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2011 GMC Sierra 1500

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2011 GMC Sierra 1500 do not stand out strongly from the model-year median of 181.

About this comparison →

When problems were reported

Mileage at the reported incident

151 reports with mileage · 133 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 113 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Structure. Review the 45 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 24 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

5 crash reports3 fire reports5 injury reports

Vehicle Speed Control complaints

7 reports
Clear category filter
100,185 miles · Feb 11, 2019
Electrical SystemElectronic Stability Control (esc)Vehicle Speed Control

ISSUE #1-WHILE DRIVING THE VEHICLE STABLITRAK WARNING LIGHT, TRACTION CONTROL, ENGINE POWER REDUCED, AND BRAKE LIGHT ALL CAME ON. VEHICLES ENGINE POWER WAS SUDDENLY REDUCED TO ABOUT 10 MPH WHILE DRIVING ON THE INTERSTATE IN WHICH I FOUND TO BE VERY DANGEROUS! HAD TO PULL OVER, TURNED OFF VEHICLE, LIGHTS WENT OFF, STARTED DRIVING…

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ISSUE #1-WHILE DRIVING THE VEHICLE STABLITRAK WARNING LIGHT, TRACTION CONTROL, ENGINE POWER REDUCED, AND BRAKE LIGHT ALL CAME ON. VEHICLES ENGINE POWER WAS SUDDENLY REDUCED TO ABOUT 10 MPH WHILE DRIVING ON THE INTERSTATE IN WHICH I FOUND TO BE VERY DANGEROUS! HAD TO PULL OVER, TURNED OFF VEHICLE, LIGHTS WENT OFF, STARTED DRIVING AGAIN, VEHICLE DID THE SAME THING. HAD TO TAKE IN FOR MECHANICAL REPAIRS. ISSUE #2- KEY IGNITION SWITCH JUST STARTED LOCKING UP ON THE VEHICLE, WOULD NOT TURN BACK TO NORMAL TO POSITION, HAD TO REPEATEDLY KEEP JIGGLING FOR OVER 30 MINUTES OR SO TO GET THE VEHICLE STARTED BACK UP?? HAD TO TAKE VEHICLE TO DEALER FOR REPAIRS ALSO. THESE ARE VERY UNSAFE AND COSTLY ISSUES THAT GMC SHOULD BE MANDATORILY REQUIRED TO HAVE RECALLED AND IMMEDIATELY ADDRESSED FOR THE SAFETY OF THE GENERAL PUBLIC!!

NHTSA ODI #11176160

Mileage unknown · Apr 7, 2017
EngineSteeringVehicle Speed Control

No narrative supplied in this record.

NHTSA ODI #10971237

78,500 miles · Jan 7, 2014
Fuel/propulsion SystemVehicle Speed Control

WENT ABOUT A MILE WAS GETTING READY TO MAKE A LEFT ACROSS MD RT 4 WHEN I LOST POWER AND REDUCED ENGINE POWER LIGHT CAME, HAD A CLOSE CALL, ON DID SOME RESEARCH AND FOUND A TECHNICAL NOTICE ABOUT THROTTLE BODY AND INJECTOR SENSORS THEY NEED A RECALL. *TR

NHTSA ODI #10558740

90,000 miles · Nov 20, 2013
Power TrainVehicle Speed Control

TL* THE CONTACT OWNS A 2011 GMC SIERRA 1500. THE CONTACT STATED THAT THE VEHICLE WAS POWERED ON AND IN PARK WHEN IT LUNGED FORWARD ABNORMALLY. THE CONTACT HAD TO JUMP IN THE VEHICLE AND DEPRESS THE BRAKES TO STOP IT FROM TRAVELING ANY FARTHER. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS HOWEVER, THE DEALER WAS UNABLE TO DETE…

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TL* THE CONTACT OWNS A 2011 GMC SIERRA 1500. THE CONTACT STATED THAT THE VEHICLE WAS POWERED ON AND IN PARK WHEN IT LUNGED FORWARD ABNORMALLY. THE CONTACT HAD TO JUMP IN THE VEHICLE AND DEPRESS THE BRAKES TO STOP IT FROM TRAVELING ANY FARTHER. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS HOWEVER, THE DEALER WAS UNABLE TO DETERMINE THE CAUSE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE ISSUE. THE APPROXIMATE FAILURE MILEAGE WAS 90,000.

