Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
480–25K
3125–50K
3250–75K
3275–100K
18100–150K
4150K+
165 reports with mileage · 52 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.
Electrical System. Review the 56 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Engine. Review the 55 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Power Train. Review the 38 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
24 crash reports4 fire reports15 injury reports
What owners actually said
217 reports
11,000 miles · Apr 10, 2015
Tires
TL* THE CONTACT OWNS A 2013 CHEVROLET SONIC EQUIPPED WITH HANKOOK OPTIMO H428 (NA) TIRES, SIZE P195/65R15 (NA). THE CONTACT STATED THAT ALL FOUR FACTORY TIRE SIDEWALLS WERE SEVERELY CRACKED AND THE FRONT PASSENGER TIRE THREAD HAD BEGUN TO SEPARATE. THE CONTACT NOTIFIED GM AND HANKOOK OF THE FAILURE. ONLY THE FRONT PASSENGER SIDE…
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TL* THE CONTACT OWNS A 2013 CHEVROLET SONIC EQUIPPED WITH HANKOOK OPTIMO H428 (NA) TIRES, SIZE P195/65R15 (NA). THE CONTACT STATED THAT ALL FOUR FACTORY TIRE SIDEWALLS WERE SEVERELY CRACKED AND THE FRONT PASSENGER TIRE THREAD HAD BEGUN TO SEPARATE. THE CONTACT NOTIFIED GM AND HANKOOK OF THE FAILURE. ONLY THE FRONT PASSENGER SIDE TIRE WAS REPLACED. THE VEHICLE AND TIRE FAILURE MILEAGE WAS 11,000.
NHTSA ODI #10705018
25 miles · Mar 30, 2015
Air Bags
TL* THE CONTACT OWNS A 2013 CHEVROLET SONIC. THE CONTACT STATED THAT THE AIR BAG SENSOR FAILED TO RECOGNIZE THAT THE FRONT PASSENGER SEAT WAS OCCUPIED. THE VEHICLE WAS TAKEN TO A DEALER. THE TECHNICIAN STATED THAT THE VEHICLE WAS OPERATING AS DESIGNED AND STATED THAT THE PASSENGER COULD BE UNDER WEIGHT. THE FAILURE RECURRED. THE…
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TL* THE CONTACT OWNS A 2013 CHEVROLET SONIC. THE CONTACT STATED THAT THE AIR BAG SENSOR FAILED TO RECOGNIZE THAT THE FRONT PASSENGER SEAT WAS OCCUPIED. THE VEHICLE WAS TAKEN TO A DEALER. THE TECHNICIAN STATED THAT THE VEHICLE WAS OPERATING AS DESIGNED AND STATED THAT THE PASSENGER COULD BE UNDER WEIGHT. THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 25.
