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2012 Mazda MAZDA3

Owner reports · Recalls · Investigations

More warning signs than most MAZDA3 years

Owner complaints for the 2012 Mazda MAZDA3 are substantially higher than the model-year median of 108.

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When problems were reported

Mileage at the reported incident

171 reports with mileage · 55 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.

  • Power Train. Review the 40 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 32 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Exterior Lighting. Review the 31 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

9 crash reports1 fire reports3 injury reports

Power Train complaints

40 reports
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19,155 miles · Oct 30, 2013
Power TrainTraction Control System

VEHICLE WAS TRAVELING ON HIGHWAY GOING 45MPH WHEN AUTOMATIC TRANSMISSION DOWNSHIFTED SUDDENLY TO FIRST GEAR AND WOULD NOT UPSHIFT. ATTEMPTED TO MANUALLY SHIFT GEARS AND GEAR DISPLAY THAT SHOWS THE GEAR NUMBER WAS BLANK. TRACTION CONTROL LIGHT WENT ON, NO ENGINE CODES WERE TRIGGERED. CAR OPERATED NORMALLY UPON RESTART. *TR

NHTSA ODI #10550149

50,016 miles · Oct 29, 2013
Power Train

I HAVE A '12 MAZDA MAZDA3 ITOURING HATCHBACK W/2.0L SKYACTIV I-4 (BL GENERATION) WITH SKYACTIV 6MT. WHEN STARTING OFF FROM A STOP IN 1ST GEAR AND SHIFTING INTO 2ND GEAR (CLUTCH PEDAL COMPLETELY DEPRESSED BEFORE SHIFTER WAS PULLED OUT OF 1ST, NO GAS PEDAL WAS APPLIED) TRANSMISSION WOULD GRIND WHEN SHIFTER IS BEING PULLED INTO 2ND…

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I HAVE A '12 MAZDA MAZDA3 ITOURING HATCHBACK W/2.0L SKYACTIV I-4 (BL GENERATION) WITH SKYACTIV 6MT. WHEN STARTING OFF FROM A STOP IN 1ST GEAR AND SHIFTING INTO 2ND GEAR (CLUTCH PEDAL COMPLETELY DEPRESSED BEFORE SHIFTER WAS PULLED OUT OF 1ST, NO GAS PEDAL WAS APPLIED) TRANSMISSION WOULD GRIND WHEN SHIFTER IS BEING PULLED INTO 2ND GEAR. GRIND CAN BE HEARD INSIDE AND OUTSIDE, AND CAN BE FELT IN SHIFTER. GRIND WOULD CONTINUE FOR LESS THAN A SECOND THEN WOULD POP FULLY INTO 2ND GEAR. ALONG WITH ISSUE, WHENEVER GRIND DOES NOT OCCUR, SHIFTING INTO 2ND GEAR REQUIRES SIGNIFICANTLY MORE FORCE TO FULLY ENGAGE COMPARED TO REVERSE, 1ST, 3RD, 4TH, 5TH AND 6TH GEARS. MAZDA DEALERSHIP COULD NOT DUPLICATE SYMPTOM, THEREFORE DECLARING AN "NPF" OR "NO PROBLEM FOUND." *TR

NHTSA ODI #10549918

14,000 miles · Jun 6, 2013
Electronic Stability Control (esc)Power Train

MY CAR IS AN AUTOMATIC TRANSMISSION. I WAS DRIVING IN TRAFFIC ON THE HIGHWAY (ABOUT 20 MPH) AND NOTICED THAT WHEN I PRESSED THE ACCELERATOR, THE CAR DID NOT ACCELERATE OR SHIFT NORMALLY. INSTEAD, THE CAR STAYED IN LOW GEAR, AND THE RPM REACHED OVER 4000. AT THIS POINT, I NOTICED. THE STABILITY CONTROL LIGHT ON THE DASHBOARD…

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MY CAR IS AN AUTOMATIC TRANSMISSION. I WAS DRIVING IN TRAFFIC ON THE HIGHWAY (ABOUT 20 MPH) AND NOTICED THAT WHEN I PRESSED THE ACCELERATOR, THE CAR DID NOT ACCELERATE OR SHIFT NORMALLY. INSTEAD, THE CAR STAYED IN LOW GEAR, AND THE RPM REACHED OVER 4000. AT THIS POINT, I NOTICED. THE STABILITY CONTROL LIGHT ON THE DASHBOARD WAS STAYING ON, INDICATING A PROBLEM WITH THE CAR'S STABILITY CONTROL. ONCE I REACHED A PLACE I COULD STOP, I TURNED OFF THE CAR AND RESTARTED - THE PROBLEM APPEARED TO HAVE GONE AWAY - NO MORE LIGHT ON THE DASHBOARD AND NO MORE WEIRD ENGINE SPEEDS/FAILURE TO SHIFT GEARS. I AM CONCERNED ABOUT THIS BECAUSE IT SEEMS TO BE A COMMON COMPLAINT BOTH ON THE NHTSA SITE AND ON MAZDA FORUM WEBSITES. I BELIEVE AN INVESTIGATION INTO THIS PROBLEM IS WARRANTED, AS IT REPRESENTS A DEFINITE SAFETY RISK, AFFECTING THE CAR'S ABILITY TO ACCELERATE APPROPRIATELY. *TR