NHTSA ODI #10553017

3,100 miles · Sep 2, 2011
Vehicle Speed ControlInjury

I WAS GOING 40MPH WHEN I WENT TO STOP QUICK TO AVOID AN ACCIDENT. I PRESSED ON BRAKES TRUCK DID NOT SLOW DOWN THEN ALL OF A SUDDEN IT DID DOWN SHIFT BUT AT THAT THE TRUCK LUNGED FORWARD CAUSING ME TO CLIP THE TRUCK IN FRONT OF ME. *TR

NHTSA ODI #10423109

1,335 miles · Jan 19, 2011
Vehicle Speed Control

2011 GMC SIERRA 1500 SLE CREW CAB Z71 4X4 COMING OFF OF THE EXPRESSWAY AND COMING TO A STOP AT A TRAFFIC LIGHT I APPLIED BRAKE PRESSURE. THE BRAKE PEDAL WAS UNUSALLY STIFF THEN ALL OF A SUDDEN THE ENGINE REVVED TO OVER 5000 RPM'S AND STARTING TO MOVE FORWARD. I HAD MY FOOT PUSHED FIRMLY ON THE BRAKE AND THE VEHICLE REMAINED R…

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2011 GMC SIERRA 1500 SLE CREW CAB Z71 4X4 COMING OFF OF THE EXPRESSWAY AND COMING TO A STOP AT A TRAFFIC LIGHT I APPLIED BRAKE PRESSURE. THE BRAKE PEDAL WAS UNUSALLY STIFF THEN ALL OF A SUDDEN THE ENGINE REVVED TO OVER 5000 RPM'S AND STARTING TO MOVE FORWARD. I HAD MY FOOT PUSHED FIRMLY ON THE BRAKE AND THE VEHICLE REMAINED REVVING AND MOVING FORWARD. I QUICKLY PUT IT IN PARK AND TURNED OFF VEHICLE. STARTED BACK UP AND NO ISSUES ON REMAINING DRIVE. CRUISE CONTROL WAS NOT ENGAGED. VEHICLE HAS LESS THAN 1400 MILES ON IT. *TR

NHTSA ODI #10377941

2,800 miles · Dec 28, 2010
Vehicle Speed Control

SECOND REPORT - SUDDEN ACCELERATION. 2011 GMC SIERRA PU TRUCK. ON DECEMBER 20, 2010 I WAS TRAVELING TO VISIT FRIENDS. WHILE ON HIGHWAY I SET THE CRUISE CONTROL FOR 70 MPH. I EXITED THE FREEWAY AND TRAVELED APPROXIMATELY 5 MILES ON CITY STREETS. UPON ENTERING A BEDROOM TOWNSHIP KNOWN FOR SPEED TRAPS I ATTEMPTED TO ENGAGE THE…

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SECOND REPORT - SUDDEN ACCELERATION. 2011 GMC SIERRA PU TRUCK. ON DECEMBER 20, 2010 I WAS TRAVELING TO VISIT FRIENDS. WHILE ON HIGHWAY I SET THE CRUISE CONTROL FOR 70 MPH. I EXITED THE FREEWAY AND TRAVELED APPROXIMATELY 5 MILES ON CITY STREETS. UPON ENTERING A BEDROOM TOWNSHIP KNOWN FOR SPEED TRAPS I ATTEMPTED TO ENGAGE THE CRUISE CONTROL FOR 30 MPH. WHEN PRESSING THE CRUISE CONTROL TO SET THE SPEED I WAS TRAVELING (30 MPH) THE TRUCK DOWN SHIFTED AND ACCELERATED RAPIDLY (TO 4000 RPM). I IMMEDIATELY TAPPED THE BRAKE AND THE CRUISE CONTROL DISENGAGED. THIS IS THE SECOND TIME FOR THIS TRUCK TO DOWN SHIFT AND ACCELERATE RAPIDLY. A PREVIOUS REPORT WAS MADE IN NOVEMBER 2010. *TR

NHTSA ODI #10372652

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.

21V054000 · Air Bags:frontal:passenger Side:inflator Module

Feb 5, 2021

General Motors, LLC (GM) is recalling certain 2014 Cadillac Escalade, Escalade ESV, Chevrolet Silverado 2500, Silverado 3500, Suburban, Tahoe, GMC Sierra 2500, Sierra 3500, Yukon, and Yukon XL vehicles originally sold, or ever registered, in the states of AL, CA, FL, GA, HI, LA, MS, SC, TX, PR, AS, GU, the MP, and VI or "Zone A." Additionally GM is recalling certain 2011-2014 Cadillac Escalade, Escalade ESV, Chevrolet Silverado 2500, Silverado 3500, Suburban, Tahoe, GMC Sierra 2500, Sierra 3500, Yukon, Yukon XL and 2011-2013 Cadillac Escalade EXT, Chevrolet Avalanche, Silverado 1500, and GMC Sierra 1500 vehicles originally sold, or ever registered, in the states of AZ, AR, DE, DC, IL, IN, KS, KY, MD, MO, NE, NV, NJ, NM, NC, OH, OK, PA, TN, VA, and WV or "Zone B." Additionally, GM is recalling certain 2010-2014 Cadillac Escalade, Escalade ESV, Chevrolet Silverado 2500, Silverado 3500, Suburban, Tahoe, GMC Sierra 2500, Sierra 3500, Yukon, and Yukon XL and 2010-2013 Cadillac Escalade EXT, Chevrolet Avalanche, Silverado 1500, and GMC Sierra 1500 vehicles originally sold, or ever registered, in the states of AK, CO, CT, ID, IA, ME, MA, MI, MN, MT, NH, NY, ND, OR, RI, SD, UT, VT, WA, WI, and WY 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 25, 2021. Second notification letters will be mailed once the remedy is available. Owner notification letters were mailed to 40 VIN owners on May 11, 2021. A second owner notification letter was mailed to all other owners on January 24, 2022. 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 N212328800.