NHTSA ODI #10702533
26,000 miles · Feb 23, 2015
Air Bags
THE CAR HAS A DETECTION SYSTEM IN THE PASSENGER SEAT. THIS SHOULD DETECT IF ANYONE IS IN THAT SEAT. WHEN PASSENGER IS DETECTED, THE PASSENGER AIRBAGS SHOULD BE ACTIVATED. FOR SMALL CHILDREN (UNDER A CERTAIN, NOT SPECIFIED WEIGHT LIMIT), THE AIRBAGS ON PASSENGER SIDE ARE NOT ACTIVATED. PROBLEM IS THAT THE PASSENGER AIRBAGS ARE N…
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THE CAR HAS A DETECTION SYSTEM IN THE PASSENGER SEAT. THIS SHOULD DETECT IF ANYONE IS IN THAT SEAT. WHEN PASSENGER IS DETECTED, THE PASSENGER AIRBAGS SHOULD BE ACTIVATED. FOR SMALL CHILDREN (UNDER A CERTAIN, NOT SPECIFIED WEIGHT LIMIT), THE AIRBAGS ON PASSENGER SIDE ARE NOT ACTIVATED. PROBLEM IS THAT THE PASSENGER AIRBAGS ARE NOT EVEN ACTIVATED WHEN MY WIFE IS IN THAT SEAT. SHE IS BORN 06/13/1971 AND WEIGHS ABOUT 130 LB. OBVIOUSLY, THE PASSENGER AIRBAGS SHOULD BE ACTIVATED WHEN AN ADULT IS IN THAT SEAT THAT WEIGHS ~ 130 LB. SINCE THIS IS A SERIOUS SAFETY ISSUE, WE TOOK THE CAR TO CHEVROLET DEALER (AUTONATION CHEVROLET NORTHPOINT, 2175 MANSELL ROAD, ALPHARETTA, GA, 30004, PHONE 855-478-9750, CONTACT [XXX]). ENGINEER AND SERVICE MANAGER DID ALL CHECKS AND CONCLUDED THE CAR IS OPERATING AS DESIGNED. WE CALLED CHEVROLET OWNER CENTER (SR. MANAGER CALLED [XXX], CASE FILE NR. [XXX]). THEY LOOKED INTO THE CASE AND SPOKE TO CHEVROLET DEALER NORTHPOINT. CONCLUSION IS THE SAME; CAR IS WORKING AS DESIGNED. WE SPOKE TO HIGHER MANAGER OF SR. MANAGER [XXX] AT CHEVROLET'S OWNER CENTER. SHE ALSO CONCLUDED THE SAME. IN OUR OPINION, THERE IS A SERIOUS SAFETY HAZARD WITH THE CHEVROLET SONIC 2013 AS AIRBAGS ARE NOT ACTIVATED, EVEN FOR SOME ADULTS. OUR CAR WILL NOT BE FIXED BY CHEVROLET USA OR CHEVROLET DEALER SO WE ARE HOPING YOU CAN ADDRESS THIS PROBLEM. FOR FURTHER QUESTIONS, PLEASE CONTACT ME AT BELOW CONTACT DETAILS. THANKS IN ADVANCE, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10689914
40,000 miles · Feb 17, 2015
Air BagsCrashInjury
TL* THE CONTACT OWNS A 2013 CHEVROLET SONIC. WHILE DRIVING 40 MPH, ANOTHER VEHICLE CRASHED INTO THE FRONT DRIVER SIDE OF THE CONTACT'S VEHICLE. THE CONTACT LOST CONTROL OF THE VEHICLE AND CRASHED INTO A TELEPHONE POLE. THE AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED. THE CONTACT SUSTAINED A BRUISED COLLAR BONE AND SOFT …
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TL* THE CONTACT OWNS A 2013 CHEVROLET SONIC. WHILE DRIVING 40 MPH, ANOTHER VEHICLE CRASHED INTO THE FRONT DRIVER SIDE OF THE CONTACT'S VEHICLE. THE CONTACT LOST CONTROL OF THE VEHICLE AND CRASHED INTO A TELEPHONE POLE. THE AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED. THE CONTACT SUSTAINED A BRUISED COLLAR BONE AND SOFT TISSUE BRUISING, WHICH REQUIRED MEDICAL ATTENTION. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING, BUT THE RESULTS WERE UNKNOWN. THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 40,000.
