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2009 Chevrolet Suburban

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2009 Chevrolet Suburban do not stand out strongly from the model-year median of 118.

About this comparison →

When problems were reported

Mileage at the reported incident

67 reports with mileage · 39 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.

  • Air Bags. Review the 38 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 16 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Structure. Review the 11 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

1 crash reports0 fire reports2 injury reports

Electrical System complaints

16 reports
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55,000 miles · Jun 22, 2014
Electrical SystemLatches/locks/linkages

VEHICLE DRIVER SIDE BACK DOOR WOULD NOT UNLOCK USING REMOTE CONTROL. COST OVER $300.00 TO HAVE CHEVROLET DEALER FIX. NOW IN FEB 2014 WITH 7600 MILES IT STARTED NOT WORKING ON THE PASSENGER SIDE BACK DOOR STOP WORKING WITH REMOTE CONTROL. ALL OTHER LOCKS WOULD OPEN BUT NOT THE REAR DOOR AT THAT TIME. IT APPEARS THEIR ARE ISSU…

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VEHICLE DRIVER SIDE BACK DOOR WOULD NOT UNLOCK USING REMOTE CONTROL. COST OVER $300.00 TO HAVE CHEVROLET DEALER FIX. NOW IN FEB 2014 WITH 7600 MILES IT STARTED NOT WORKING ON THE PASSENGER SIDE BACK DOOR STOP WORKING WITH REMOTE CONTROL. ALL OTHER LOCKS WOULD OPEN BUT NOT THE REAR DOOR AT THAT TIME. IT APPEARS THEIR ARE ISSUES WITH THESE DOOR LOCKS. THE DOOR LOCKS WILL ONLY OPEN MANUALLY WHEN THEY FAIL WHICH IS A PAIN DUE TO THE SIZE OF THE VEHICLE. *TR

NHTSA ODI #10605017

33,000 miles · Aug 3, 2013
Air BagsElectrical System

THE DISCOVERY OF THE DEFECT WAS ON SEPTEMBER 2012. THERE IS A CRACK ON THE DASH ABOVE THE VEHICLES INSTRUMENTATION I.E. SPEEDOMETER, OIL PRESSURE, GAS LEVEL, ETC. I REPORTED TO LOCAL GM DEALERSHIP (HENRY BROWN CHEVROLET) ABOUT THE DEFECT AND MY CONCERN FOR SAFETY. THEY SAID THERE IS NO AVAILABLE SAFETY RECALL FOR THIS PROBLE…

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THE DISCOVERY OF THE DEFECT WAS ON SEPTEMBER 2012. THERE IS A CRACK ON THE DASH ABOVE THE VEHICLES INSTRUMENTATION I.E. SPEEDOMETER, OIL PRESSURE, GAS LEVEL, ETC. I REPORTED TO LOCAL GM DEALERSHIP (HENRY BROWN CHEVROLET) ABOUT THE DEFECT AND MY CONCERN FOR SAFETY. THEY SAID THERE IS NO AVAILABLE SAFETY RECALL FOR THIS PROBLEM. THINKING THAT THIS WAS AN ISOLATED CASE I DID NOT PURSUE THE MATTER. THEN RECENTLY WHEN I SURFED THE INTERNET I CAME UPON A GROUP OF GM VEHICLE OWNER WITH THE SAME TYPE OF VEHICLE AND THE SAME TYPE OF ISSUE. SO I INVESTIGATED FURTHER. GOING TO DIFFERENT WEB BLOGS, I FOUND MORE GM VEHICLE OWNERS WITH THE SAME PROBLEM. EVERYBODY HAVE THE SAME ISSUE. THEY HAVE CRACKED DASH ON THEIR GM VEHICLES. SOME HAVE THE CRACKS ON BOTH SIDE WHERE THE PASSENGER AIRBAG IS. THE DANGER IS THAT THIS MIGHT PUNCTURE THE AIRBAG AND RENDER IT INEFFECTIVE. THE MAIN CONCERN IS SAFETY BECAUSE I DON'T WANT MY VEHICLE TO FAIL ON ME AND MY FAMILY. IF FOR SOME REASON WATER GETS IN THE VEHICLES INSTRUMENTATION AND CAUSES AN ELECTRICAL SHORT, ME AND MY FAMILY COULD BE IN DANGER OF A VEHICLE ACCIDENT. I AM TRYING TO BE PROACTIVE AND HAVE THIS PROBLEM RESOLVED RATHER THAN WAIT TO BE A VICTIM OF AN UNSAFE VEHICLE OR CAUSE ANOTHER DRIVER TO BE IN AN AVOIDABLE ACCIDENT. WE NEED THIS VEHICLES RECALLED SO THAT GM CAN TAKE RESPONSIBILITY AND FIX AN UNSAFE VEHICLE. *TR

