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2015 Honda CR-V

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2015 Honda CR-V do not stand out strongly from the model-year median of 400.5.

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When problems were reported

Mileage at the reported incident

491 reports with mileage · 179 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.

  • Engine. Review the 243 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 148 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 83 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

38 crash reports4 fire reports18 injury reports

What owners actually said

670 reports
Mileage unknown · Nov 24, 2016
Unknown Or Other

VIBRATION AT IDLE

NHTSA ODI #10927766

20,000 miles · Nov 23, 2016
Wheels

I TOOK THE VEHICLE FOR A TRANSMISSION RECALL ON 11/23/16 TO APPLE HONDA RIVERHEAD, NY 11901. AND WAS INFORMED THAT AT 20,000 MILES ALL FOUR TIRES WERE WORN OUT. TIRES ON A NEW VEHICLE SHOULD NOT WEAR OUT AT 20,000 MILES. FIRST THEY TRIED TO BLAME IT ON POOR DRIVING, UNDER INFLATION, EVEN THE FACT THAT THE CAR HAS ALL WHEEL DRIVE…

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I TOOK THE VEHICLE FOR A TRANSMISSION RECALL ON 11/23/16 TO APPLE HONDA RIVERHEAD, NY 11901. AND WAS INFORMED THAT AT 20,000 MILES ALL FOUR TIRES WERE WORN OUT. TIRES ON A NEW VEHICLE SHOULD NOT WEAR OUT AT 20,000 MILES. FIRST THEY TRIED TO BLAME IT ON POOR DRIVING, UNDER INFLATION, EVEN THE FACT THAT THE CAR HAS ALL WHEEL DRIVE. I DID A LITTYLE CHECKING AND FOUND OUT HONDA PUT TIRES ON THE CAR THAT THE MANUFACTURER WON'T PUT A WEAR GAURANTEE ON, HONDA SPECED OUT THESE TIRES TO CONTINENTAL. GOING ON LINE IT APPEARS THIS IS NOT AN ISOLATED CASE DEALING WITH CRV TIRES. I AM REQUESTING AN OFFICIAL INVESTIGATION INTO THIS ISSUE. THEY TRIED TO SELL ME THE SAME TIRES, I WENT ELSEWHERE

NHTSA ODI #10927740

20,000 miles · Nov 12, 2016
Steering

LOST MY POWER STEERING BECAUSE HONDA WRAPS THE ELECTRONIC POWER STEERING WIRING HARNESS IN SOY BASED MATERIAL WHICH ATTRACTS RODENTS TO CHEW. AS I'VE SEEN AND HEARD SEEMS TO BE A COMMON PROBLEM. HONDA WOULDN'T COVER THE COST OR ISSUE RECALL. NOT EVEN UNDER THE VEHICLE WARRANTY. FORTUNATELY I WASN'T DRIVING AT THE TIME I LOST MY …

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LOST MY POWER STEERING BECAUSE HONDA WRAPS THE ELECTRONIC POWER STEERING WIRING HARNESS IN SOY BASED MATERIAL WHICH ATTRACTS RODENTS TO CHEW. AS I'VE SEEN AND HEARD SEEMS TO BE A COMMON PROBLEM. HONDA WOULDN'T COVER THE COST OR ISSUE RECALL. NOT EVEN UNDER THE VEHICLE WARRANTY. FORTUNATELY I WASN'T DRIVING AT THE TIME I LOST MY STEERING OR THE SITUATION COULD HAVE BEEN A LOT WORSE FOR ME OR SOMEONE ELSE IF IT CAUSED AN ACCIDENT BECAUSE I LOST MY STEERING. DEFINITELY A SAFETY ISSUE THAT I THINK NEEDS TO BE A RECALL BECAUSE IT'S SUCH A COMMON PROBLEM

NHTSA ODI #10925630

15,000 miles · Nov 4, 2016
Service Brakes

AFTER 15,000 MILES REAR BRAKES HAD TO BE REPLACED. 4 WEEKS LATER ROTORS ARE PITTING

NHTSA ODI #10924323

12,028 miles · Sep 26, 2016
Service Brakes

TL* THE CONTACT OWNS A 2014 HONDA CR-V. THE CONTACT STATED THAT WHILE AT THE DEALER FOR ROUTINE SERVICE, THE TECHNICIAN STATED THAT THERE WAS PREMATURE WEAR ON THE REAR PASSENGER SIDE BRAKE PADS AND THEY NEEDED TO BE REPLACED. IN ADDITION, THE REAR PASSENGER SIDE ROTORS NEEDED TO BE RESURFACED. THE VEHICLE WAS REPAIRED. THE MANU…

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TL* THE CONTACT OWNS A 2014 HONDA CR-V. THE CONTACT STATED THAT WHILE AT THE DEALER FOR ROUTINE SERVICE, THE TECHNICIAN STATED THAT THERE WAS PREMATURE WEAR ON THE REAR PASSENGER SIDE BRAKE PADS AND THEY NEEDED TO BE REPLACED. IN ADDITION, THE REAR PASSENGER SIDE ROTORS NEEDED TO BE RESURFACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 12,028.