NHTSA ODI #10683816
5,000 miles · Feb 4, 2015
Power Train
WHEN STOPPED THE VEHICLE WOULD LUNGE FORWARD WITHOUT WARNING. VEHICLE WAS TAKEN TO DEALER FOR SERVICE AND THEY REPLACED THE 1-2-3-4 CLUTCH. THE PROBLEM FIRST APPEARED IN 2013, VEHICLE CURRENTLY HAS 31460 MILES AND IS STARTING TO EXHIBIT THE SAME SYMPTOMS OF THE ORIGINAL PROBLEM TWO YEARS LATER. *TR
NHTSA ODI #10681357
17,900 miles · Feb 4, 2015
EnginePower Train
VEHICLE IS LOOSING COOLANT AND A SMALL PUDDLE OF COOLANT DEVELOPED UNDER THE PASSENGER SIDE OF VEHICLE. COOLANT TEMPERATURE LIGHT CAME ON INDICATING OVERHEATING WHILE TAKING VEHICLE IN FOR SERVICE. DEALER DETERMINED THAT A FAULTY SEAL WAS CAUSING THE WATER PUMP TO LEAK COOLANT. *TR
NHTSA ODI #10681356
31,460 miles · Feb 4, 2015
Unknown Or Other
VEHICLE HAS BEEN LOSING COOLANT FOR LAST SIX MONTHS. THERE IS A STRONG ODOR OF COOLANT INSIDE AND OUTSIDE OF THE VEHICLE AND THERE IS WATER INSIDE CABIN AIR FILTER BOX. DEALER ACKNOWLEDGED THE ISSUE AND INSPECTED VEHICLE WITH A GM ENGINEER, BUT COULD NOT FIND THE CAUSE OF EITHER ISSUE.
NHTSA ODI #10681353
37,000 miles · Feb 1, 2015
Power Train
THE SHIFTER BUTTON WOULD GET STUCK WHEN SHIFTING AND CAN CHANGE INTO PARK OR DRIVE OR REVERSE WITH OUT HOLDING THE BUTTON IN. *TR
NHTSA ODI #10680308
Mileage unknown · Jan 23, 2015
Power Train
OUR 2013 CHEVROLET SONIC IS AN AUTOMATIC AND WHEN WE WERE DRIVING IN IT THE BUTTON TO SHIFT IT FELL OFF. IT HAD TO BE PUT BACK, WHICH WAS DIFFICULT, WHILE STEPPING ON THE BRAKE. IT STICKS AND I AM AFRAID IT WILL STICK AND SHIFT AND CAUSE A SERIOUS ACCIDENT. *TR
NHTSA ODI #10678535
30,921 miles · Jan 21, 2015
Power Train
I WAS DRIVING DOWN THE HIGHWAY AT APPROXIMATELY 50 MPH. I SHIFTED FROM 4TH TO 5TH AND SOMETHING DIDN'T FEEL RIGHT, LIKE THE TRANSMISSION DIDN'T ENGAGE. I THEN REALIZED I COULD NOT MOVE THE SHIFT LEVER ON THE TRANSMISSION OUT OF GEAR. I ATTEMPTED TO TAKE THE NEXT EXIT BUT THE RAMP WAS ONLY SUITABLE FOR AROUND 30MPH. I TRIED T…
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I WAS DRIVING DOWN THE HIGHWAY AT APPROXIMATELY 50 MPH. I SHIFTED FROM 4TH TO 5TH AND SOMETHING DIDN'T FEEL RIGHT, LIKE THE TRANSMISSION DIDN'T ENGAGE. I THEN REALIZED I COULD NOT MOVE THE SHIFT LEVER ON THE TRANSMISSION OUT OF GEAR. I ATTEMPTED TO TAKE THE NEXT EXIT BUT THE RAMP WAS ONLY SUITABLE FOR AROUND 30MPH. I TRIED TO KEEP THE ENGINE FROM STALLING AS BEST AS I COULD. AS I GOT AROUND THE RAMP I PULLED TO THE SHOULDER AND NEARLY HIT A GUARD RAIL BECAUSE THE SHOULDER ENDED AND I BARELY STOPPED IN TIME. I CALLED CHEVY ROADSIDE ASSISTANCE FOR A TOW VEHICLE AND THEY DISPATCHED ONE. WHILE I WAS WAITING I GOOGLE'D MY PROBLEM ("CHEVY SONIC STUCK IN GEAR"). ALAS, ANOTHER PERSON HAD THE SAME EXACT ISSUE WITH THE SAME EXACT VEHICLE. ACCORDING TO THIS MESSAGE BOARD POSTER A SMALL PLASTIC CLAMP SLID OUT OF PLACE CAUSING THE SHIFT CABLE TO BE REMOVED FROM IT'S HOUSING, ESSENTIALLY RENDERING IT USELESS. I TOOK APART MY CONSOLE AND FOUND I HAD THE SAME PROBLEM. WHEN I REINSTALLED THE PLASTIC CLAMP THAT HOLDS THE CABLE IN PLACE EVERYTHING WORKED NORMALLY, I WAS ABLE TO SHIFT IN AND OUT OF GEAR. I BELIEVE A RECALL SHOULD BE ISSUED AS THIS IS A VERY DANGEROUS SITUATION TO BE IN WHEN TRAVELING AT HIGHWAY SPEEDS. *TR
General Motors, LLC (GM) is recalling certain 2013 Buick Verano, Chevrolet Camero, Sonic, and Volt vehicles. The driver-side 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, resulting in serious injury or death.