NHTSA ODI #10533422

30,000 miles · Jun 28, 2013
Electrical SystemLatches/locks/linkages

THE DOOR LOCKS INTERMITTENTLY WORK. SEEMS TO HAPPEN TO A LOT OF PEOPLE. SAFETY ISSUE. CAN'T GET IN OR OUT OF VEHICLE. WE HAD ONE FIXED AND NOW ALL OF THE DOORS ARE DOING IT. SOMETIMES THE CAR LOCKS ITSELF. *TR

NHTSA ODI #10522198

51,000 miles · May 17, 2013
Electrical SystemLatches/locks/linkages

ABOUT A YEAR AGO THE REAR PASSENGER DOOR LOCK WOULDN'T WORK, NOW ALL DOOR LOCKS WILL NOT LOCK OR UNLOCK WITH REMOTE OR SWITCH. ALSO WILL NOT LOCK/UNLOCK WHEN PUT INTO GEAR OR BACK INTO PART. LOCKS MOVE SLIGHTLY WHEN YOU PUSH THE BUTTON BUT WILL NOT FULLY ENGAGE OR DISENGAGE WHEN MANUALLY PUSHED. NO RECALL DATA AVAILABLE BUT …

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ABOUT A YEAR AGO THE REAR PASSENGER DOOR LOCK WOULDN'T WORK, NOW ALL DOOR LOCKS WILL NOT LOCK OR UNLOCK WITH REMOTE OR SWITCH. ALSO WILL NOT LOCK/UNLOCK WHEN PUT INTO GEAR OR BACK INTO PART. LOCKS MOVE SLIGHTLY WHEN YOU PUSH THE BUTTON BUT WILL NOT FULLY ENGAGE OR DISENGAGE WHEN MANUALLY PUSHED. NO RECALL DATA AVAILABLE BUT I SEE MANY COMPLAINTS. *TR

NHTSA ODI #10512614

49,000 miles · Nov 7, 2011
Electrical SystemPower Train

TL* THE CONTACT OWNS A 2009 CHEVROLET SUBURBAN. WHILE PARKED, THE CONTACT EXITED THE VEHICLE AND WAS UNABLE TO UNLOCK THE DRIVER SIDE DOOR. THE CONTACT TURNED THE KEY TO SHUT THE VEHICLE OFF BUT THE GEAR SHIFT SELECTOR SHIFTED INTO DRIVE AND BEGAN TO REVERSE INDEPENDENTLY. THE CONTACT WAS ABLE TO DEPRESS THE BRAKE PEDAL AND SHUT…

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TL* THE CONTACT OWNS A 2009 CHEVROLET SUBURBAN. WHILE PARKED, THE CONTACT EXITED THE VEHICLE AND WAS UNABLE TO UNLOCK THE DRIVER SIDE DOOR. THE CONTACT TURNED THE KEY TO SHUT THE VEHICLE OFF BUT THE GEAR SHIFT SELECTOR SHIFTED INTO DRIVE AND BEGAN TO REVERSE INDEPENDENTLY. THE CONTACT WAS ABLE TO DEPRESS THE BRAKE PEDAL AND SHUT THE VEHICLE OFF. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTICS OR REPAIRS. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 49,000.

NHTSA ODI #10434770

100 miles · Apr 26, 2010
Electrical SystemExterior LightingInterior Lighting

ELECTRICAL MALFUNCTION ON MY 2009 CHEVROLET SUBURBAN LTZ. THE CAR WAS PURCHASED NEW FROM THE DEALER IN NOV 2009. UPON DELIVERY, IT WAS NOTED THAT THE DASH LIGHTS FOR FUNCTION BUTTONS DID NOT ILLUMINATE AND VISOR LAMPS WERE INOPERABLE. DEALER ASSURED US THAT THEY WOULD FIX THE PROBLEM. THE HAZARD OCCURS WHEN THE LIGHT COMPLETELY …