NHTSA ODI #10909676

Mileage unknown · Sep 20, 2016
EnginePower Train

MY HONDA CR-V 2015 POWER SUDDENLY TURNS OFF, CAR STALLS, RED OIL LIGHT COMES, CAR IS STILL IN REVERSE GEAR AS I WAS BACKING OUT OF GARAGE. IT HAD MOVED ABOUT 8 FEET. AFTER A MOMENT OR TWO ENGINE LIGHT COMES ON. THERE IS ABSOLUTELY NO POWER. TO RESTART CAR I SHIFT TO PARK AND PROCEED. ALL SYSTEMS RESTART AND NO PROBLEM LIGH…

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MY HONDA CR-V 2015 POWER SUDDENLY TURNS OFF, CAR STALLS, RED OIL LIGHT COMES, CAR IS STILL IN REVERSE GEAR AS I WAS BACKING OUT OF GARAGE. IT HAD MOVED ABOUT 8 FEET. AFTER A MOMENT OR TWO ENGINE LIGHT COMES ON. THERE IS ABSOLUTELY NO POWER. TO RESTART CAR I SHIFT TO PARK AND PROCEED. ALL SYSTEMS RESTART AND NO PROBLEM LIGHTS TURN ON. AFTER THREE OCCURRENCES OVER ABOUT TWO MONTHS. I TOOK CAR TO HONDA SERVICE 08/22/2016. THEY NOTED THEY CHECKED "CAR STOPS WHEN GOING IN REVERSE" AND COULD NOR GET IT TO FAIL. THEY STATED THEY MADE A SYSTEM UPDATE "16-053 PER BULLETIN PGM-FI SOFTWARE." THEY DID NOT ACKNOWLEDGE ANY OTHER SAFETY RECALLS MATCHING MY PROBLEM. ON 09/18/2016 I EXPERIENCED THE SAME PROBLEM. IT WAS SUNDAY AND RAY LAKS, HONDA WAS CLOSED. I SPENT TIME LOOKING UP RECALLS AND FOUND YOUR LETTER NVS-215SM TO HONDA DEALERS DATED 03/9/2015 WHICH DENOTES THE SAME PROBLEM I HAD - "LOSS OF ENGINE POWER WHILE IN MOTION." IT WOULD APPEAR TO BE SIMILAR PROBLEM. PERHAPS RAY LAKS, HONDA DEALER, 3590 SOUTHWESTERN BLVD., ORCHARD PARK, NY 14127, 716-824-6300 DID NOT DOUBLE CHECK MY CAR FOR THAT UPDATE.

NHTSA ODI #10908267

5,000 miles · Sep 15, 2016
Power TrainWheels

TL* THE CONTACT OWNS A 2015 HONDA CR-V. WHILE DRIVING APPROXIMATELY 55 TO 60 MPH, THE RPMS SURGED AND THERE WAS A DISCONNECT WITH THE TRANSMISSION THAT CAUSED THE FRONT WHEELS TO SEIZE. THE FAILURE RECURRED. THE DEALER AND MANUFACTURER WERE NOTIFIED. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 5,000.

NHTSA ODI #10906944

11,000 miles · Sep 9, 2016
Air BagsSeat BeltsCrashInjury

TL* THE CONTACT OWNS A 2015 HONDA CR-V. WHILE DRIVING AT VARIOUS SPEEDS, THE CONTACT'S VEHICLE COLLIDED INTO ANOTHER VEHICLE WHILE MAKING A LEFT TURN. THE DETAILS OF WHERE THE CONTACT'S VEHICLE WAS STRUCK COULD NOT BE PROVIDED. THE AIR BAGS FAILED TO DEPLOY AND THE SEAT BELT FAILED TO RETRACT. THE CONTACT SUSTAINED MINOR INJURIE…

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TL* THE CONTACT OWNS A 2015 HONDA CR-V. WHILE DRIVING AT VARIOUS SPEEDS, THE CONTACT'S VEHICLE COLLIDED INTO ANOTHER VEHICLE WHILE MAKING A LEFT TURN. THE DETAILS OF WHERE THE CONTACT'S VEHICLE WAS STRUCK COULD NOT BE PROVIDED. THE AIR BAGS FAILED TO DEPLOY AND THE SEAT BELT FAILED TO RETRACT. THE CONTACT SUSTAINED MINOR INJURIES, BUT IT WAS UNKNOWN IF MEDICAL ATTENTION WAS RECEIVED. A POLICE REPORT WAS FILED. THE VEHICLE WAS DRIVEN FROM THE SCENE AND THEN TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS CONFIRMED THAT THE DRIVER SIDE FRAME RAIL WAS CRUSHED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 11,000.