Remedy: Dealers will replace the driver-side air bag module, free of charge. On some 2013 Volt vehicles, the steering wheel will be replaced as well, free of charge. Owner notification letters were mailed October 23, 2023. Owners may contact Buick customer service at 1-800-521-7300 and Chevrolet customer service at 1-800-222-1020. GM's number for this recall is N232413120.
General Motors LLC (GM) is recalling certain model year 2013-2016 Chevrolet Sonic and Trax vehicles and 2013-2015 Chevrolet Spark vehicles equipped with a Bring Your Own Media radio. The affected radios may fail to provide an audible warning chime when the driver, after turning off the ignition and leaving the key in the cylinder, waits 10 minutes or longer to open the door. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 114 "Theft Protection."
Consequence & remedy
Consequence: Without audible indicators, the driver may leave the key in the ignition, increasing the risk of theft.
Remedy: GM will notify owners, and dealers will update the radio software, free of charge. The manufacturer has not yet provided a notification schedule. Owners may contact Chevrolet customer service at 1-800-222-1020. GM's number for this recall is 17130.
Additional source detail variants (2)
Electrical System:software
General Motors LLC (GM) is recalling certain model year 2013-2016 Chevrolet Sonic and Trax vehicles and 2013-2015 Chevrolet Spark vehicles equipped with a Bring Your Own Media radio. The affected radios may fail to provide an audible warning chime when the driver, after turning off the ignition and leaving the key in the cylinder, waits 10 minutes or longer to open the door. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 114 "Theft Protection."
Consequence: Without audible indicators, the driver may leave the key in the ignition, increasing the risk of theft.
Remedy: GM will notify owners, and dealers will update the radio software, free of charge. The manufacturer has not yet provided a notification schedule. Owners may contact Chevrolet customer service at 1-800-222-1020. GM's number for this recall is 17130.
Equipment:electrical:radio/tape Deck/cd Etc.
General Motors LLC (GM) is recalling certain model year 2013-2016 Chevrolet Sonic and Trax vehicles and 2013-2015 Chevrolet Spark vehicles equipped with a Bring Your Own Media radio. The affected radios may fail to provide an audible warning chime when the driver, after turning off the ignition and leaving the key in the cylinder, waits 10 minutes or longer to open the door. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 114 "Theft Protection."
Consequence: Without audible indicators, the driver may leave the key in the ignition, increasing the risk of theft.
Remedy: GM will notify owners, and dealers will update the radio software, free of charge. The manufacturer has not yet provided a notification schedule. Owners may contact Chevrolet customer service at 1-800-222-1020. GM's number for this recall is 17130.
General Motors LLC (GM) is recalling certain model year 2013-2014 Buick Encore all-wheel-drive vehicles manufactured August 23, 2012, to September 9, 2013; Verano vehicles manufactured August 8, 2012, to June 20, 2013; Chevrolet Cruze vehicles manufactured August 7, 2012, to August 16, 2013, and 2012-2014 Chevrolet Sonic vehicles manufactured May 10, 2011, to August 16, 2012 equipped with a Calix oil pan/block heater. In cold temperatures, the insulation on the engine block heater cord can become damaged, allowing the wires to be exposed.
