IllustrationEvery time I fill the gas tank, the fuel spills out of the fill tube when it gets full. I have tried putting it in slow but before the nozzle can shut off it blows the fuel back out of the fill tube. This is a substantial amount of fuel which I believe is a serious hazard.
2009 Chrysler Aspen
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all Aspen years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
Limited mileage data: 10 of 25 reports include usable mileage. There isn’t enough coverage to show a useful chart.
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.
- Power Train. Review the 9 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 5 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Fuel/propulsion System. Review the 5 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
2 crash reports0 fire reports2 injury reports
What owners actually said
25 reportsThe contact owned a 2009 Chrysler Aspen. The contact stated that while driving at an unknown rate of speed, she was run off the road by a vehicle by another vehicle. The contact crashed into an unknown object and hit her face on the steering wheel since the airbags did not deploy. The contact temporarily lost consciousness; once…
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The contact owned a 2009 Chrysler Aspen. The contact stated that while driving at an unknown rate of speed, she was run off the road by a vehicle by another vehicle. The contact crashed into an unknown object and hit her face on the steering wheel since the airbags did not deploy. The contact temporarily lost consciousness; once she regained consciousness, blood was coming from her mouth. The contact immediately checked on her two young children who were both treated by an ambulance. The contact stated that her son was treated for facial injuries. A police report was filed. The contact had yet to seek medical attention for her injuries. The vehicle was initially towed to an independent tow yard but was later towed back to her home. The dealer nor the manufacturer had yet to be notified of the failure. The contact stated that the vehicle was a total loss. The failure mileage was unknown.
The contact owns a 2009 Chrysler Aspen. The contact stated while driving 35 MPH, the vehicle inadvertently shifted from 4-wheel drive to 4-wheel low. The contact stated no warning light was illuminated. The contact was able to park on the side of the roadway. The contact stated that a family member arrived at her location and as…
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The contact owns a 2009 Chrysler Aspen. The contact stated while driving 35 MPH, the vehicle inadvertently shifted from 4-wheel drive to 4-wheel low. The contact stated no warning light was illuminated. The contact was able to park on the side of the roadway. The contact stated that a family member arrived at her location and assisted her with resetting the 4-wheel drive. The vehicle was not diagnosed or repaired. A dealer was not contacted. The manufacturer had not been informed of the failure. The failure mileage was 109,369.
THE VEHICLE WAS PARKED OUTSIDE. PROBABLE TRANSMISSION ISSUE. THE VEHICLE WAS IN PARK. I STARTED THE VEHICLE USING THE REMOTE START AND THE VEHICLE LURCHED FORWARD SEVERAL INCHES THEN SETTLED BACK WERE IT WAS. THE OUTSIDE TEMPERATURE HAD BEEN +- ZERO FOR SEVERAL DAYS. IT DID NOT REPEAT AFTER BEING WARMED UP. IT HAS NEVER HAPPENED…
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THE VEHICLE WAS PARKED OUTSIDE. PROBABLE TRANSMISSION ISSUE. THE VEHICLE WAS IN PARK. I STARTED THE VEHICLE USING THE REMOTE START AND THE VEHICLE LURCHED FORWARD SEVERAL INCHES THEN SETTLED BACK WERE IT WAS. THE OUTSIDE TEMPERATURE HAD BEEN +- ZERO FOR SEVERAL DAYS. IT DID NOT REPEAT AFTER BEING WARMED UP. IT HAS NEVER HAPPENED BEFORE. 116,000 MILES.
CHRYSLER HAS A MAJOR PROBLEM WITH THEIR 5.8 HEMI ENGINE. 12/16/2020 I PAID $3791.07 TO REPLACE A BAD CAMSHAFT AND LIFTERS ON A VEHICLE WITH ONLY 72,768 MILES. AFTER RESEARCHING THIS PROBLEM, I FIND HUNDREDS OF OTHERS HAVING THE SAME ISSUES! IN CONTACTING CHRYSLER, THEY OF COURSE, REFUSE TO ACCEPT ANY RESPONSIBILITY FOR THIS DE…
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CHRYSLER HAS A MAJOR PROBLEM WITH THEIR 5.8 HEMI ENGINE. 12/16/2020 I PAID $3791.07 TO REPLACE A BAD CAMSHAFT AND LIFTERS ON A VEHICLE WITH ONLY 72,768 MILES. AFTER RESEARCHING THIS PROBLEM, I FIND HUNDREDS OF OTHERS HAVING THE SAME ISSUES! IN CONTACTING CHRYSLER, THEY OF COURSE, REFUSE TO ACCEPT ANY RESPONSIBILITY FOR THIS DESIGN FLAW. ALTHOUGH THIS IS NOT A SAFETY ISSUE, IT IS A MAJOR ENGINE DEFECT WHICH NEEDS TO BE ADDRESSED. I WOULD BE INTERESTED IF ANYONE ELSE HAS EXPRESSED THEIR CONCERNS ABOUT THIS PROBLEM AND CHRYSLER'S COMPLETE DISREGARD.
