At random the car will display “Drivetrain Malfunction” which causes the car to shift into neutral and begins to slow down until it doesn’t move anymore. There is no check engine light or any other indicator of what might be the problem. The message just pops out of no where. It’s happen in the freeway making me scare to cause a…
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At random the car will display “Drivetrain Malfunction” which causes the car to shift into neutral and begins to slow down until it doesn’t move anymore. There is no check engine light or any other indicator of what might be the problem. The message just pops out of no where. It’s happen in the freeway making me scare to cause an accident because it so random. I’ve had to quickly turn my hazards and beginning switching lanes to avoid any accidents.
NHTSA ODI #11427667
38,000 miles · Feb 25, 2021
Unknown Or Other
THERE WERE MULTIPLE OCCASIONS (3 TIMES LAST YEAR AND 2 THIS YEAR) WHEN DRIVER SIDE DOOR LATCH FAILED TO OPEN THE DOOR. THE IMMEDIATE REMEDY IS TO UNLOCK USING THE CENTER CONSOLE LOCK/UNLOCK BUTTON. THIS IS A DANGEROUS SITUATION ESP. WHEN A CAR GETS IN AN ACCIDENT OR NOT REACH BUTTON PREVENTING SAFE ESCAPE. THIS HAS HAPPENED WHEN…
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THERE WERE MULTIPLE OCCASIONS (3 TIMES LAST YEAR AND 2 THIS YEAR) WHEN DRIVER SIDE DOOR LATCH FAILED TO OPEN THE DOOR. THE IMMEDIATE REMEDY IS TO UNLOCK USING THE CENTER CONSOLE LOCK/UNLOCK BUTTON. THIS IS A DANGEROUS SITUATION ESP. WHEN A CAR GETS IN AN ACCIDENT OR NOT REACH BUTTON PREVENTING SAFE ESCAPE. THIS HAS HAPPENED WHEN CAR HAS PARKED AND ATTEMPTING TO OPEN DOOR FROM LATCH. I ENDED UP HAVING THE CAR FIXED BY DEALER AT STEVEN CREEK BMW FOR $1200+ LAST WEEK REPLACING CABLE/LATCH ASSEMBLY. MY 328I XDRIVE IS BARELY 6 YEARS OLD AND FEEL THAT A MATURE PLATFORM SHOULD NOT PREVENT YOU FROM SAFELY EXITING YOUR CAR.
NHTSA ODI #11397830
27,904 miles · Jan 11, 2020
Unknown Or Other
DRIVER'S DOOR AND FRONT PASSENGER'S DOOR WILL NOT OPEN WITH THE INTERIOR DOOR LEVER. THIS IS AN INTERMITTENT PROBLEM THAT CAN HAPPEN ONCE A MONTH OR ONCE A WEEK. LOCK KNOB ON THE DOOR POPS UP AND THEN BACK DOWN WHEN USING THE LEVER. THE ONLY WAY TO UNLOCK THE DOOR IS TO PRESS THE DASH DOOR LOCK BUTTON. THIS IS EXTREMELY DANGEROU…
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DRIVER'S DOOR AND FRONT PASSENGER'S DOOR WILL NOT OPEN WITH THE INTERIOR DOOR LEVER. THIS IS AN INTERMITTENT PROBLEM THAT CAN HAPPEN ONCE A MONTH OR ONCE A WEEK. LOCK KNOB ON THE DOOR POPS UP AND THEN BACK DOWN WHEN USING THE LEVER. THE ONLY WAY TO UNLOCK THE DOOR IS TO PRESS THE DASH DOOR LOCK BUTTON. THIS IS EXTREMELY DANGEROUS AS ALL BMW'S HAVE AN AUTOMATIC BATTERY DISCONNECT IN THE EVENT OF AN ACCIDENT; THEREFORE THERE WOULD BE NO WAY TO EXIT THE VEHICLE! I SPOKE TO THE LOCAL BMW SERVICE AGENT AND HE SAID THEY KNEW OF THE PROBLEM BUT IT WAS NOT COVERED BY BMW. THIS SHOULD BE A SAFETY RECALL!!!!!