Consequence & remedy
Consequence: Exposed wires increase the risk of electrical shock and personal injury if the cord is handled while it is plugged in.
Remedy: GM will notify owners, and dealers will replace the engine oil pan/block heater cord with a new cord that is rated for temperatures of minus 40 degree Celsius. The recall began in August 2014. Owners may contact Buick customer service at 1-800-521-7300 or Chevrolet customer service at 1-800-222-1020. GM's number for this recall is 14257.
General Motors (GM) is recalling certain model year 2013 and 2014 Chevrolet Sonic vehicles manufactured August 2, 2013, through August 12, 2013. Due to insufficient welds, the front fuel tank strap bracket may separate from the vehicle.
Consequence & remedy
Consequence: If the front fuel tank strap bracket separates, the increased load may lead to the failure of the other tank support. As a result, the fuel tank may come loose from the vehicle causing a fuel leak. A fuel leak, in the presence of an ignition source, may result in a fire.
Remedy: GM will notify owners, and dealers will inspect the front fuel tank strap bracket, and repair it as necessary, free of charge. The recall began on November 7, 2013. Owners may contact GM at 1-800-521-7300. GM's recall campaign number is 13296.
General Motors LLC (GM) is recalling certain model year 2013 Cadillac ATS and model year 2013 Cadillac XTS; model year 2014 Chevrolet Impala; and 2013 Chevrolet Sonic vehicles. Originally, in May 2013, GM recalled 1,627 model year 2013 Cadillac ATS and model year 2013 Cadillac XTS; and model year 2014 Chevrolet Impala vehicles. In October 2013, GM informed the agency that it was adding model year 2013 Chevrolet Sonic vehicles to this campaign , representing an additional 8,050 units. The total number of vehicles being recalled is now 9,677. On the affected vehicles, the brake lamps may intermittently flash without the brakes being applied and the cruise control may disengage. Thus, these vehicles fail to conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 108, "Lamps, reflective devices, and associated equipment."
Consequence & remedy
Consequence: If the brake lamps flash when the vehicle is not slowing, a following driver may not adjust vehicle speed when the vehicle is in fact braking, and the brake lamps are illuminating as intended, increasing the risk of a crash.
Remedy: GM will notify owners, and dealers will reprogram the body control module. The recall began on June 13, 2013. Owner's may contact Chevrolet at 1-800-630-2438 or Cadillac at 1-866-982-2339. GM's recall number is 13158.
Additional source detail variants (2)
Exterior Lighting:brake Lights
General Motors LLC (GM) is recalling certain model year 2013 Cadillac ATS and model year 2013 Cadillac XTS; model year 2014 Chevrolet Impala; and 2013 Chevrolet Sonic vehicles. Originally, in May 2013, GM recalled 1,627 model year 2013 Cadillac ATS and model year 2013 Cadillac XTS; and model year 2014 Chevrolet Impala vehicles. In October 2013, GM informed the agency that it was adding model year 2013 Chevrolet Sonic vehicles to this campaign , representing an additional 8,050 units. The total number of vehicles being recalled is now 9,677. On the affected vehicles, the brake lamps may intermittently flash without the brakes being applied and the cruise control may disengage. Thus, these vehicles fail to conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 108, "Lamps, reflective devices, and associated equipment."
Consequence: If the brake lamps flash when the vehicle is not slowing, a following driver may not adjust vehicle speed when the vehicle is in fact braking, and the brake lamps are illuminating as intended, increasing the risk of a crash.
Remedy: GM will notify owners, and dealers will reprogram the body control module. The recall began on June 13, 2013. Owner's may contact Chevrolet at 1-800-630-2438 or Cadillac at 1-866-982-2339. GM's recall number is 13158.
