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2009 BMW 135I

Owner reports · Recalls · Investigations

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There is not enough comparable history to draw a useful model-year comparison.

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Owner complaints by model year

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

All reported categories

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When problems were reported

Mileage at the reported incident

25 reports with mileage · 4 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Fuel System, Gasoline. Review the 13 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Air Bags. Review the 3 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

0 crash reports0 fire reports0 injury reports

What owners actually said

29 reports
Mileage unknown · Apr 18, 2022
Unknown Or Other

glass sun roof exploded spontaneously while driving at freeway speeds.

NHTSA ODI #11461159

57,000 miles · May 5, 2021
Electrical SystemStructure

TL* THE CONTACT OWNS A 2009 BMW 135I. THE CONTACT STATED THAT UPON TAKING HIS VEHICLE FOR SERVICE AT OTTO'S BMW (1275 WILMINGTON PIKE, WEST CHESTER, PA 193820) HE WAS INFORMED THAT THE ROLL OVER CONTROL MODULE WAS DEFECTIVE. THE CONTACT CALLED THE MANUFACTURER AND WAS INFORMED THAT THE VIN WAS NOT UNDER RECALL. THE CONTACT WAS P…

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TL* THE CONTACT OWNS A 2009 BMW 135I. THE CONTACT STATED THAT UPON TAKING HIS VEHICLE FOR SERVICE AT OTTO'S BMW (1275 WILMINGTON PIKE, WEST CHESTER, PA 193820) HE WAS INFORMED THAT THE ROLL OVER CONTROL MODULE WAS DEFECTIVE. THE CONTACT CALLED THE MANUFACTURER AND WAS INFORMED THAT THE VIN WAS NOT UNDER RECALL. THE CONTACT WAS PROVIDED AN ESTIMATE FOR THE REPAIR WHICH HE DECLINED. THE VEHICLE WAS NOT YET REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 57,000. I TOOK MY CAR TO OTTO'S BMW FOR A STATE INSPECTION, NOT FOR ANY OTHER SERVICE, AND OTTO'S DID NOT INFORM ME THAT THE ROC MODULE HAD FAILED. I FOUND OUT THE MODULE HAD FAILED BY USING MY CODE READER. WHEN I TRIED TO START MY CAR TO TAKE IT FOR THE STATE INSPECTION, I FOUND THE BATTERY HAD DIED. WHEN I REPLACED THE BATTERY, I FOUND THAT THE ROC MODULE HAD FAILED JUST BECAUSE MY CAR BATTERY DIED. THE ROC MODULE IS A MAJOR SAFETY MODULE, THAT EXTENDS THE HEAD PROTECTION IN A ROLL OVER ACCIDENT. THIS MODULE SHOULDN'T FAIL SIMPLY BECAUSE YOUR CAR BATTERY DIES. RESEARCH ONLINE SHOWS MANY OWNERS OF BMW'S EXPERIENCE THIS MODULE FAILURE JUST BECAUSE THEIR BATTERY WAS DISCONNECTED OR THEIR BATTERY HAD FULLY DISHARGED. I HAVE NEVER OWNED ANY OTHER CAR THAT A MAJOR SAFETY MODULE FAILED JUST BECAUSE THE BATTERY DISCHARGES. EVERY OTHER CAR, I WOULD SIMPLY REPLACE THE BATTERY AND EVERYTHING STILL WORKED. THIS IS A MAJOR SAFETY ISSUE WHEN THIS MODULE FAILS, AS THE ROLL OVER PROTECTION DEVICES WILL NOT ACTIVATE IN A ROLL OVER ACCIDENT, AND THIS CAR IS A CONVERTIBLE. THIS MODULE COSTS OVER $500 AT BMW DEALERS, AND SEVERAL HUNDRED MORE FOR INSTALLATION CHARGES. FURTHER RESEARCH ONLINE SHOWS THAT MANY OWNERS FAIL TO HAVE THIS REPAIR DONE DUE TO THE VERY HIGH COST, OR THEY GO TO A SECONDARY MARKET WHERE THESE MODULES ARE REPAIRED FOR A LOWER PRICE. ALL OF THIS IS SETTING UP OWNERS FOR MAJOR INJURY OR DEATH IF THEY ARE INVOLVED IN A ROLL OVER ACCIDENT AND THIS MODULE IS NOT WORKING PROPERLY. BMW SHOULD BE REQUIRED TO REPAIR THIS OR AT LEAST OFFER A COST EFFECTIVE SOLUT