NHTSA ODI #11298517
Mileage unknown · Dec 24, 2018
Fuel/propulsion SystemUnknown Or Other
MY CAR SMELLS LIKE GASOLINE AND IS LEAKING GAS
NHTSA ODI #11163277
Mileage unknown · Jul 26, 2018
Unknown Or Other
DOUBLE PULL HANDLE UNLOCK FEATURE NOT WORKING. WHEN I PULL THE HANDLE AFTER TURNING OFF THE VEHICLE, THE LOCK WOULD NOT UNLOCK. INSTEAD THE KNOB RETURNS TO LOCKED POSITION UNTIL I PRESS THE UNLOCK BUTTON ON CENTER CONSOLE. AS SHOWED IN THIS VIDEO HTTPS://WWW.YOUTUBE.COM/WATCH?V=IATTXL7PMOW
NHTSA ODI #11113985
22,000 miles · Feb 8, 2018
StructureUnknown Or OtherFire
REAR SPOILER MALFUNCTION APPEARED ON MY SCREEN WHILE I WAS DRIVING ROUGHLY 30 MILES PER HOUR, THEN THE REAR SPOILER BEGAN TO SMOKE WITHIN 60 SECONDS. I PULLED THE CAR OVER TO PARK IT, AND AFTER ANOTHER 100 SECONDS, THE SPOILER CAUGHT FIRE AND WITHIN 180 MORE SECONDS THE WHOLE REAR OF THE CAR WAS ON FIRE. BY THIS TIME THE FIRE D…
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REAR SPOILER MALFUNCTION APPEARED ON MY SCREEN WHILE I WAS DRIVING ROUGHLY 30 MILES PER HOUR, THEN THE REAR SPOILER BEGAN TO SMOKE WITHIN 60 SECONDS. I PULLED THE CAR OVER TO PARK IT, AND AFTER ANOTHER 100 SECONDS, THE SPOILER CAUGHT FIRE AND WITHIN 180 MORE SECONDS THE WHOLE REAR OF THE CAR WAS ON FIRE. BY THIS TIME THE FIRE DEPARTMENT SHOWED UP AND EXTINGUISHED THE FLAMES.
NHTSA ODI #11071840
Mileage unknown · Jun 25, 2017
Unknown Or Other
MY COMPLAINT CONCERNS THE RADIO, AND RECEPTION. I HAVE BEEN TO 3 DIFFERENT DEALERSHIPS IN 3 DIFFERENT TOWNS AND HAVE BEEN TOLD ON 3 DIFFERENT OCCASIONS THE RADIO/ANTENNA IS OK. THE PROBLEM IS I HAVE A 2007 BMW AND A 3012 GOTD FUSION, AS WELL AS MY FORMER SPOUSE HAS A 2017 FORD MUSTANG AND THERE IS NO PROBLEM GETTING RADIO STATI…
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MY COMPLAINT CONCERNS THE RADIO, AND RECEPTION. I HAVE BEEN TO 3 DIFFERENT DEALERSHIPS IN 3 DIFFERENT TOWNS AND HAVE BEEN TOLD ON 3 DIFFERENT OCCASIONS THE RADIO/ANTENNA IS OK. THE PROBLEM IS I HAVE A 2007 BMW AND A 3012 GOTD FUSION, AS WELL AS MY FORMER SPOUSE HAS A 2017 FORD MUSTANG AND THERE IS NO PROBLEM GETTING RADIO STATIONS IN EITHER OF THESE VEHICLES.
NHTSA ODI #11001277
16,300 miles · Feb 1, 2017
Electrical SystemUnknown Or Other
GRAN TURISMO TAILGATE CRASHED UPON MY HEAD WITHOUT TAIL WARNING LIGHTS FLASHING OR ALARM. NO FOOT KICKING TO ACTIVATE THE FEATURE WAS INVOKED. WHILE PARKED WITH THE HATCH OPEN, I WAS SIMPLY PLACING GROCERIES INTO MY TRUNK. THE PROBLEM IS INTERMITTENT, AND CAN NOT BE REPEATED UPON DEMAND. I HAVE BEEN ABLE TO DEMO THE PROBLE…
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GRAN TURISMO TAILGATE CRASHED UPON MY HEAD WITHOUT TAIL WARNING LIGHTS FLASHING OR ALARM. NO FOOT KICKING TO ACTIVATE THE FEATURE WAS INVOKED. WHILE PARKED WITH THE HATCH OPEN, I WAS SIMPLY PLACING GROCERIES INTO MY TRUNK. THE PROBLEM IS INTERMITTENT, AND CAN NOT BE REPEATED UPON DEMAND. I HAVE BEEN ABLE TO DEMO THE PROBLEM SEVERAL TIMES SINCE THE FIRST EVENT. I ALSO UNCOVERED SEVERAL OTHER PROBLEMS WITH THE TAILGATE. THE KICKING FEATURE TO ACTIVATE TAILGATE LIFTING AND LOWERING DOESN'T WORK 100%. VIGOROUS KICKING IN DIFFERENT SPOTS IS NEEDED TO ACTIVATE THE HANDS FREE FEATURE. SOMETIMES THERE IS A PARTIAL DROP AND REOPENING OF THE TAILGATE. SOMETIMES THE ALARM WORKS AND SOMETIMES NOT. WHEN HANDS FREE CLOSING OF HATCH, AN OBSTRUCTION WILL NOT CAUSE THE DOOR TO RETREAT. FINALLY THE HATCH WILL CLOSE WITHOUT ANY WARNING.