NHTSA ODI #10515446

17,758 miles · Feb 15, 2013
Electronic Stability Control (esc)EnginePower Train

WHILE DRIVING DOWN THE HIGHWAY THE VEHICLE ALL OF A SUDDEN LOST POWER AND BEGAN TO SLOW DOWN. THE TRACTION CONTROL LIGHT TURNED ON AT THIS TIME. PUSHING THE ACCELERATOR DID NOTHING. WHEN I SWITCHED THE MANUAL MODE FOR THE TRANSMISSION THE GEAR WAS NOT DISPLAYED ON THE DASHBOARD AND TRYING TO UP OR DOWNSHIFT DID NOTHING. AFTER PU…

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WHILE DRIVING DOWN THE HIGHWAY THE VEHICLE ALL OF A SUDDEN LOST POWER AND BEGAN TO SLOW DOWN. THE TRACTION CONTROL LIGHT TURNED ON AT THIS TIME. PUSHING THE ACCELERATOR DID NOTHING. WHEN I SWITCHED THE MANUAL MODE FOR THE TRANSMISSION THE GEAR WAS NOT DISPLAYED ON THE DASHBOARD AND TRYING TO UP OR DOWNSHIFT DID NOTHING. AFTER PULLING OFF TO THE SIDE OF THE ROAD I WAS ABLE TO PLACE THE TRANSMISSION IN PARK. I LIFTED THE HOOD AND CHECKED FOR FLUID LEAKS OR SPILLS OF WHICH THERE WERE NONE. AFTER TURNING OFF THE CAR AND WAITING A COUPLE OF MINUTES I TURNED IT BACK ON AND NOW HAD THE TRACTION CONTROL, AT, AND CHECK ENGINE LIGHTS LIT. AFTER PUTTING THE TRANSMISSION IN DRIVE AND PUSHING THE ACCELERATOR THE VEHICLE WAS EXTREMELY SLUGGISH IN ACCELERATION AND WOULD SHIFT THROUGH THE FIRST FOUR GEARS BUT AT RPMS MUCH HIGHER THAN NORMAL. I WAS ABLE TO LIMP THE VEHICLE HOME AS THE DEALERSHIP WAS ALREADY CLOSED. AFTER LETTING THE VEHICLE SIT FOR 15 MINUTES OR SO I TURNED IT BACK ON AND NOW ONLY THE CHECK ENGINE LIGHT IS LIT. WILL BE TAKING TO THE DEALER IN THE MORNING. *TR

NHTSA ODI #10498315

1,000 miles · Jan 1, 2013
EnginePower TrainVehicle Speed Control

MY 2012 MAZDA 3 SKYACTIV HATCHBACK WITH THE 6 SPEED MANUAL TRANSMISSION IS EXHIBITING UNINTENDED ACCELERATION. THE SYMPTOMS EXHIBITED ARE CONSISTENT WITH MULTIPLE OTHER REPORTS IN THIS SYSTEM. AFTER DOWNSHIFTING INTO 2ND OR 3RD GEAR, OR AFTER COASTING IN ONE OF THOSE GEARS WITH THE CLUTCH DISENGAGED, THE ENGINE REVS AND THE CAR …

