Lemon 2023 Nissan Frontier

Start a case with Nissan
Exactly, and escalate it to Japan or send a letter to Nissan's CEO. Apparently customer service in Japan takes these issues more seriously than the customer service games you will get in the US.

Ideally, you get to sell your vehicle back to Nissan for a fair value.

Otherwise, you will have to keep going back to the dealer 20x times for other issues (might be a few if the tech assigned has never done this before) until they declare this thing a lemon. Check the lemon laws in your state.
 
It's not lego, and there's hundreds of little plastic pieces to hold wires and lines designed to be assembled easily but not taken apart. I'm sure there's an easy order of disassembly and reassembly too, but it might not be documented?
It would be interesting to see what toyota supplied in addition to the frame for their frame recall, probably dozens of little finicky parts, alignment guides, and a set of detailed tested and refined instructions!
You would think a tech would get lots of "extra" time to do it right the first time, but maybe their experienced guys don't want the potential headache?
Don't forget the scores of electrical grounding lugs/ points all over the frame. Miss or break one and it would be gremlin party time.

Time to find out what was not welded or rivited on the frame. Is it just a link tab or bracket? I would just get it welded at a collision/ frame shop. I snapped the left front LCA U-tab anchor bracket off a brand new Cherokee back in the 90's when the thing started wheel hopping gooing up my ski-slope driveway. I could not believe how insubstantial that bracket was - or that a Subaru could get up that hill and not a 4WD Jeep.

I do understand Nissan's only path forward is frame replacement. Even a frame shop would balk on repairing an under warranty vehicle that was not hit with an INS claim.

Nostalgia Warning - I had a big C-body '65 Buick where the frame rusted through and broke at the rear kick-up. In Massachusetts you could only get the whole rail replaced - no patch repairs allowed. I brought it to a combo Used Car lot and garage in N.H. and they agreed to fix it. The guy welded a large L shaped flame cut of boiler plate - the car drove great after. 69 buck fix back in the early Seventies.

- Arco
 
Here are the photos I was able to get of the broken frame.

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I see that. Interesting miss by a robotic welder, yours may not be the only one. Could be spotty though. Maybe funky fixture.

THANK YOU FOR THE PICS!!

Usually placing individual components in a fixture is a manual process performed by human, so I think this is probably a human error.

But this should’ve been caught as I’m sure they must have some sort of final inspection, be it camera system or other measurement methods, because that piece is off its place by quite a lot.
 
It's not lego, and there's hundreds of little plastic pieces to hold wires and lines designed to be assembled easily but not taken apart. I'm sure there's an easy order of disassembly and reassembly too, but it might not be documented?
It would be interesting to see what toyota supplied in addition to the frame for their frame recall, probably dozens of little finicky parts, alignment guides, and a set of detailed tested and refined instructions!
You would think a tech would get lots of "extra" time to do it right the first time, but maybe their experienced guys don't want the potential headache?

All of which is solved with basic trim removal tools that a jr mechanic should have in their box.

Its clear that some posters here have mental blocks on what the job entails or are armchair mechanics.
 
Usually placing individual components in a fixture is a manual process performed by human, so I think this is probably a human error.

But this should’ve been caught as I’m sure they must have some sort of final inspection, be it camera system or other measurement methods, because that piece is off its place by quite a lot.
All speculation on speculation. I would say back in the day, if that's the case, why wasn't the operator able to load the tool properly?
 
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