NHTSA ODI #11415310

80,000 miles · Jan 20, 2021
Electrical SystemExterior LightingService Brakes

TAIL LIGHTS BURN OUT AND REQUIRE ENTIRE HOUSING TO BE REPLACED INSTEAD OF JUST BULBS. LED'S BURN OUT VERY QUICKLY, CONTRARY TO TYPICAL LED'S AND ARE COSTLY TO REPLACE

NHTSA ODI #11389074

142,000 miles · Sep 23, 2019
Exterior Lighting

THE WIRING OF MY 2009 BMW HEADLIGHTS, BOTH SIDES, HAS ITS INSULATION DISINTEGRATE, EXPOSING BARE COPPER WIRE (AS IT IS MADE OF BIODEGRADABLE MATERIAL) TO THE POINT WHERE MY DAYTIME RUNNING LIGHTS HAVE SHORTED OUT AND THE ADAPTIVE HEADLIGHT CONTROL ON THE PASSENGER HEADLIGHT IS STUCK AT AN ANGLE THAT IS TOO HIGH. AS THESE ARE AD…

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THE WIRING OF MY 2009 BMW HEADLIGHTS, BOTH SIDES, HAS ITS INSULATION DISINTEGRATE, EXPOSING BARE COPPER WIRE (AS IT IS MADE OF BIODEGRADABLE MATERIAL) TO THE POINT WHERE MY DAYTIME RUNNING LIGHTS HAVE SHORTED OUT AND THE ADAPTIVE HEADLIGHT CONTROL ON THE PASSENGER HEADLIGHT IS STUCK AT AN ANGLE THAT IS TOO HIGH. AS THESE ARE ADAPTIVE HEADLIGHTS, A SHORT HERE CAN RENDER THE CAR'S HEADLIGHT IN A BLINDING STATE. LOCAL SHOPS WANT TO CHARGE $900+ PER LIGHT HOUSING TO COMPLETELY REPLACE THE LIGHT ASSEMBLY.

NHTSA ODI #11257434

93,000 miles · Nov 8, 2018
Fuel/propulsion System

HIGH PRESSURE FUEL PUMP IS BAD IN CAR. THE CAR GOES INTO LIMP MODE ON HIGHWAY WHEN PASSING CAR LEAVING YOU NO POWER TO GET OUT OF THE WAY OF CAR GOING 75 MPH. BMW KNOWS IT BAD BUT WILL NOT HELP!

NHTSA ODI #11150173

70,000 miles · Nov 3, 2017
Electrical SystemExterior Lighting

WIRING INSIDE HEADLIGHT ASSEMBLY HAS INSUFFICIENTLY INSULATED WIRING. THE WIRE INSULATION IS FLAKING OFF DUE TO HEAT EXPOSURE FROM NORMAL OPERATING CONDITIONS. THIS IS A SAFETY PROBLEM. FIRE POTENTIAL. LIGHTS COULD STOP WORKING WHILE DRIVING AT NIGHT.

NHTSA ODI #11043012

Mileage unknown · Jul 24, 2017
Air Bags

TL* TAKATA RECALL. THE CONTACT OWNS A 2009 BMW 135I CONVERTIBLE. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V071000 (AIR BAGS); HOWEVER, THE PARTS TO DO THE REPAIR WERE UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE DEALER (SUN MOTOR CARS, …

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TL* TAKATA RECALL. THE CONTACT OWNS A 2009 BMW 135I CONVERTIBLE. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V071000 (AIR BAGS); HOWEVER, THE PARTS TO DO THE REPAIR WERE UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE DEALER (SUN MOTOR CARS, INC. 6677 CARLISLE PIKE, MECHANICSBURG, PA 17050 (717) 691-3333) WAS CONTACTED AND CONFIRMED THAT THE PARTS WERE UNAVAILABLE FOR THE RECALL REMEDY. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE AND CONFIRMED WITH THE CONTACT THAT HIS VIN WAS IN PRIORITY GROUP 5 AND PARTS WOULD NOT BE AVAILABLE UNTIL LATE SEPTEMBER. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.