Electrical System
General Motors LLC (GM) is recalling certain model year 2013 Cadillac ATS and model year 2013 Cadillac XTS; model year 2014 Chevrolet Impala; and 2013 Chevrolet Sonic vehicles. Originally, in May 2013, GM recalled 1,627 model year 2013 Cadillac ATS and model year 2013 Cadillac XTS; and model year 2014 Chevrolet Impala vehicles. In October 2013, GM informed the agency that it was adding model year 2013 Chevrolet Sonic vehicles to this campaign , representing an additional 8,050 units. The total number of vehicles being recalled is now 9,677. On the affected vehicles, the brake lamps may intermittently flash without the brakes being applied and the cruise control may disengage. Thus, these vehicles fail to conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 108, "Lamps, reflective devices, and associated equipment."
Consequence: If the brake lamps flash when the vehicle is not slowing, a following driver may not adjust vehicle speed when the vehicle is in fact braking, and the brake lamps are illuminating as intended, increasing the risk of a crash.
Remedy: GM will notify owners, and dealers will reprogram the body control module. The recall began on June 13, 2013. Owner's may contact Chevrolet at 1-800-630-2438 or Cadillac at 1-866-982-2339. GM's recall number is 13158.
General Motors LLC (GM) is recalling certain model year 2013 Chevrolet Sonic vehicles manufactured from May 29, 2012, through August 29, 2012. When a turn signal lamp fails to operate, the Body Control Module (BCM) in these vehicles does not detect this condition and will not indicate the condition to the driver. Thus, These vehicles fail to conform to Federal Motor Vehicle Safety Standard No. 108, "Lamps, Reflective Devices, and Associated Equipment."
Consequence & remedy
Consequence: If the driver is not aware that the turn signal is not functioning and does not have the light repaired, other drivers may not be alerted that the vehicle is turning, increasing the risk of a crash.
Remedy: GM will notify owners, and dealers will reprogram the BCM and the vehicle's key fobs, free of charge. The safety recall began on October 3, 2012. Owners may contact the Chevrolet owner center at 1-866-694-6546.
Additional source detail variants (2)
Exterior Lighting:turn Signal
General Motors LLC (GM) is recalling certain model year 2013 Chevrolet Sonic vehicles manufactured from May 29, 2012, through August 29, 2012. When a turn signal lamp fails to operate, the Body Control Module (BCM) in these vehicles does not detect this condition and will not indicate the condition to the driver. Thus, These vehicles fail to conform to Federal Motor Vehicle Safety Standard No. 108, "Lamps, Reflective Devices, and Associated Equipment."
Consequence: If the driver is not aware that the turn signal is not functioning and does not have the light repaired, other drivers may not be alerted that the vehicle is turning, increasing the risk of a crash.
Remedy: GM will notify owners, and dealers will reprogram the BCM and the vehicle's key fobs, free of charge. The safety recall began on October 3, 2012. Owners may contact the Chevrolet owner center at 1-866-694-6546.
Electrical System
General Motors LLC (GM) is recalling certain model year 2013 Chevrolet Sonic vehicles manufactured from May 29, 2012, through August 29, 2012. When a turn signal lamp fails to operate, the Body Control Module (BCM) in these vehicles does not detect this condition and will not indicate the condition to the driver. Thus, These vehicles fail to conform to Federal Motor Vehicle Safety Standard No. 108, "Lamps, Reflective Devices, and Associated Equipment."
Consequence: If the driver is not aware that the turn signal is not functioning and does not have the light repaired, other drivers may not be alerted that the vehicle is turning, increasing the risk of a crash.
Remedy: GM will notify owners, and dealers will reprogram the BCM and the vehicle's key fobs, free of charge. The safety recall began on October 3, 2012. Owners may contact the Chevrolet owner center at 1-866-694-6546.
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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