NHTSA ODI #10948950
17,500 miles · Jul 4, 2016
Unknown Or Other
SUNROOF EXPLODED-2015 BMW 328I SEDAN-ON FRIDAY, 6/24/16 AROUND 8:15AM, WHILE TRAVELING IN WASH, DC'S RUSH HOUR TRAFFIC AT 35-45MPH ON ROUTE 295N, A LOUD BLAST, LIKE A BOMB, SUDDENLY JOLTED MY CAR! FEARFULLY, I CONTINUED TO STEER THE CAR LOOKING FOR A SAFE PLACE TO PULL OVER, WHICH WAS APPROXIMATELY 150 FEET BEYOND A CURVE IN THE…
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SUNROOF EXPLODED-2015 BMW 328I SEDAN-ON FRIDAY, 6/24/16 AROUND 8:15AM, WHILE TRAVELING IN WASH, DC'S RUSH HOUR TRAFFIC AT 35-45MPH ON ROUTE 295N, A LOUD BLAST, LIKE A BOMB, SUDDENLY JOLTED MY CAR! FEARFULLY, I CONTINUED TO STEER THE CAR LOOKING FOR A SAFE PLACE TO PULL OVER, WHICH WAS APPROXIMATELY 150 FEET BEYOND A CURVE IN THE ROAD. I PULLED OVER, MY DAUGHTER AND I WERE OK BUT BEWILDERED WHEN WE SAW A LARGE GAPING HOLE IN THE CENTER OF MY SUNROOF! I IMMEDIATELY THOUGHT THAT WE HAD BEEN SHOT OR A LARGE OBJECT HAD HIT US. GLASS CHIPS BEGAN FALLING ON US. STILL IN SHOCK, IT TOOK ME A FEW MINUTES TO REALIZE THAT I SHOULD CLOSE THE SUNSHADE! NOT KNOWING WHAT HAPPENED, WE WERE TOO SCARED TO EXIT THE CAR, SO MY DAUGHTER CALLED 911 AND I PRESSED MY SOS BUTTON FOR ASSISTANCE. WE SIMULTANEOUSLY WERE TRYING TO EXPLAIN THE SITUATION TO THE RECEIVERS OF OUR CALLS. A DC POLICE OFFICER ARRIVED AND QUICKLY ACCESSED THE INCIDENT. HE'D WITNESSED THE SAME ON A FEW OTHER MAKES OF CARS. HE ASSURED US THAT BASED ON THE OUTWARD PROTRUSION OF THE REMAINING GLASS, THE IMPACT WAS FROM WITHIN, IT HAD EXPLODED, NOT IMPLODED. THERE WAS NO INDICATION OF A SHOT OR OBJECT OF ANY SIZE HITTING THE CAR. THERE WERE A FEW PIECES OF VARIOUS SIZED SHATTERED GLASS ON THE BACKSEAT, WHERE MY GRANDSON'S CAR SEAT CADDY WAS. THE OFFICER EVENTUALLY CONVINCED ME IT WAS SAFE TO DRIVE TO MY DEALER AND I DID SO. WHEN I ARRIVED AT THE BMW DEALER, THE SERVICE MGR. IMMEDIATELY ACKNOWLEDGED TO ME AND GATHERING COWORKERS, OF SEEING PREVIOUS SUNROOF EXPLOSIONS. HOWEVER, IN TWO FOLLOW-UP CALLS HE STATED THAT BMW WOULD NOT COVER (PAY). THE 2ND CALL, AFTER FOLLOWING UP WITH HIS MANAGER PER MY REQUEST, HE STATED THAT [IT] COULD ONLY SHATTER IF SOMETHING HIT AN EXISTING CRACK...THE SAME WITH THE PREVIOUS SUNROOFS INCIDENTS HE HAD SEEN. I DID NOT HAVE A CRACK IN MY SUNROOF PREVIOUS TO THIS INCIDENT!
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.
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.
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.
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.
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
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.
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