NHTSA Escalates Range Rover Suspension Failure Probe to Engineering Analysis, 331K Vehicles at Risk

The National Highway Traffic Safety Administration (NHTSA) has escalated its investigation into Range Rover suspension failures to an engineering analysis, expanding scrutiny to over 331,000 vehicles in the United States.

This probe, now under the Office of Defects Investigation (ODI), focuses on a critical defect: the upper control arm breaking free from the steering knuckle assembly. The issue has prompted concerns over potential detachment while driving.

The investigation began as a preliminary evaluation last year, based on a dozen reports from owners describing a crack forming at the top of the aluminum front steering knuckle assembly. This crack can cause the upper control arm to separate from the vehicle entirely.

Jaguar Land Rover (JLR) has since provided additional data to the NHTSA, confirming at least 522 failures reported by the automaker. The total number of affected vehicles now stands at 331,559, including:

• 2014-2022 Range Rover models
• 2014-2022 Range Rover Sport models

JLR’s 2025 Recall: Limited Scope Raises Concerns

On August 5, 2025, Jaguar Land Rover issued a safety recall addressing this issue. However, the recall only covers 2015-2017 Range Rover and Range Rover Sport models. Under the recall, dealers are instructed to:

• Replace cracked knuckles with new components
• Strengthen knuckles without visible cracks using a new brace to prevent detachment if a crack forms

Despite this recall, the NHTSA has continued to receive reports of fractures, including two alleged failures on 2020 and 2021 models. This suggests the problem may extend beyond the vehicles included in JLR’s recall.

Potential Outcomes of the NHTSA Investigation

If the engineering analysis determines that the steering knuckle issue affects more vehicles than those covered by JLR’s recall, the NHTSA may compel the automaker to issue a larger recall. Alternatively, the NHTSA could pre-emptively initiate its own recall to address the defect across all impacted models.

The escalation of this probe underscores the seriousness of the issue and the need for a comprehensive solution to ensure driver safety.