I HAD TROUBLE WITH A HUMMING NOISE AND POPPING UNDER MY VEHICLE FOR A FEW MONTHS. THE HUMMING GOT SO LOUD THAT WE COULD NOT HEAR EACH OTHER TALK TO ONE ANOTHER AT ALL. IT POPPED PULLING OUT, GOING AROUND A CURVE, GOING BACKWARDS, OR SLOWING DOWN. THE HUMMING STOPPED ALL OF A SUDDEN AFTER IT GOT VERY LOUD. MY ASPEN THEN FELL TOWA…
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I HAD TROUBLE WITH A HUMMING NOISE AND POPPING UNDER MY VEHICLE FOR A FEW MONTHS. THE HUMMING GOT SO LOUD THAT WE COULD NOT HEAR EACH OTHER TALK TO ONE ANOTHER AT ALL. IT POPPED PULLING OUT, GOING AROUND A CURVE, GOING BACKWARDS, OR SLOWING DOWN. THE HUMMING STOPPED ALL OF A SUDDEN AFTER IT GOT VERY LOUD. MY ASPEN THEN FELL TOWARD THE RIGHT SIDE AND SMOKE STARTED SHOOTING OUT FROM THE PASSENGER BACK TIRE WHEN DRIVING IT. I THEN TOOK IT TO THE MECHANIC. HE SAID IT WAS VERY BAD. THE REAR AXLE AND REAR AXLE BEARING ARE DESTROYED AND IT WILL NEED A NEW REAR END. THIS VEHICLE HAD NO8 REAR PINION NUT RECALL COMPLETED ON 1/13/2014. IF THE RECALL REALLY SOLVES THE 2009 ASPEN PROBLEM OF THE REAR END AXLE AND AXLE BEARINGS FROM BEING DESTROYED THEN WHY AM I NOW HAVING TO GET A NEW REAR END IN DECEMBER OF 2019. I SEE COMPLAINTS ALL OVER THE INTERNET ABOUT THIS PROBLEM WITH THE VEHICLE AFTER THE RECALL WAS COMPLETED SO NOW PEOPLE ARE PAYING FOR REPAIRS OUT OF POCKET. A $2500+ REPAIR FOR A VEHICLE IS AN AWFUL PRODUCT FLAW THAT CHRYSLER IS NOT BEING RESPONSIBLE FOR. I HAVE HAD CARS FOR 20 YEARS THAT I NEVER HAD TO POCKET MONEY LIKE THAT FOR ALL THEIR REPAIRS TOGETHER.
TL* THE CONTACT OWNS A 2009 CHRYSLER ASPEN. AFTER REFUELING THE VEHICLE, THE CONTACT BEGAN TO DRIVE AND ALMOST IMMEDIATELY THE VEHICLE STALLED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE. THE CONTACT, WHO WAS A CERTIFIED MECHANIC, DIAGNOSED THE VEHICLE. THE CONTACT ALSO CONFIRMED WITH OURISMAN CHRYSLER DODGE JEEP RAM OF BOWIE (…
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TL* THE CONTACT OWNS A 2009 CHRYSLER ASPEN. AFTER REFUELING THE VEHICLE, THE CONTACT BEGAN TO DRIVE AND ALMOST IMMEDIATELY THE VEHICLE STALLED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE. THE CONTACT, WHO WAS A CERTIFIED MECHANIC, DIAGNOSED THE VEHICLE. THE CONTACT ALSO CONFIRMED WITH OURISMAN CHRYSLER DODGE JEEP RAM OF BOWIE (LOCATED AT 2406 CRAIN HWY, BOWIE, MD 20716, (855) 822-3228) THAT THE CHECK VALVE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE CONTACT STATED THAT THE FAILURE WAS MORE PROMINENT AFTER THE VEHICLE WAS FILLED WITH FUEL. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 189,000.
