NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
15 reportsClear category filterMileage unknown · Aug 5, 2026
Fuel/propulsion System
On XXX, while driving on Interstate XXX with my family near [XXX], the engine shut off and the vehicle lost all power. The event was preceded by a "Reduced Power" error displayed on the dashboard. Traffic was moderate and I was able to pull over to the right shoulder. The engine shutting off while on an interstate highway is obv…
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On XXX, while driving on Interstate XXX with my family near [XXX], the engine shut off and the vehicle lost all power. The event was preceded by a "Reduced Power" error displayed on the dashboard. Traffic was moderate and I was able to pull over to the right shoulder. The engine shutting off while on an interstate highway is obviously quite dangerous. After waiting for a few minutes I was able to restart the car and continue travel. I took my vehicle to a mechanic and several potentially relevant codes were found: 110001: Cylinder injection shutdown: pressure too low in high pressure system 11A002: Fuel high pressure, plausibility: pressure too low 481B03: EKPS control current too low Review of the issue and codes with the mechanic and internet forums indicates the fuel pump control module (EKPS) is failing. This can be exacerbated by hot weather. A failing EKPS can cause sudden stalling at any time, including at highway speeds, making the vehicle unsafe to drive until repaired. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11754958
Mileage unknown · Jul 17, 2026
Electrical SystemEngineFuel/propulsion System
The engine intake tract, PCV infrastructure, and the main lower engine wiring harness loom failed due to improper reassembly during Federal Safety Recall 24V-608. The technician left the main intake coupler completely loose and spinning freely by hand, and left the MAF sensor crooked. This introduced a massive unmetered air leak…
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The engine intake tract, PCV infrastructure, and the main lower engine wiring harness loom failed due to improper reassembly during Federal Safety Recall 24V-608. The technician left the main intake coupler completely loose and spinning freely by hand, and left the MAF sensor crooked. This introduced a massive unmetered air leak and severe vacuum leaks. Simultaneously, the technician over-tensioned, pinched, or damaged the Cylinder 2 wiring loom components. The vehicle is currently parked dead and untouched at my residence, and it is 100% available for immediate federal or corporate inspection.The unsealed intake tract and damaged wiring harness caused the engine to run dangerously lean at highway speeds. This resulted in sudden, violent engine shuttering, rapid deceleration, severe mechanical engine knocking, and a terminal Cylinder 2 misfire. This component failure caused an immediate loss of vehicle propulsion on a high-speed public highway, creating an extreme risk of a high-speed collision and leaving the vehicle completely disabled. The issue has not yet been physically inspected by a third party because the vehicle is unsafe to drive. I went to the originating dealer (BMW of Henderson) in person on July 16, 2026, to coordinate a safety re-inspection under an active BMW North America Corporate Case. Dealership management actively obstructed the safety process, gave technically impossible justifications regarding the recall execution, and flatly refused to dispatch a complimentary flatbed tow. They attempted to hold the safety re-inspection hostage behind out-of-pocket customer towing costs and upfront retail diagnostic fees. There were 0 mechanical warnings or symptoms prior to the recall. The vehicle was meticulously maintained with 5,000-mile oil changes and a perfectly tight timing chain. The severe drivetrain malfunction warnings, violent front-end shaking, and terminal engine knocking appeared after picking up my car.
NHTSA ODI #11751142
Mileage unknown · May 14, 2026
EngineExterior LightingFuel/propulsion SystemFire
I Was In My Vehicle Parked Up On January 1st 2026 And The Vehicle Caught On Fire While I Was Inside Of It,The Fire Started From The Right Side Of The Car And Flamed Up Everything,The Car Had A Check Engine Light On And A Lightning System Issue Was Popping Up On The Dash Right Before This Situation Accord I Did Research And Found…
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I Was In My Vehicle Parked Up On January 1st 2026 And The Vehicle Caught On Fire While I Was Inside Of It,The Fire Started From The Right Side Of The Car And Flamed Up Everything,The Car Had A Check Engine Light On And A Lightning System Issue Was Popping Up On The Dash Right Before This Situation Accord I Did Research And Found That The Cause Of The Fire Is Related To NHTSA Recall 24V-608 (Water Pump/Connector Fire Risk).