NHTSA ODI #11010246

Mileage unknown · Jul 3, 2017
Air Bags

THERE IS A RECALL AND IT IS INCOMPLETE DUE TO IT NOT BEING REPLACED IN A TIMELY MANNER NO INCIDENT AS OF NOW BUT NEEDS TO BE REPLACED.

NHTSA ODI #11002908

Mileage unknown · May 4, 2016
Air Bags

TL* TAKATA RECALL. THE CONTACT OWNS A 2009 BMW 135I. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V071000 (AIR BAGS); HOWEVER, THE PART NEEDED TO REPAIR THE VEHICLE WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOTIFIED …

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TL* TAKATA RECALL. THE CONTACT OWNS A 2009 BMW 135I. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V071000 (AIR BAGS); HOWEVER, THE PART NEEDED TO REPAIR THE VEHICLE WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. VIN TOOL CONFIRMS PARTS NOT AVAILABLE. UPDATED 07/12/16*LJ UPDATED 07/14/16. *JB

NHTSA ODI #10863013

8,500 miles · Apr 13, 2015
EngineFuel/propulsion System

AT 8,532 MILES MY BMW 135I HAD A HIGH PRESSURE FUEL PUMP FAILURE THAT CAUSED MY CAR TO DECELERATE BELOW THE SPEED OF TRAFFIC. AT 24,384 MILES THE CAR ILLUMINATED A ENGINE CAUTION FOR OVER TEMPERATURE. THE ONLY GAUGE AVAILABLE WAS FOR OIL TEMPERATURE WHICH DID NOT INDICATE HOT. THERE WAS NOT A SHOULDER TO PULL OVER FOR 3 MILES. …

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AT 8,532 MILES MY BMW 135I HAD A HIGH PRESSURE FUEL PUMP FAILURE THAT CAUSED MY CAR TO DECELERATE BELOW THE SPEED OF TRAFFIC. AT 24,384 MILES THE CAR ILLUMINATED A ENGINE CAUTION FOR OVER TEMPERATURE. THE ONLY GAUGE AVAILABLE WAS FOR OIL TEMPERATURE WHICH DID NOT INDICATE HOT. THERE WAS NOT A SHOULDER TO PULL OVER FOR 3 MILES. *TR

NHTSA ODI #10705277

Official recalls

4

20V017000 · Air Bags:frontal:driver Side:inflator Module

Jan 15, 2020

BMW of North America, LLC (BMW) is recalling certain 2008-2013 128i and 135i Convertibles, 128i, 135i, and M Coupes, 2007-2010 X3 30si and X3 xDrive30i, 2013-2015 X1 sDrive28i, X1 xDrive28i and X1 xDrive35i, 2007-2013 328i, 328i xDrive, 335i, 335is, 335i xDrive and M3 Coupes, 2006-2011 328i, 328xi, 328i xDrive, 325i, 325xi, 330i, 330xi, 335i, 335xi, 335i xDrive and M3, 2009-2011 335D, 2006-2012 325xi, 328i, 328xi and 328i xDrive, 2010-2011 X6 ActiveHybrid, 2007-2013 328i, 335i, 335is, M3 Coupes, X5 30si, X5 xDrive30i, X5 xDrive35i, X5 48i, X5 xDrive48i, X5 xDrive50i and X5 M, 2009-2013 X5 xDrive35d and 2008-2014 X6 xDrive35i, X6 xDrive50i and X6M vehicles equipped with non-desiccated driver frontal air bag inflators containing phase stabilized ammonium nitrate (PSAN) that were used as interim remedy parts for previous Takata recalls. These inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.

Consequence & remedy

Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.

Remedy: BMW will notify owners, and dealers will replace the driver air bag. On X5 and X6 vehicles, only the inflator will be replaced. All repairs will be performed free of charge. The recall began March 11, 2020. Owners may contact BMW customer service at 1-800-525-7417.