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ELECTRICAL MALFUNCTION ON MY 2009 CHEVROLET SUBURBAN LTZ. THE CAR WAS PURCHASED NEW FROM THE DEALER IN NOV 2009. UPON DELIVERY, IT WAS NOTED THAT THE DASH LIGHTS FOR FUNCTION BUTTONS DID NOT ILLUMINATE AND VISOR LAMPS WERE INOPERABLE. DEALER ASSURED US THAT THEY WOULD FIX THE PROBLEM. THE HAZARD OCCURS WHEN THE LIGHT COMPLETELY GO OUT ON THIS VEHICLE WHILE DRIVING AT NIGHT FOR NO APPARENT REASON. AFTER FOUR ATTEMPTS TO FIX THE PROBLEM AND GM TECHNICAL SUPPORT HAS YIELDED NO CLEAR ANSWERS OR ASSISTANCE. I AM CONCERNED THAT MY FAMILY WILL BE INJURED IN THIS VEHICLE. *TR

NHTSA ODI #10327505

Official recalls

5

21V050000 · Air Bags:frontal:passenger Side:inflator Module

Feb 5, 2021

General Motors, LLC (GM) is recalling certain 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, GMC Sierra 1500, Yukon, Yukon XL, and 2009-2011 Chevrolet Silverado 2500, Silverado 3500, GMC Sierra 2500 and Sierra 3500 vehicles originally sold, or ever registered, in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A." Additionally, GM is recalling certain 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT, Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, GMC Sierra 1500, Yukon, Yukon XL vehicles originally sold, or ever registered, in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B." These vehicles are equipped with non-desiccated passenger frontal inflators containing phase-stabilized ammonium nitrate (PSAN) propellant. These inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.

Consequence & remedy

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

Remedy: GM will notify owners, and dealers will replace the front passenger air bag inflator with an alternate one, free of charge. Interim letters notifying owners of the safety risk were mailed on February 22, 2021. Second notification letters will be mailed once the remedy is available. Owner notification letters were mailed on March 1, 2021. Owners may contact Chevrolet customer service at 1-800-222-1020; Cadillac customer service at 1-800-458-8006; and GMC customer service at 1-800-462-8782. GM's number for this recall is N212328760.

21V052000 · Air Bags:frontal:passenger Side:inflator Module

Feb 5, 2021

General Motors, LLC (GM) is recalling certain 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, Chevrolet Avalanche, Silverado 1500, Silverado 2500, Silverado 3500, Suburban, Tahoe, GMC Sierra 1500, Sierra 2500, Sierra 3500, Yukon, and Yukon XL vehicles originally sold, or ever registered, in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B." Additionally, GM is recalling certain 2007-2008 Cadillac Escalade, Escalade ESV, and Escalade EXT, Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, GMC Sierra 1500, Yukon, and Yukon XL vehicles originally sold, or ever registered, in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin, and Wyoming or "Zone C." These vehicles are equipped with non-desiccated passenger frontal inflators containing phase-stabilized ammonium nitrate (PSAN) propellant. These inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.

Consequence & remedy

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

Remedy: GM will notify owners, and dealers will replace the front passenger air bag inflator with an alternate one, free of charge. Interim letters notifying owners of the safety risk were mailed on February 23, 2021. Second notification letters will be mailed once the remedy is available. Owner notification letters were mailed on September 20, 2021. Owners may contact Chevrolet customer service at 1-800-222-1020, Cadillac customer service at 1-800-458-8006, and GMC customer service at 1-800-462-8782. GM's number for this recall is N212328780.

21V053000 · Air Bags:frontal:passenger Side:inflator Module

Feb 5, 2021

General Motors, LLC (GM) is recalling certain 2013 Cadillac Escalade, Escalade ESV, and Escalade EXT, Chevrolet Avalanche, Silverado 1500, Silverado 2500/3500, Suburban, Tahoe, GMC Sierra 1500, Sierra 2500/3500, Yukon, and Yukon XL vehicles originally sold, or ever registered, in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A." Additionally, GM is recalling certain 2010 Cadillac Escalade, Escalade ESV, and Escalade EXT, Chevrolet Avalanche, Silverado 1500, Silverado 2500/3500, Suburban, Tahoe, GMC Sierra 1500, Sierra 2500/3500, Yukon, and Yukon XL vehicles originally sold, or ever registered in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B." Additionally, GM is recalling certain 2009 Cadillac Escalade, Escalade ESV, and Escalade EXT, Chevrolet Avalanche, Silverado 1500, Silverado 2500/3500, Suburban, Tahoe, GMC Sierra 1500, Sierra 2500/3500, Yukon, and Yukon XL vehicles originally sold, or ever registered, in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin, and Wyoming or "Zone C."

