definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
37,628 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2002 Nissan Pathfinder exhaust system problems

exhaust system problem

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2002 Nissan Pathfinder Owner Comments

problem #14

Mar 152010

Pathfinder 4WD 6-cyl

  • 65,000 miles


I own a 2002 Nissan Pathfinder with 97,000. Miles on it. There is a crack in the exhaust manifold that has been getting louder over the last 24 months and recently I have begun to smell exhaust inside the car. This apparently is a manufacturing defect and should be corrected by Nissan.

- Fremont, CA, USA

problem #13

Aug 192009


  • 71,000 miles
1: events leading to failure: 2002 Nissan Pathfinder, 71,000 miles. Loud exhaust sounds. Dealership looked at car (charged $50 to look) and reported the exhaust system pipes going into the catalytic converter are cracked - again - already repaired once. Dealership will not repair/replace without charge. This is a recurring defect and possibly an emissions problem. The pipes carry exhaust from engine into catalytic converter and muffler and they are leaking and this is not the first time for this vehicle or many others online. Dealership mechanic specifically told me, "we see this alot" "!"! defective! nothing has been done to correct, I need assistance ensuring that the dealership takes responsibility for a recurring issue.

- Wylie , TX, USA

problem #12

Oct 102007


  • 60,000 miles
1. exhaust leak sounds, exhaust into cab of vehicle, loud rattling sounds while driving. 2. noticed around 60,000 miles, progressively getting worse! 3. taken to Nissan, Nissan refuses to pay for defect. Nissan claimed cracked pipes, no recall.

- Lex, KY, USA

problem #11

Jul 212009


  • 35,000 miles


Exhaust system problem on 2002 Nissan Pathfinder. Just paid $645 to have two CO2 oxygen sensors replace on vehicle and then was told that I needed to have my resonators replace in order to pass the emission control test. I have been smelling emission from the car for a year and was informed that it was CO2 sensors that need to be replaced.

- Tacoma, WA, USA

problem #10

May 152007


  • 70,000 miles
I have a 2002 Nissan Pathfinder. The vehicle developed an exhaust leak about 2 years and 30,000 miles ago. The vehicle now has 100,000 miles on it. You could smell the exhaust leak and hear the exhaust leak. The leak is coming from the resonators or catalytic converter, whatever you want to call it.figuring that my warranty was up, I had the vehicle fixed at my own cost. Recent investigation into website complaint forums made me realize that this has been a recurring problem for 02-03 Nissan Pathfinder owners and should have been covered under the 8/80 rule to be fixed by Nissan at no cost. The failure of Nissan to provide information to the owners of these vehicles that there is a possible problem with manufacturing is an outrage.

- Walker, LA, USA

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problem #9

Sep 152004


  • 28,000 miles
The exhaust "resonators" on my 2002 Pathfinder began to leak at a welded seam at about 28,000 miles. The Nissan dealer refused to replace the exhaust pipes and insisted on installing a patch kit. This kit only lasts approximately 20,000 miles and they begin to leak again. This repair has been performed 4 times thus far and it is leaking again. Truck now has 103,000 miles. Nissan now refuses to pay for the patch. My service engine light is now on so I suspect this is tied to the exhaust leak. This is a safety concern as it allows exhaust gases to come from underneath the vehicle and enter the cabin when sitting idle. Based on local dealers own admissions, this is a design flaw.

- Southampton, MA, USA

problem #8

Oct 012008


  • miles


I am complaining about the exhaust system on my 2002 Nissan Pathfinder. I had a leak at the bottom of the pipe at what looks like a catalytic converter. I paid Nissan to fix the problem. A year later it is leaking again. I brought the car back to be repaired. They told me the part on the bottom of the pipe is not a catalytic converter. I was told by a mechanic it was. Either way this seems to be a large problem and should be fixed by Nissan.