19V579000 · Electrical System:wiring

Aug 6, 2019

BMW of North America, LLC (BMW) is recalling certain 2008-2012 BMW 128i, 135i, 135is Coupes and 128i, 135i Convertible vehicles. The wiring and electrical connectors in the blower-regulator wiring harness may overheat.

Consequence & remedy

Consequence: Wiring that overheats could cause the electrical connectors to melt, and increase the risk of a fire, even when the vehicle is unattended.

Remedy: BMW will notify owners, and dealers will inspect the blower-regulator wiring harness, and replace it with a new part, free of charge. The recall began October 4, 2019. Owners may contact BMW customer service at 1-800-525-7417. Note: This recall is an expansion of an earlier recall number 17V-676.

16V071000 · Air Bags:frontal:driver Side:inflator Module

Feb 5, 2016

BMW of North America, LLC (BMW) is recalling certain model year 2008-2013 128i and 135i coupes and convertibles and 1 Series M coupes, 2006-2011 325i, 325xi, 328i, 328xi, 328i xDrive, 330i, 330xi, 335i, 335xi, 335i xDrive Sedans, 2009-2011 335d sedans, 2006-2012 325xiT, 328i and 328xi sports wagons, 2007-2013 328i, 328xi, 328i xDrive, 335i, 335xi, 335i xDrive, 335is and M3 Coupes and Convertibles, 2013-2015 X1 sDrive28i, X1 xDrive28i and X1 xDrive35i SAVs, 2007-2010 X3 xDrive30i SAVs, 2007-2013 X5 xDrive30i, X5 xDrive35i, X5 xDrive48i, X5 xDrive50i and X5 M SAVs, 2009-2013 BMW X5 xDrive35d SAVs, 2008-2014 X6 xDrive35i, X6 xDrive50i, and X6 M SACs, 2010-2011 BMW X6 xDrive50i SACs and 2008-2011 M3 Sedan vehicles. Upon deployment of the driver's frontal air bag, excessive internal pressure may cause the inflator to rupture.

Consequence & remedy

Consequence: In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could rupture with metal fragments striking the driver or other occupants resulting in serious injury or death.

Remedy: BMW will notify owners, and dealers will replace the driver's frontal air bag module or inflator depending on the vehicle model, free of charge. The recall began March 9, 2018. Owners may contact BMW customer service at 1-800-525-7417.

13V044000 · Electrical System; Electrical SYSTEM:12V/24V/48V Battery:cables; Electrical System:wiring:fuses And Circuit Breakers

Feb 7, 2013

BMW is recalling certain model year 2008-2012 1-Series coupes and convertibles manufactured December 2007 through September 2011; and 2007-2011 3-Series coupes and convertibles manufactured March 2007 through October 2011; 2007-2011 3-Series sedans manufactured March 2007 through October 2011; 2007-2011 3-Series sports wagons manufactured March 2007 through June 2011; and 2009-2011 Z4 vehicles manufactured March 2009 through June 2011. In February 2013, BMW recalled 504,545 vehicles. In July 2013, BMW informed the agency that it was adding 1-Series, 3-Series, and Z4 vehicles, representing an additional 12,094 vehicles. The total number of vehicles being recalled is now 516,791. The connector for the positive battery cable connector and the corresponding terminal on the fuse box may degrade over time. Over time, the high current flow and heat from electrical resistance may lead to a breakage of the connection, and a loss of electrical power to the vehicle.

Consequence & remedy

Consequence: If there is a loss of electrical power to the vehicle, the vehicle may unexpectedly stall, increasing the risk of a crash.

Remedy: BMW will notify owners, and dealers will replace the positive battery cable connector and secure it with an improved method, free of charge. The recall began on March 13, 2013. Owners may call BMW at 1-800-525-7417 or email BMW at CustomerRelations@bmwusa.com.

