMISSION AT 45,000 MILES, TWO WINDOW REGULATORS, MULTIPLE COOLANT LEAKS, BLOWN HEAD GASKET. DANGEROUS ON THE ROAD, DUE TO STALLING OUT FOR NO REASON, AND OVERHEATING CONSTANTLY. HAVE HAD TO PAY FOR MULTI…
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2002 LAND ROVER FREELANDER WITH ONLY 65,000 MILES HAS HAD REPAIRS THAT ARE BEYOND WHAT SHOULD BE NORMAL, INCLUDING A NEW TRANSMISSION AT 45,000 MILES, TWO WINDOW REGULATORS, MULTIPLE COOLANT LEAKS, BLOWN HEAD GASKET. DANGEROUS ON THE ROAD, DUE TO STALLING OUT FOR NO REASON, AND OVERHEATING CONSTANTLY. HAVE HAD TO PAY FOR MULTIPLE TOWS. TODAY, ENGINE OVERHEATED IN MALL PARKING LOT, LEAVING ME STRANDED. ALL COOLANT POURED ONTO THE GROUND. CAR NEEDS A NEW ENGINE AT ONLY 65,000 MILES. *TR
NHTSA ODI #10210626
65,000 miles · Dec 1, 2007
Engine And Engine Cooling
MY COOLANT TANK HAS LEAKED, MY WATER TANK HAS CRACKED. NONE OF MY SAFETY LIGHTS FLASHED EVER, SO I DROVE WITHOUT ANY KNOWLEDGE OF THE PROBLEM AND SOMEHOW DESTROYED THE ENGINE. APPARENTLY I NEED A NEW ENGINE FOR A CAR THAT ONLY HAS 65,000 MILES ON IT, AND THE SAFETY LIGHTS ARE NOT LIT. *TR
NHTSA ODI #10210463
Mileage unknown · Nov 30, 2007
Power Train
I ALWAYS HAD A PROBLEM WITH TRANSMISSION WHICH WAS REPLACED ONCE 2 YEAR AGO AND NOW I NEED TO DO OUT OF MY POCKET ALL OVER AGAIN. *TR
NHTSA ODI #10210395
75,000 miles · Nov 25, 2007
Electrical SystemEngine And Engine CoolingPower Train
TRANSMISSION FAILURE AT 75,000 MILES. EXCESSIVE CHECK ENGINE LIGHT WARNINGS. BAD SENSORS. ENGINE NOISE. *TR
NHTSA ODI #10209858
55,433 miles · Nov 15, 2007
Power Train
2002 LAND ROVER FREELANDER NEEDS TRANSMISSION REPLACED AT ONLY 55K MILES. NEED HELP IN FORCING LAND ROVER NORTH AMERICA TO ISSUE A RECALL. *TR
NHTSA ODI #10209077
50,000 miles · Nov 14, 2007
Engine And Engine CoolingExterior LightingFuel System, Gasoline
WATER PUMP FAILED, TOOK TO DEALER FOR REPLACEMENT, GAS PUMP FAILED TOOK IT TO SHOP TO REPLACE IT, GAS TANK LID FAILED, BOTH ONE FROM DEALER TO REPLACE IT, ENGINE COOLING SYSTEM FAILED, TRANSMISSION FAILED, TOOK IT TO SHOP THEY REFUSE TO FIX, THEY SAY IS NOT THEIR FAULT AND IS NOT COVER BY WARRANTY ANYMORE, WINDOW MOTOR FAILED, W…
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WATER PUMP FAILED, TOOK TO DEALER FOR REPLACEMENT, GAS PUMP FAILED TOOK IT TO SHOP TO REPLACE IT, GAS TANK LID FAILED, BOTH ONE FROM DEALER TO REPLACE IT, ENGINE COOLING SYSTEM FAILED, TRANSMISSION FAILED, TOOK IT TO SHOP THEY REFUSE TO FIX, THEY SAY IS NOT THEIR FAULT AND IS NOT COVER BY WARRANTY ANYMORE, WINDOW MOTOR FAILED, WINDSHIELD WIPER SWITCH FAILED, HEADLIGHTS FAILED, COOLANT CONTAINER CRACK, REPLACED WITH NEW ONE FROM DEALER. STOP LIGHT RECALLED. AIR FILTERING SYSTEM RETAINS WATER WHICH ALLOWS MOLD TO GROW, AIR FILTERS REPLACED. *TR