18V267000 · Equipment

Apr 26, 2018

General Motors LLC (GM) is recalling certain 2009-2014 Chevrolet Silverado HD and GMC Sierra HD, 2009 GMC Topkick 5000, 6000, 7000 and 8000 Series and Isuzu F Series, and 2009-2018 Chevrolet Express, and GMC Savana vehicles, equipped with certain Plastic-Handle Fire Extinguishers or Push Button 'Pindicator' Fire Extinguishers. These extinguishers may become clogged, preventing the extinguisher from discharging as expected or requiring excessive force to activate the extinguisher. Additionally, in certain models, the nozzle may detach from the valve assembly with enough force that it could cause injury and also render the product inoperable. For a full list of the affected fire extinguisher models visit: https://static.nhtsa.gov/odi/rcl/2017/RMISC-17E062-5427.pdf

Consequence & remedy

Consequence: In the event of a fire, if the fire extinguisher does not function properly, it can increase the risk of injury.

Remedy: GM will notify owners, instructing them to contact Kidde to get a replacement fire extinguisher, free of charge. The recall began June 11, 2018. Owners may contact Chevrolet customer service at 1-800-222-1020, GMC customer service at 1-800-462-8782, and Isuzu customer service at 1-866-441-9638. GM's number for this recall is 18146.

11V007000 · Suspension:rear:axle:spindle

Jan 6, 2011

GENERAL MOTORS IS RECALLING CERTAIN MODEL YEAR 2011 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT; CHEVROLET AVALANCHE, COLORADO, EXPRESS, SILVERADO, SUBURBAN, TAHOE; AND GMC CANYON, SIERRA, SAVANA, YUKON AND YUKON XL VEHICLES. THE REAR AXLE CROSS PINS WERE NOT PROPERLY HEAT TREATED AND COULD FRACTURE AND BECOME DISPLACED WITHIN THE REAR AXLE. SHOULD THE PIN SHIFT OUT OF POSITION, IT COULD CREATE AN INTERFERENCE CONDITION AND CAUSE THE REAR AXLE TO LOCK.

Consequence & remedy

Consequence: THE DRIVER MAY NOT BE ABLE TO MAINTAIN DIRECTIONAL CONTROL OF THE VEHICLE AND A CRASH COULD OCCUR WITHOUT WARNING.

Remedy: DEALERS WILL INSTALL A NEW REAR AXLE CROSS PIN FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JANUARY 11, 2011. OWNERS MAY CONTACT CADILLAC AT 1-866-982-2339, CHEVROLET AT 1-800-630-2438, GMC AT 1-866-996-9463 AND AT THE OWNER CENTER AT WWW.GMOWNERCENTER.COM.

10V643000 · Suspension:rear:axle:spindle

Dec 17, 2010

GENERAL MOTORS IS RECALLING CERTAIN MODEL YEAR 2011 CADILLAC ESCALADE EXT, CHEVROLET AVALANCHE, SILVERADO LD AND GMC SIERRA LD VEHICLES. THE REAR AXLE CROSS PINS WERE NOT PROPERLY HEAT TREATED AND COULD FRACTURE AND BECOME DISPLACED WITHIN THE REAR AXLE. SHOULD THE PIN SHIFT OUT OF POSITION, IT COULD CREATE AN INTERFERENCE CONDITION AND CAUSE THE REAR AXLE TO LOCK.

Consequence & remedy

Consequence: THE DRIVER MAY NOT BE ABLE TO MAINTAIN DIRECTIONAL CONTROL OF THE VEHICLE AND A CRASH COULD OCCUR WITHOUT WARNING.

Remedy: DEALERS WILL INSTALL A NEW REAR AXLE CROSS PIN FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JANUARY 11, 2011. OWNERS MAY CONTACT CADILLAC AT 1-866-982-2339, CHEVROLET AT 1-800-630-2438, GMC AT 1-866-996-9463 AND AT THE OWNER CENTER 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

2

DP22005 · Pedestrian Alert Sounds

Opened Jan 27, 2023 · Closed Aug 7, 2023

Status: closed (inferred from source dates) · Electrical System:propulsion System

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

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.