NHTSA ODI #11737824
Mileage unknown · Jan 16, 2026
Electrical SystemEngineFuel/propulsion SystemFire
On November 17, 2025, my 2015 BMW 328i (VIN: [XXX] ) caught fire while parked, locked, and turned off inside my enclosed residential garage in Irvine, California. The vehicle had been parked for approximately 90 minutes prior to the incident. No flammable materials were stored in or around the vehicle. Responding police and fir…
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On November 17, 2025, my 2015 BMW 328i (VIN: [XXX] ) caught fire while parked, locked, and turned off inside my enclosed residential garage in Irvine, California. The vehicle had been parked for approximately 90 minutes prior to the incident. No flammable materials were stored in or around the vehicle. Responding police and fire personnel identified the vehicle itself as the source of the fire, with ignition originating in the engine bay. The building’s fire sprinkler system activated, and residents were evacuated due to smoke and fire conditions. No injuries occurred, but the incident posed a serious risk to life and property due to the residential setting. The vehicle was a total loss. While the exact technical cause of ignition could not be determined at the scene, first responders confirmed that the fire originated within the vehicle’s engine compartment. BMW of North America was notified of the incident and represented that an inspection would be coordinated. I remained in contact with all involved parties and relied on BMW’s stated intent to contact the tow facility directly to arrange inspection. Despite this, BMW did not make contact with the tow company prior to the vehicle’s disposal. After the vehicle had already been sold by the tow yard, BMW indicated that coordination had not occurred and that inspection was no longer possible, resulting in loss of physical evidence. This complaint is submitted due to concern regarding a vehicle fire occurring while the vehicle was not in operation, inside a residential structure, and due to the manufacturer’s handling of the matter in a way that prevented timely inspection and meaningful safety review despite early notification and cooperation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11711412
Mileage unknown · Jun 21, 2025
EngineFuel/propulsion SystemPower Train
Engine coolant pump recall (August 2024) with no remedy to this day. Has caused major smoking issues from exhaust and engine. The turbocharger has been affected and deemed inoperable. Fluid leaks from chassis and engine bay. The car is inoperable. Prior to being unable to drive I was experiencing transmission issues, went for …
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Engine coolant pump recall (August 2024) with no remedy to this day. Has caused major smoking issues from exhaust and engine. The turbocharger has been affected and deemed inoperable. Fluid leaks from chassis and engine bay. The car is inoperable. Prior to being unable to drive I was experiencing transmission issues, went for a few repairs but would experience the car coming to a complete stop on its own at highway speeds. Experienced this on the bridge, being left stuck and almost causing a wreck. Made the bridge very unsafe for others. I had a “drive train malfunction” warning& check engine light that I thought was fixed with multiple mechanic trips but problems have only gotten worse. No inspections have been done in regards to the recall. The car has sat unable to drive for 2 full months now.
NHTSA ODI #11668307
Mileage unknown · Sep 6, 2023
EngineFuel/propulsion System
Drivetrain malfunction warning comes on when the car runs for a few hours in the heat or when randomly driving. Sometimes the warning will clear itself after waiting a few minutes, but it might come back after a few minutes driving or not. In other instances, the drivetrain will not clear itself and will take more than a few hou…
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Drivetrain malfunction warning comes on when the car runs for a few hours in the heat or when randomly driving. Sometimes the warning will clear itself after waiting a few minutes, but it might come back after a few minutes driving or not. In other instances, the drivetrain will not clear itself and will take more than a few hours. Took it to the repair shop 3 times and they indicated it could be the fuel pump modular or spark plugs or it could just be that the heat is messing up the software system. The mechanic has mentioned that drivetrain malfunctions have been occurring more regularly with BMWs. The issue is that this drivetrain can malfunction at any random time. Driving on a highway, street, or just starting up the car after letting it sit for a few minutes or days. It's a safety hazard because it can happen at any time unexpectedly. When it does, the car goes into neutral and this is dangerous if driving on the highway at higher speeds and needing to pull over into right hand lane. I've not yet taken it to a dealer to look at, just a certified BMW repair shop. There have been no warning issues and the car clears whenever it is taken to the repair shop.