NHTSA ODI #10904991

11,000 miles · Sep 9, 2016
Air BagsSeat BeltsStructureCrashInjury

THE CRV WAS INVOLVED IN A LARGE ACCIDENT AND THE LEFT FRONT LOWER FRAME RAIL IS CRUSHED FROM A HEAD ON COLLISION. THE LEFT AIR BAG DID NOT DEPLOY NOR THE SEATBELT LOCK UP CAUSING A MINOR INJURY TO THE DRIVER. HONDA USA WAS CONTACTED BUT REFUSED TO SEND AN ENGINEER TO INSPECT THE CAR.

NHTSA ODI #10904988

14,000 miles · Sep 6, 2016
Structure

TL* THE CONTACT OWNS A 2015 HONDA CR-V. AFTER EXITING THE VEHICLE AFTER PARKING IT IN A GARAGE, IT CONTINUED TO RUN WHILE IDLING. AS A RESULT, CARBON MONOXIDE FILLED THE RESIDENCE. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE CONTACT AND HIS SPOUSE WENT TO THE HOSPITAL. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VI…

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TL* THE CONTACT OWNS A 2015 HONDA CR-V. AFTER EXITING THE VEHICLE AFTER PARKING IT IN A GARAGE, IT CONTINUED TO RUN WHILE IDLING. AS A RESULT, CARBON MONOXIDE FILLED THE RESIDENCE. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE CONTACT AND HIS SPOUSE WENT TO THE HOSPITAL. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 14,000. THE CONSUMER STATED THE VEHICLE WAS ACCIDENTALLY LEFT RUNNING., DUE TO THE VEHICLE BEING EQUIPPED WITH PUSH START. UPDATED 11/08/16.*JB

NHTSA ODI #10903814

Official recalls

3

23V858000 · Fuel System, Gasoline:delivery:fuel Pump

Dec 18, 2023

Honda (American Honda Motor Co.) is recalling certain 2013-2023 Honda Accord, Civic Coupe, Civic Sedan, Civic Hatchback, Civic Type R, CR-V, HR-V, Ridgeline, Odyssey, Acura ILX, MDX, MDX Hybrid, RDX, RLX, TLX, 2019-2022 Honda Insight, Passport, 2020 Honda CR-V Hybrid, 2018-2019 Honda Clarity PHEV, Fit, and 2015-2020 Honda Accord Hybrid, Pilot, Acura NSX vehicles. The fuel pump inside the fuel tank may fail.

Consequence & remedy

Consequence: Fuel pump failure can cause an engine stall while driving, increasing the risk of a crash.

Remedy: Dealers will replace the fuel pump module, free of charge. Owner letters were mailed September 6, 2024. Owners may contact Honda customer service at 1-888-234-2138. Honda's numbers for this recall are KGC and KGD. This recall is an expansion of NHTSA recall numbers 21V-215 and 20V-314.

17V305000 · Engine

May 4, 2017

Honda (American Honda Motor Co.) is recalling certain 2015-2016 Honda CR-V vehicles that recently received a replacement engine. The replacement engine may have been built with the wrong pistons, potentially affecting the engine's performance.

Consequence & remedy

Consequence: The reduced performance may result in an engine stall, increasing the risk of a crash.

Remedy: Honda will notify owners, and dealers will inspect the engines and replace the incorrect components, as necessary, free of charge. The recall began June 20, 2017. Owners may contact Honda customer service at 1-888-234-2138. Honda's number for this recall is KF6.

15V121000 · Engine And Engine Cooling:engine

Mar 2, 2015

American Honda Motor Co. (Honda) is recalling certain model year 2014 Accord L4 vehicles manufactured July 29, 2014, to July 31, 2014, 2015 Accord L4 vehicles manufactured August 14, 2014, to January 30, 2015, and 2015 CR-V vehicles manufactured September 9, 2014, to February 6, 2015. The affected vehicles may have been assembled with improperly torqued connecting rod bolts, which can cause the engine to lose power or leak oil.

Consequence & remedy

Consequence: Loss of engine power may result in a vehicle stall, increasing the risk of a crash. If the engine leaks oil in the proximity of hot engine or exhaust components, there is an increased risk of a fire.

Remedy: Honda will notify owners, and dealers will replace the engine short block, free of charge. The recall began on March 27, 2015. Owners may contact Honda customer service at 1-888-234-2138. Honda's number for this recall is JP2 (for Accord models) and JP3 (for CR-V models).

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

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.

EA19001 · Electrical Overstress

Opened Apr 19, 2019 · Closed Sep 19, 2024

Status: closed (inferred from source dates) · Air Bags: Air Bag/restraint Control Module

The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect.  During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW.  The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications.  The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU.  In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment.  FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle.  Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW.  These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes.  An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time.   In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU.  This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners.  Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW.  The risk associated with the ASIC is equally shared among all OEMS involved in the investigation.  The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage.  There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation.  The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU.  If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC.  Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC.  All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled.  In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024.  With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.

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