NHTSA ODI #10208918
40,000 miles · Nov 14, 2007
Engine And Engine CoolingExterior LightingPower Train
WATER PUMP FAILED, TOOK TO DEALER FOR REPLACEMENT, GAS PUMP FAILED TOOK IT TO SHOP TO REPLACE IT, GAS TANK LID FAILED, BOTH ONE FROM DEALER TO REPLACE IT, ENGINE COOLING SYSTEM FAILED, TRANSMISSION FAILED, TOOK IT TO SHOP THEY REFUSE TO FIX, THEY SAY IS NOT THEIR FAULT AND IS NOT COVER BY WARRANTY ANYMORE, WINDOW MOTOR FAILED, W…
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WATER PUMP FAILED, TOOK TO DEALER FOR REPLACEMENT, GAS PUMP FAILED TOOK IT TO SHOP TO REPLACE IT, GAS TANK LID FAILED, BOTH ONE FROM DEALER TO REPLACE IT, ENGINE COOLING SYSTEM FAILED, TRANSMISSION FAILED, TOOK IT TO SHOP THEY REFUSE TO FIX, THEY SAY IS NOT THEIR FAULT AND IS NOT COVER BY WARRANTY ANYMORE, WINDOW MOTOR FAILED, WINDSHIELD WIPER SWITCH FAILED, HEADLIGHTS FAILED, COOLANT CONTAINER CRACK, REPLACED WITH NEW ONE FROM DEALER. STOP LIGHT RECALLED. AIR FILTERING SYSTEM RETAINS WATER WHICH ALLOWS MOLD TO GROW, AIR FILTERS REPLACED. *TR
NHTSA ODI #10208911
Mileage unknown · Nov 12, 2007
Engine And Engine Cooling
COMPLAINED TO DEALER OF OVERHEATING 2X'S. EACH TIME SYSTEM WAS PRESSURE TESTED AND REPORTED OK. 3RD TIME A PROBLEM WAS DETECTED AND PARTS REPLACED, TO NO AVAIL. NOW AM TOLD THAT I NEED A NEW ENGINE AT 46K MI. WATER MUST BE ADDED EVERY DAY TO USE THE VEHICLE, BUT THE DEALER REFUSES TO DO REPAIRS BECAUSE THE WARRANTY EXPIRED A MON…
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COMPLAINED TO DEALER OF OVERHEATING 2X'S. EACH TIME SYSTEM WAS PRESSURE TESTED AND REPORTED OK. 3RD TIME A PROBLEM WAS DETECTED AND PARTS REPLACED, TO NO AVAIL. NOW AM TOLD THAT I NEED A NEW ENGINE AT 46K MI. WATER MUST BE ADDED EVERY DAY TO USE THE VEHICLE, BUT THE DEALER REFUSES TO DO REPAIRS BECAUSE THE WARRANTY EXPIRED A MONTH AGO. *TR
NHTSA ODI #10208703
52,000 miles · Nov 7, 2007
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2002 LAND ROVER FREELANDER. THE VEHICLE WOULD NOT START. THERE WERE NO WARNING INDICATOR LIGHTS PRESENT. THE DEALER STATED THAT THE HEAD GASKET SEAL MALFUNCTIONED AND LEAKED OIL INTO THE ENGINE. THE ENGINE NEEDED TO BE REBUILT. THE REPAIR WAS NOT MADE. THE CURRENT AND FAILURE MILEAGES WERE 52,000.
NHTSA ODI #10208143
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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