NHTSA ODI #11542816
Mileage unknown · May 8, 2023
Fuel/propulsion SystemService BrakesCrash
My son's 2015, BMW 328i was taken to BMW in Canton, Ohio due to "fluttering" in gas pedal and "possible transmission slipping and variations in transmission while driving. The check engine light was on and was diagnosed at dealership that the Mass Flow Sensor was malfunctioning. The wires to the Mass Flow Sensor were corroded a…
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My son's 2015, BMW 328i was taken to BMW in Canton, Ohio due to "fluttering" in gas pedal and "possible transmission slipping and variations in transmission while driving. The check engine light was on and was diagnosed at dealership that the Mass Flow Sensor was malfunctioning. The wires to the Mass Flow Sensor were corroded and needed fixed before sensor could be assessed. The wires were fixed and the check engine light went out so the car was considered by the BMW dealer service department to be fixed and I paid $545 for $42 in parts and $503 in labor. The service advisor named Mark, assured me that it had been test driven by service technician and that the car was in proper working condition. I picked the car up, for my son, at 10 am and drove south to West Virginia to deliver the car to my son. At 12:15, I pulled off the freeway and stopped at a light that was at a busy intersection, with a car in front of me. I came to a complete stop with my foot on the brake and my car accelerated at a high speed with my foot completely on the brake almost to the floor. I rammed into the car in front of me and the car flew forward 500 feet. My BMW stopped after it hit the car in front of me. I sat in the car in shock with my foot still on the brake as the driver in front of me came to my window and asked me " what the hell are you doing"? She could clearly see that my foot was still on the brake. There were minor scratches on her bumper and, her and her son had sore necks. The front of my car had a broken grill, and other broken pieces. Broken pieces were lying on thre road. I called AAA and had it towed to BMW in St. Albans, West Virginia. A call was made to Canton, BMW and Corporate BMW to make a report on BMW rapidly accelerating with brakes completely on. Corporate personelle are to call me to get a report from me and send a special team to investigate the "rapid acceleration" while the brakes were on. Now awaiting for the 2015 BMW 328i to be looked at.
NHTSA ODI #11521081
Mileage unknown · Feb 1, 2023
Fuel/propulsion SystemService BrakesUnknown Or OtherCrashInjury
Reporting very dangerous sudden unintended acceleration of 2015 BMW 328i: When about to back out of a parking space in a parking garage, I pressed the brakes and turned on the ignition switch. After looking around to ensure no cars or people were near the car, I put the gear shift in reverse, turned my whole head entirely over m…
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Reporting very dangerous sudden unintended acceleration of 2015 BMW 328i: When about to back out of a parking space in a parking garage, I pressed the brakes and turned on the ignition switch. After looking around to ensure no cars or people were near the car, I put the gear shift in reverse, turned my whole head entirely over my right shoulder to look through the back windshield and, seeing nothing behind me, began to slowly lift my foot from the brake to reverse out of the parking space. I turned the steering wheel towards the left and the back of the car went to the left. The bumper gently tapped a white column that had been out of sight all the way further over my right shoulder. I gently pressed on the brake, and when I switched the gear shift into drive, the car suddenly and explosively accelerated forward extremely fast and sped out of control. I pressed the brakes to stop the car, which did nothing, and the car slammed into cement wall so hard that it sounded like an explosion and the air bags deployed. I hit my mouth/face/head on the air bag and got whiplash from the sudden stop. When I got out of the car, a couple who’d heard the explosion drove by and asked if I was ok. After a few moments I reached into the car to turn off ignition switch. This event resulted in very serious damage to the car, which was totaled, and I received medical injuries. This incident was reported to my automobile insurance company and to North America BMW, who has escalated the report to higher levels due to the seriousness of the incident, and will be doing investigations this week. The accelerator pedal or gear box dangerously and seriously malfunctioned, and the car is available for inspection upon request. My safety was seriously at risk as I have headaches and whiplash symptoms. If there were no wall there, or if there had been people or cars anywhere in front of the car, they would have been killed and smashed because the car suddenly accelerated so quickly.