FUEL PUMP SHORT CIRCUIT. AFTER PUMPING GAS THE TRUCK WILL NOT TURN ON. SHORT CIRCUIT FROM THE PUMP TO THE STARTER. AFTER TURNING THE KEY TO POWER ON THE TRUCK ALL THE GAS SPILLED FROM UNDERNEATH. I DROVE TO MY KIDS SCHOOL AT 230PM , AFTER LEAVING POWERED ON THE TRUCK TO ROLL THE WINDOW DOWN AND THATS WHEN ALL THE GAS SPILLE…
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FUEL PUMP SHORT CIRCUIT. AFTER PUMPING GAS THE TRUCK WILL NOT TURN ON. SHORT CIRCUIT FROM THE PUMP TO THE STARTER. AFTER TURNING THE KEY TO POWER ON THE TRUCK ALL THE GAS SPILLED FROM UNDERNEATH. I DROVE TO MY KIDS SCHOOL AT 230PM , AFTER LEAVING POWERED ON THE TRUCK TO ROLL THE WINDOW DOWN AND THATS WHEN ALL THE GAS SPILLED FROM UNDERNEATH.
THE OVERHEAD CONTROL MODULE HAS FAILED 3 TIMES IN THE LAST 2 YEARS. WE ARE BEING ASKED TO COVER IT OUR OF POCKET AGAIN EVEN THOUGH THE PART SHOULD BE UNDER THE 12 MONTH WARRANTY. CHRYSLER CUSTOMER SERVICE TELLS ME THAT SINCE IT WAS REPLACE UNDER WARRANTY THE LAST TIME (12 MONTHS AGO) OUR CONSUMER WARRANTY GOES BACK TO THE ONE …
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THE OVERHEAD CONTROL MODULE HAS FAILED 3 TIMES IN THE LAST 2 YEARS. WE ARE BEING ASKED TO COVER IT OUR OF POCKET AGAIN EVEN THOUGH THE PART SHOULD BE UNDER THE 12 MONTH WARRANTY. CHRYSLER CUSTOMER SERVICE TELLS ME THAT SINCE IT WAS REPLACE UNDER WARRANTY THE LAST TIME (12 MONTHS AGO) OUR CONSUMER WARRANTY GOES BACK TO THE ONE WE PURCHASED THE FIRST TIME IT FAILED AND WON'T COVER IT THIS TIME.
TL* TAKATA RECALL. THE CONTACT OWNS A 2009 CHRYSLER ASPEN. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V352000(AIR BAGS); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF TH…
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TL* TAKATA RECALL. THE CONTACT OWNS A 2009 CHRYSLER ASPEN. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V352000(AIR BAGS); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE.
Official recalls
418V021000 · Air Bags:frontal:passenger Side:inflator Module
Jan 9, 2018
Chrysler (FCA US LLC) is recalling certain 2009-2013 Jeep Wrangler, Chrysler 300, Dodge Challenger and Dodge Charger vehicles, and 2009-2011 Dodge Dakota vehicles 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, Chrysler is recalling certain 2009-2010 RAM 4500 Cab Chassis, RAM 5500 Cab Chassis, RAM 3500 Cab Chassis, Jeep Wrangler, Chrysler 300, Dodge Dakota, Dodge Challenger, and Dodge Charger vehicles 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." Chrysler is also recalling certain 2009 RAM 3500, RAM 2500, RAM 4500 Cab Chassis, RAM 5500 Cab Chassis, Dodge Durango, Chrysler Aspen, RAM 3500 Cab Chassis, Jeep Wrangler, Chrysler 300, Dodge Dakota, Dodge Challenger, and Dodge Charger vehicles 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. In the event of a crash necessitating deployment of the passenger frontal air bag, these passenger air bag inflator may explode due to propellant degradation occurring after long-term exposure to absolute humidity and 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: Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. The recall began February 28, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is U03.
16V947000 · Air Bags:frontal:driver Side:inflator Module
Dec 22, 2016
Chrysler (FCA US LLC) is recalling certain model year 2009 Dodge Durango and Chrysler Aspen vehicles manufactured January 17, 2007, to December 18, 2008, and 2010 RAM 3500 cab chassis manufactured September 25, 2009, to February 1, 2010. The affected vehicles are equipped with a dual-stage driver frontal air bag that may be susceptible to moisture intrusion which, over time, could cause the inflator to rupture.
