Honda, Acura Recall Over Brake Defect

American Honda Motor Co. has issued a significant safety recall for nearly 260,000 vehicles due to a manufacturing defect that could compromise braking performance. The issue centers on an improperly secured brake pedal, creating a potential safety hazard for drivers.

Key Highlights

Recall Scope: The recall affects 259,033 vehicles across the Acura and Honda brands.
Affected Models: The specific models included are the 2021-2025 Acura TLX , 2023-2025 Acura MDX , and 2023-2025 Honda Pilot.
The Defect: A key component, the brake pedal pivot pin, was not properly staked during assembly. This can allow the brake pedal to shift, potentially hindering the driver’s ability to brake safely.
Remedy: Dealers will inspect the brake pedal assembly and replace it if necessary, free of charge.
Owner Notification: Vehicle owners will be notified by mail, with letters scheduled to be sent starting July 28, 2025.

The Defect Explained

The core of the recall is a flaw in the brake pedal assembly. During the manufacturing process, the brake pedal pivot pin was not staked, or secured, correctly. This oversight can lead to lateral movement in the brake pedal, which may cause unintended brake application or interfere with the driver’s ability to slow or stop the vehicle. This condition means the affected vehicles do not comply with Federal Motor Vehicle Safety Standards. As a result, the risk of a crash or injury is increased.

Cause of the Defect

The problem originated from a series of issues at the supplier, Otsuka Koki Co, Ltd. During a production transition from a U.S. facility to one in Mexico, the supplier increased its staff to build up an inventory of parts. However, due to insufficient training, the new staff did not perform the required staking process on the brake pedal pivot pins.

Compounding the error, a QR code scanning system designed to prevent such process omissions malfunctioned. The supplier then disabled the verification function and continued with production, allowing the defective parts to be manufactured and distributed without detection.

Affected Vehicles and Population

The recall encompasses three popular models with specific production dates:

2021-2025 Acura TLX: 7,332 vehicles produced between October 23, 2020, and February 28, 2025.
2023-2025 Acura MDX: 67,448 vehicles produced between May 3, 2023, and November 13, 2024.
2023-2025 Honda Pilot: 184,253 vehicles produced between December 16, 2022, and November 6, 2024.

The population was identified using supplier and manufacturing records. While a large number of vehicles are potentially involved, Honda estimates that only 1% of the recalled vehicles have the defect.

Safety Risk and Warning Signs

Drivers of affected vehicles may observe specific warning signs indicating a problem with the brake pedal assembly. These include:

An illuminated brake malfunction light on the dashboard.
Movement in the brake pedal or an abnormal feeling during operation.
Brake lights that remain lit even when the pedal is not being pressed.

Remedy and Recall Schedule

Registered owners of all affected vehicles will be contacted by mail and instructed to take their vehicle to an authorized Honda or Acura dealer. The dealer will inspect the brake pedal assembly and, if necessary, replace it with a new part that has a properly staked pivot pin. This service will be performed free of charge.

Owners who have already paid for repairs related to this issue may be eligible for reimbursement.

Dealer Notification: Began on June 13, 2025.
Owner Notification: Scheduled to begin and end on or about July 28, 2025.

Owners may contact Honda’s customer service at 1-888-234-2138. Honda’s internal numbers for this recall are FLX and XLY, and the NHTSA campaign number is 25V391.