Additional source detail variants (3)

Electrical System:wiring:fuses And Circuit Breakers

BMW is recalling certain model year 2008-2012 1-Series coupes and convertibles manufactured December 2007 through September 2011; and 2007-2011 3-Series coupes and convertibles manufactured March 2007 through October 2011; 2007-2011 3-Series sedans manufactured March 2007 through October 2011; 2007-2011 3-Series sports wagons manufactured March 2007 through June 2011; and 2009-2011 Z4 vehicles manufactured March 2009 through June 2011. In February 2013, BMW recalled 504,545 vehicles. In July 2013, BMW informed the agency that it was adding 1-Series, 3-Series, and Z4 vehicles, representing an additional 12,094 vehicles. The total number of vehicles being recalled is now 516,791. The connector for the positive battery cable connector and the corresponding terminal on the fuse box may degrade over time. Over time, the high current flow and heat from electrical resistance may lead to a breakage of the connection, and a loss of electrical power to the vehicle.

Consequence: If there is a loss of electrical power to the vehicle, the vehicle may unexpectedly stall, increasing the risk of a crash.

Remedy: BMW will notify owners, and dealers will replace the positive battery cable connector and secure it with an improved method, free of charge. The recall began on March 13, 2013. Owners may call BMW at 1-800-525-7417 or email BMW at CustomerRelations@bmwusa.com.

Electrical SYSTEM:12V/24V/48V Battery:cables

BMW is recalling certain model year 2008-2012 1-Series coupes and convertibles manufactured December 2007 through September 2011; and 2007-2011 3-Series coupes and convertibles manufactured March 2007 through October 2011; 2007-2011 3-Series sedans manufactured March 2007 through October 2011; 2007-2011 3-Series sports wagons manufactured March 2007 through June 2011; and 2009-2011 Z4 vehicles manufactured March 2009 through June 2011. In February 2013, BMW recalled 504,545 vehicles. In July 2013, BMW informed the agency that it was adding 1-Series, 3-Series, and Z4 vehicles, representing an additional 12,094 vehicles. The total number of vehicles being recalled is now 516,791. The connector for the positive battery cable connector and the corresponding terminal on the fuse box may degrade over time. Over time, the high current flow and heat from electrical resistance may lead to a breakage of the connection, and a loss of electrical power to the vehicle.

Consequence: If there is a loss of electrical power to the vehicle, the vehicle may unexpectedly stall, increasing the risk of a crash.

Remedy: BMW will notify owners, and dealers will replace the positive battery cable connector and secure it with an improved method, free of charge. The recall began on March 13, 2013. Owners may call BMW at 1-800-525-7417 or email BMW at CustomerRelations@bmwusa.com.

Electrical System

BMW is recalling certain model year 2008-2012 1-Series coupes and convertibles manufactured December 2007 through September 2011; and 2007-2011 3-Series coupes and convertibles manufactured March 2007 through October 2011; 2007-2011 3-Series sedans manufactured March 2007 through October 2011; 2007-2011 3-Series sports wagons manufactured March 2007 through June 2011; and 2009-2011 Z4 vehicles manufactured March 2009 through June 2011. In February 2013, BMW recalled 504,545 vehicles. In July 2013, BMW informed the agency that it was adding 1-Series, 3-Series, and Z4 vehicles, representing an additional 12,094 vehicles. The total number of vehicles being recalled is now 516,791. The connector for the positive battery cable connector and the corresponding terminal on the fuse box may degrade over time. Over time, the high current flow and heat from electrical resistance may lead to a breakage of the connection, and a loss of electrical power to the vehicle.

Consequence: If there is a loss of electrical power to the vehicle, the vehicle may unexpectedly stall, increasing the risk of a crash.

Remedy: BMW will notify owners, and dealers will replace the positive battery cable connector and secure it with an improved method, free of charge. The recall began on March 13, 2013. Owners may call BMW at 1-800-525-7417 or email BMW at CustomerRelations@bmwusa.com.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

1

EA21002 · Desiccated Air Bag Inflator Rupture

Opened Sep 17, 2021 · No close date supplied

Status: open (inferred from source dates) · Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:passenger Side:inflator Module

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

Additional source detail variants (2)

Air Bags:frontal:driver Side:inflator Module

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

Air Bags:frontal:passenger Side:inflator Module

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.