Consequence & remedy
Consequence: In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could rupture with metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler has notified owners, and dealers will replace the driver's frontal air bag inflator, free of charge. The recall began January 11, 2017. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is S92. Note: This recall covers vehicles that were accidentally excluded from recall 15V-313.
16V352000 · Air Bags:frontal:passenger Side:inflator Module
May 24, 2016
Chrysler (FCA US LLC) expanded the affected population to include 73,712 2005-2009 RAM 2500 trucks produced at the St. Louis North Assembly Plant. With this change, Chrysler is recalling certain model year 2004-2008 RAM 1500, 2005-2009 RAM 2500, 2006-2009 RAM 3500, 2007-2010 RAM 3500 Cab Chassis, 2008-2010 RAM 4500 and 5500 Cab Chassis, 2004-2009 Dodge Durango, 2007-2009 Chrysler Aspen, 2007-2012 Jeep Wrangler, 2008-2012 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2012 Chrysler 300, 2006-2012 Dodge Charger, 2005-2011 Dodge Dakota, and 2006-2009 Mitsubishi Raider vehicles originally sold, or ever registered, in AL, CA, FL, GA, HI, LA, MS, SC, TX, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Chrysler is also recalling 2004-2008 RAM 1500, 2005-2009 RAM 2500, 2006-2009 RAM 3500, 2007-2009 RAM 3500 Cab Chassis, 2008-2009 RAM 4500 and 5500 Cab Chassis, 2004-2009 Dodge Durango, 2007-2009 Chrysler Aspen, 2007-2009 Jeep Wrangler, 2008-2009 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2009 Chrysler 300, 2006-2009 Dodge Charger, 2005-2009 Dodge Dakota and 2006-2009 Mitsubishi Raider vehicles originally sold, or ever registered, in AZ, AR, DE, Washington D.C., IL, IN, KS, KY, MD, MO, NE, NV, NJ, NM, NC, OH, OK, PA, TN, VA, and WV, or "Zone B." Lastly, unless included in "Zone A" or "Zone B" above, Chrysler is recalling certain 2005-2008 RAM 2500, 2006-2008 RAM 3500, 2007-2008 RAM 3500 Cab Chassis, 2008 RAM 4500 and 5500 Cab Chassis, 2004-2008 Dodge Durango, 2007-2008 Chrysler Aspen, 2007-2008 Jeep Wrangler, 2008 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2008 Chrysler 300, 2006-2008 Dodge Charger, 2005-2008 Dodge Dakota, and 2006-2008 Mitsubishi Raider vehicles originally sold, or registered, in AK, CO, CT, ID, IA, ME, MA, MI, MN, MT, NH, NY, ND, OR, RI, SD, UT, VT, WA, WI, and WY.
Consequence & remedy
Consequence: These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. These inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling. An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler will notify the Chrysler, Dodge, Jeep and RAM owners. Mitsubishi owners will be notified by their company. Dealers will replace the passenger frontal air bag inflator, free of charge. The recall began on March 27, 2017. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is S43. Note: This recall supersedes recall 14V-7700.
13V038000 · Power Train:driveline:differential Unit
Feb 6, 2013
Chrysler is recalling certain model year 2009-2012 Ram 1500 trucks manufactured from February 27, 2008, through June 30, 2009, and from December 1, 2009, through October 20, 2011; model year 2009-2011 Dodge Dakota trucks manufactured from February 27, 2007, through June 30, 2009, and from December 1, 2009, through September 30, 2011; model year 2009 Chrysler Aspen trucks manufactured from January 3, 2008, through December 18, 2008; and model year 2009 Dodge Durango trucks manufactured from January 3, 2008, through December 18, 2008. The rear axle pinion nut may loosen due to an undersized pinion spline that can allow relative motion between the nut and companion flange.
Consequence & remedy
Consequence: If the rear axle pinion nut loosens, the axle can lock up and cause a loss of vehicle control and/or a vehicle crash with little warning.
Remedy: On November 7, 2013 Chrysler notified owners that dealers would install a pinion nut retainer, free of charge. In July 2015, and under a consent order with NHTSA, the company agreed to offer owners three options for remedying their vehicles: perform the original remedy, offer to repurchase the vehicle at the fair market value plus 10%, or offer an additional incentive offer towards the purchase of a new Dodge, Jeep, Chrysler, or Fiat vehicle. Chrysler will notify owners of the new recall options in a letter expected to be mailed on August 31, 2015. Owners may contact Chrysler at 1-800-247-9753. Chrysler's recall campaign number is N08.
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.