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: GM will notify owners, and dealers will replace the front passenger air bag inflator with an alternate one, free of charge. Interim letters notifying owners of the safety risk were mailed on February 24, 2021. Second notification letters will be mailed once the remedy is available. Owner notification letters were mailed on May 11, 2021. Owners may contact Cadillac customer service at 1-800-458-8006; Chevrolet customer service at 1-800-222-1020; and GMC customer service at 1-800-462-8782. GM's number for this recall is N212328790.

10V240000 · Electrical System

Jun 4, 2010

GM IS RECALLING CERTAIN MODEL YEAR 2006-2009 BUICK, LUCERNE; CADILLAC DTS; HUMMER H2; MODEL YEAR 2008-2009 BUICK ENCLAVE; CADILLAC CTS; MODEL YEAR 2007-2009 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT; CHEVROLET AVALANCHE, SILVERADO, SUBURBAN, TAHOE; GMC ACADIA, SIERRA, YUKON, YUKON XL; SATURN OUTLOOK; AND MODEL YEAR 2009 CHEVROLET TRAVERSE VEHICLES EQUIPPED WITH A HEATED WASHER FLUID SYSTEM (HWFS). A RECALL WAS IMPLEMENTED IN 2008 TO ADD A FUSE TO THE CONTROL CIRCUIT HARNESS TO ADDRESS THE POTENTIAL CONSEQUENCES OF A PRINTED CIRCUIT BOARD (PCB) ELECTRICAL SHORT. HOWEVER, THERE HAVE BEEN NEW REPORTS OF THERMAL INCIDENTS ON HWFS MODULES AFTER THIS IMPROVEMENT WAS INSTALLED. THESE INCIDENTS RESULTED FROM A NEW FAILURE MODE ATTRIBUTED TO THE DEVICE'S THERMAL PROTECTION FEATURE. THE SIGNIFICANCE VARIES FROM MINOR DISTORTION TO CONSIDERABLE MELTING OF THE PLASTIC AROUND THE HWFS FLUID CHAMBER.

Consequence & remedy

Consequence: IT IS POSSIBLE FOR THE HEATED WASHER MODULE TO IGNITE AND A FIRE MAY OCCUR.

Remedy: DEALERS WILL PERMANENTLY DISABLE AND REMOVE THE HEATED WASHER FLUID MODULE. AN UPDATED PAGE FOR THE OWNER MANUAL WILL BE PROVIDED AND INSERTED IN THE OWNER MANUAL TO DOCUMENT THAT THE FEATURE HAS BEEN PERMANENTLY DISABLED AND REMOVED FROM THE VEHICLE. THE SAFETY RECALL BEGAN ON JUNE 11, 2010. OWNERS MAY CONTACT BUICK AT 1-866-608-8080, CADILLAC AT 1-866-982-2339, CHEVROLET AT 1-800-630-2438, SATURN AT 1-800-972-8876, GMC AT 1-866-996-9463 AND HUMMER AT 1-800-732-5493 OR AT THE OWNER CENTER AT WWW.GMOWNERCENTER.COM.

09V154000 · Fuel System, Gasoline

May 6, 2009

GM IS RECALLING 27,188 MY 2009 CADILLAC ESCALADE, ESCALADE HYBRID, ESCALADE ESV, AND ESCALADE EXT; CHEVROLET AVALANCHE, SUBURBAN, TAHOE, TAHOE HYBRID, AND COLORADO; AND GMC YUKON, YUKON HYBRID, YUKON XL, AND CANYON VEHICLES. THE FUEL SYSTEM CONTROL MODULES MAY HAVE A CONDITION IN WHICH AN ADHESIVE SEPARATION OF THE ROOM TEMPERATURE VULCANIZING (RTV) SEAL BETWEEN THE SEAL AND THE HOUSING MAY ALLOW WATER TO SEEP INTO THE MODULE.

Consequence & remedy

Consequence: WATER IN THE MODULE COULD CAUSE A SHORT OR OPEN CIRCUIT, ILLUMINATION OF THE SERVICE ENGINE SOON LAMP, SETTING OF DIAGNOSTIC TROUBLE CODES OR THE ENGINE MAY BE HARD TO START, MAY NOT START OR MAY STALL INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSTALL A NEW FUEL SYSTEM CONTROL MODULE FREE OF CHARGE. THE RECALL BEGAN ON MAY 18, 2009. OWNERS MAY CONTACT CADILLAC AT 1-866-982-2339, CHEVROLET AT 1-800-630-2438 AND GMC AT 1-866-996-9463 OR AT WWW.GMOWNERCENTER.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.