- Waltham, MA, USA

problem #7

Oct 272008


  • miles
I have a 2002 Nissan Pathfinder with 67,000 miles. According to my mechanic, my two rear catalytic converters are leaking CO2 from their seams. According to my service manual, catalytic converters are covered under the federal warranty 8/80. I took the car to the white plains Nissan dealer and was told that it's the exhaust tubes that are leaking. The service manager said it could be repaired but I would have to pay. I understand that this has been an ongoing and frequent problem with 2002-2003 Pathfinders and that the epa has notified Nissan in the past that this production defect could cause health and safety issues. I don't see why they can call these parts "exhaust tubes" when they are really catalytic converters and have them not subject to the federal warranty. I believe Nissan should be responsible for replacing these defective parts with a product recall. Can you help me in this matter? thank you, dorrine livson

- White Plains, NY, USA

problem #6

Jul 302008

Pathfinder 6-cyl

  • 58,000 miles
The contact owns a 2002 Nissan Pathfinder. The contact heard a loud noise coming from her vehicle. In addition, the engine warning indicator illuminated on the instrument control panel. She took her vehicle to a local repair shop and the technician stated that the catalytic converter was split in the middle. She took the vehicle to an authorized dealer and they stated that the resonator needed to be repaired instead of the catalytic converter. The repair would cost over $1,500. The vehicle has not been repaired. The contact recently smelled vapors coming from her vehicle. She filed a complaint with the manufacturer. The failure mileage was 58,000 and current mileage was 60,000. Updated 11/07/08. The front exhaust tubes were leaking and vent control valve was leaking. Updated 11/07/08.

- Lakewood, OH, USA

problem #5

Aug 192008


  • 33,927 miles
When we purchased the car used in Sept 2007, it had 24,509 miles on it. The exhaust sounded somewhat loud but not too abnormal. Just under a year later, the exhaust was very loud and rattling. We took it in to the Nissan dealership and they told us the front exhaust tubes were rusted and leak. They said Nissan supplies a 'repair kit' to put a patch on these tubes. The dealership told us they have seen many other problems like this and I have found there are many entries for this exact problem on online forums. One such forum can be found at topix.com. Just the fact that Nissan supplies a 'repair kit' to fix this exact problem shows these exhaust tubes are faulty and should be recalled.

- Evanston, IL, USA

problem #4

Jul 082008


  • 64,365 miles


Rumbling sound coming from exhaust. Local repair shop said it was a leaking catalytic converter. Took it to Nissan dealership. They said it was a cracked tube in the exhaust and there was a service bulletin classification FE04-002. Reference ntb04-092. Issued 9-1-2004. They would not repair under warranty. My subsequent research found numerous complaints about this, mostly safety related, several people suffered dizziness while idling. I believe this is a safety issue and a defective product and should be recalled. Their fix is to clamp a patch on to the leaking area. Many of the reports I read said that this also fails. I would suggest that their solution is a failure also.

- Galena, IL, USA

problem #3

Apr 092008

Pathfinder 4WD 6-cyl

  • Automatic transmission
  • 15,000 miles
2002 Nissan Pathfinder - split seams in resonators / catalytic converter the exhaust on this vehicle had been a bit noisy since it was about a year old. Recently when it went to a shop for some undercar work, I was informed that the catalytic converters were both split and needed to be replaced. I brought the car back to the dealer and requested replacement under the 8 year 80,000 mile warranty mandated on emissions equipment. They informed me that those parts were indeed leaking badly, and that Nissan had so many failures that they had developed a special patch kit for them. I declined the patch due to an excessive cost for a few large clamps and some exhaust cement. Subsequent research indicates that numerous other Pathfinders of similar vintage have had the same problem, thus there is a manufacturing issue in the welding of the seams of this part which according to midas is a catalytic converter and according to Nissan is a resonator. This is a safety issue as carbon monoxide is being released directly under the passenger compartment. A complaint was filed with Nissan and they claim it is part of standard warranty and thus not covered, and they have not issued a recall. I informed them of my intent to proceed with complaints to NHTSA and a class action lawsuit if necessary to force a recall of this defect that is causing safety issues for all owners of Nissan Pathfinders of similar vintage.

- Norwalk, CT, USA

problem #2

Oct 202007

Pathfinder 4WD 6-cyl

  • Automatic transmission
  • miles
2002 Nissan Pathfinder has leaking exhaust tube that fail emissions test. Nissan has a tsb ntb04-092 but does not pay to fix this issue. The repair is a patch with questionable durability. Since this leak is directly beneath passenger compartment, an idling vehicle would pose a threat to occupants.

- Wilmington, NC, USA

problem #1

Apr 292004

Pathfinder 4WD 6-cyl

  • Automatic transmission
  • 26,500 miles
Defective converter pipes. Replaced by dealer under warranty May 03. Both need to be replaced 1 year later. Beyond the 12.000 warranty. Cost approx. $2,000. Creating emissions problem.

- Maplewood, NJ, USA

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