NHTSA ODI #11504968
Mileage unknown · Sep 13, 2022
Fuel/propulsion System
while im driving at my normal speed about 70mph the car start to get in safe mode, i was on the free way at the time so the car start to stop and lost accerlation, when i checl with my mechanic he told me i need to change the fuel pump and i found out there is a complane "Report Receipt Date: MAR 31, 2015 NHTSA Campaign Number…
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while im driving at my normal speed about 70mph the car start to get in safe mode, i was on the free way at the time so the car start to stop and lost accerlation, when i checl with my mechanic he told me i need to change the fuel pump and i found out there is a complane "Report Receipt Date: MAR 31, 2015 NHTSA Campaign Number: 15V189000 Component(s): FUEL SYSTEM, GASOLINE Potential Number of Units Affected: 18,054" but when i called the dealership they told me im not covered to fix the problem but my car was listed on here" Manufacturer: BMW of North America, LLC SUMMARY: BMW of North America LLC (BMW) is recalling certain model year 2014 228i Coupe, M235i Coupe, 320i, 320xi, 328i, 328xi, 335i, 335xi, ActiveHybrid 3, 328xi Sports Wagon, 428i Coupe, 428xi Coupe, 435i Coupe, 435xi Coupe, 428i Convertible, 428xi Convertible, 435i Convertible, 328xi Gran Turismo, 335xi Gran Turismo, and 2015 428i Gran Coupe, 428xi Gran Coupe, and 435i Gran Coupe vehicles. Improper nickel plating of components within the fuel pump may result in the fuel pump failing.
NHTSA ODI #11484264
Mileage unknown · Jul 15, 2021
Fuel/propulsion System
My girlfriend has owned this vehicle for about two years now. Along with other maintenance (all understandable until now) there is a $2000 cost. The Fuel tank has started leaking due to a major design flaw by BMW. To save money they (bmw) used tanks from previous model years and glued a cap over a no longer needed hole and now t…
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My girlfriend has owned this vehicle for about two years now. Along with other maintenance (all understandable until now) there is a $2000 cost. The Fuel tank has started leaking due to a major design flaw by BMW. To save money they (bmw) used tanks from previous model years and glued a cap over a no longer needed hole and now the cap is not sealing and the tank is leaking! If you do not believe me look at pictures of used 2015 BMW 328i fuel tanks. It is beyond me why a car so expensive could have something designed so amateur.
NHTSA ODI #11424997
Official recalls
4Aug 13, 2024
BMW of North America, LLC. (BMW) is recalling certain 2012-2015 X1 sDrive28i, X1 xDrive28i, 2012-2016 Z4 sDrive28i, 528i, 528i xDrive, 328i, 328xi, 2016-2018 X5 xdrive 40e, 2014-2016 228i, 228xi, 428i, 428i xDrive, 328xi Gran Turismo, 2013-2017 X3 sDrive28i, X3 xDrive28i, 2015-2018 X4 xDrive28i, 2015-2016 428xi vehicles. An improperly sealed electrical connector on the water pump may be exposed to water and short circuit.
Consequence & remedy
Consequence: An electrical short increases the risk of a fire.
Remedy: Dealers will inspect and replace the water pump and plug connector as necessary, and install a protective shield, free of charge. Owner notification letters were mailed on March 28, 2025. Owners may contact BMW customer service at 1-800-525-7417.
Additional source detail variants (2)
Electrical System:wiring:connectors/plugs/receptacles
BMW of North America, LLC. (BMW) is recalling certain 2012-2015 X1 sDrive28i, X1 xDrive28i, 2012-2016 Z4 sDrive28i, 528i, 528i xDrive, 328i, 328xi, 2016-2018 X5 xdrive 40e, 2014-2016 228i, 228xi, 428i, 428i xDrive, 328xi Gran Turismo, 2013-2017 X3 sDrive28i, X3 xDrive28i, 2015-2018 X4 xDrive28i, 2015-2016 428xi vehicles. An improperly sealed electrical connector on the water pump may be exposed to water and short circuit.
Consequence: An electrical short increases the risk of a fire.
Remedy: Dealers will inspect and replace the water pump and plug connector as necessary, and install a protective shield, free of charge. Owner notification letters were mailed on March 28, 2025. Owners may contact BMW customer service at 1-800-525-7417.
Engine And Engine Cooling:cooling System:pump
BMW of North America, LLC. (BMW) is recalling certain 2012-2015 X1 sDrive28i, X1 xDrive28i, 2012-2016 Z4 sDrive28i, 528i, 528i xDrive, 328i, 328xi, 2016-2018 X5 xdrive 40e, 2014-2016 228i, 228xi, 428i, 428i xDrive, 328xi Gran Turismo, 2013-2017 X3 sDrive28i, X3 xDrive28i, 2015-2018 X4 xDrive28i, 2015-2016 428xi vehicles. An improperly sealed electrical connector on the water pump may be exposed to water and short circuit.
Consequence: An electrical short increases the risk of a fire.
Remedy: Dealers will inspect and replace the water pump and plug connector as necessary, and install a protective shield, free of charge. Owner notification letters were mailed on March 28, 2025. Owners may contact BMW customer service at 1-800-525-7417.
Jul 11, 2024
BMW of North America, LLC (BMW) is recalling certain 2015 6 Series Gran Coupe, 2014 5 Series Gran Turismo, 2014 5 Series Sedan, 2015 6 Series Convertible, 2015 6 Series Coupe, 2014 X5, 2013-2014 X3, 2014-2015 3 Series Sedan, 2014 4 Series Coupe, 2014 4 Series Convertible, 2014 3 Series Gran Turismo, and 2015 4 Series Gran Coupe vehicles. Please see the recall report for the complete list of models. The driver's air bag inflator may explode during deployment, due to a manufacturing defect.
Consequence & remedy
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, increasing the risk of injury or death.
Remedy: The driver's front air bag will be replaced, free of charge. Owner notification letters were mailed September 6, 2024. Owners may contact BMW customer service at 1-800-525-7417.
Apr 24, 2024
BMW of North America, LLC (BMW) is recalling certain 2014-2015 2 Series Coupe (228i, 228i xDrive, M235i), 3 Series Sedan (320i, 320i xDrive, 328i, 328i xDrive, 335i, 335i xDrive, M3, 328d, 328d xDrive), 4 Series Coupe (428i, 428i xDrive, 435i, 435i xDrive, M4), and 2015 4 Series Gran Coupe (428i, 428i xDrive, 435i, 435i xDrive) vehicles. The head air bag inflator may fail at the weld joint, which can cause gas to leak from the inflator or result in an inflator rupture.
Consequence & remedy
Consequence: An inflator that ruptures may cause sharp metal fragments to enter or exit the vehicle, increasing the risk of injury. Additionally, an inflator that leaks gas may only partially inflate during a crash, increasing the risk of injury.
Remedy: Dealers will replace the head air bags, free of charge. Owner notification letters were mailed November 4, 2024. Owners may contact BMW customer service at 1-800-525-7417.
Aug 17, 2015
BMW North America, LLC (BMW) is recalling certain model year 2012-2015 320i, 320xi, 328i, 328xi, 335i, 335xi, and ActiveHybrid3 vehicles manufactured October 20, 2011, to June 22, 2015, 2014-2015 328xi Sports Wagon vehicles manufactured March 21, 2013, to March 17, 2015, 2014-2015 328d, 328xd vehicles manufactured June 28, 2013, to April 21, 2015, and 2014-2015 328xd Sports Wagon vehicles manufactured July 5, 2013, to April 21, 2015. The affected vehicles may have been programmed with new software that inadvertently makes the front side marker lights inoperative in conjunction with the parking lights or the headlights. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, "Lamps, Reflective Devices, and Associated Equipment."
Consequence & remedy
Consequence: If the side marker lights do not illuminate, the vehicle may be less visible at night, increasing the risk of a crash.
Remedy: BMW will notify owners, and dealers will upload revised software to correct the issue, free of charge. The recall began on October 7, 2015. Owners may contact BMW customer service at 1-800-525-7417 or by email 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
1EA21002 · 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.