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MY 2012 MAZDA 3 SKYACTIV HATCHBACK WITH THE 6 SPEED MANUAL TRANSMISSION IS EXHIBITING UNINTENDED ACCELERATION. THE SYMPTOMS EXHIBITED ARE CONSISTENT WITH MULTIPLE OTHER REPORTS IN THIS SYSTEM. AFTER DOWNSHIFTING INTO 2ND OR 3RD GEAR, OR AFTER COASTING IN ONE OF THOSE GEARS WITH THE CLUTCH DISENGAGED, THE ENGINE REVS AND THE CAR "SURGES" FORWARD UPON RE-ENGAGEMENT OF THE CLUTCH. WHEN THIS OCCURS, THE ACCELERATOR PEDAL IS ONLY BEING SLIGHTLY PUSHED, BUT THE CAR ACTS AS IF IT HAS BEEN PUSHED ALMOST TO THE FLOOR. DEPENDING ON THE POSITION OF THE CLUTCH PEDAL WHEN THIS OCCURS, THE ENGINE WILL EITHER REV TO 3000 TO 4000 RPM, OR THE CAR WILL ACCELERATE FORWARD UNTIL EITHER THE BRAKE OR CLUTCH PEDAL IS PRESSED. THIS ISSUE HAS BEEN CONFIRMED BY MAZDA AFTER MULTIPLE TRIPS TO THE DEALERSHIP FOR SERVICE. UPON THE LAST VISIT, A DATA RECORDER WAS INSTALLED AND RECORDED 7 SPECIFIC UNINTENDED ACCELERATION EVENTS BETWEEN THE DATES OF 11/13/12 AND 11/20/12. ACCORDING TO AN EMAIL I RECEIVED FROM THE DISTRICT SERVICE & PARTS MANAGER FOR DISTRICT 2 OF MAZDA NORTH AMERICA OPERATIONS (MNAO) ON 12/23/12, "THE CONCERN FOUND ON THE DATA RECORDINGS TAKEN FROM YOUR VEHICLE WERE FOUND TO BE A PCM CALIBRATION ISSUE. MAZDA CORPORATION IS WORKING ON A NEW CALIBRATION FOR THE PCM WITH AN UNKNOWN TIME OF COMPLETION." WHEN I REQUESTED THAT MY VEHICLE BE REPLACED WITH ANOTHER OF THE SAME MODEL, THIS WAS THE RESPONSE FROM THE SAME DISTRICT SERVICE & PARTS MANAGER: "SINCE THE CALIBRATION OF THE PCM IS THE SAME ON A 2013 LIKE MODEL WITH A MANUAL TRANSMISSION IT WOULD NOT BE ADVISED TO TRADE YOU INTO THAT VEHICLE AS IT COULD POTENTIALLY EXHIBIT THE SAME CONCERN DEPENDING ON YOUR DRIVING HABITS AND CONDITIONS." I AM CURRENTLY AWAITING A RESPONSE FROM MNAO'S MEDIATION DEPARTMENT REGARDING EITHER REPLACING MY CAR WITH ANOTHER MODEL, OR BUYING BACK THE CAR FROM ME. *TR

NHTSA ODI #10490670

100 miles · Dec 27, 2012
EnginePower TrainVehicle Speed Control

APPROXIMATELY TWO OR THREE TIMES A WEEK WHEN DOWNSHIFTING OUT OF A RIGHT OR LEFT HAND CURVE OR TURN, MY 2012 MANUAL TRANSMISSION MAZDA 3 HATCHBACK WILL ACCELERATE ON ITS OWN. THIS IS CHARACTERIZED BY A VARYING INCREASE OF RPMS: 2100 RPMS TO 4500 RPMS, DEPENDING ON THE INCIDENT, AND A SUDDEN LURCHING OR SURGING FORWARD OF THE VEH…

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APPROXIMATELY TWO OR THREE TIMES A WEEK WHEN DOWNSHIFTING OUT OF A RIGHT OR LEFT HAND CURVE OR TURN, MY 2012 MANUAL TRANSMISSION MAZDA 3 HATCHBACK WILL ACCELERATE ON ITS OWN. THIS IS CHARACTERIZED BY A VARYING INCREASE OF RPMS: 2100 RPMS TO 4500 RPMS, DEPENDING ON THE INCIDENT, AND A SUDDEN LURCHING OR SURGING FORWARD OF THE VEHICLE ITSELF. WHEN APPROACHING CURVES OR TURNS, AT 30 OR 40 MPH, THAT DO NOT HAVE TO BE TAKEN AT A COMPLETE STOP, I ENGAGE THE CLUTCH, APPLY THE BRAKES, AND SLOW THE VEHICLE TO 15-20 MPH. UPON COMING OUT OF THE TURN I SHIFT THE VEHICLE INTO SECOND GEAR. WHEN I SLOWLY RELEASE THE CLUTCH, WITHOUT DEPRESSING THE GAS PEDAL AT ALL, THE CAR'S ENGINE WILL REV, RPMS WILL SURGE TO AS HIGH AS 4000 - 4500, AND THE CAR WILL LURCH FORWARD UNTIL THE CLUTCH IS ONCE AGAIN DEPRESSED. THESE INCIDENTS ARE RANDOM AND ARE NOT DEPENDENT ON SPEED, WEATHER CONDITIONS, OR LOCATION. THESE INCIDENTS HAVE ONLY BEEN DUPLICATED WITH A MINIMAL INCREASE OF RPMS AND NO LURCHING FORWARD WHEN A MECHANIC IS PRESENT. THESE INCIDENTS CAN NOT BE DUPLICATED FOR THE DEALERSHIP AT THEIR FULLEST AND MOST DANGEROUS. *TR

NHTSA ODI #10490230

10,200 miles · Dec 9, 2012
EnginePower Train

WHEN DOWNSHIFTING (MANUAL TRANSMISSION) FROM 3RD TO 2ND AS I WAS SLOWING DOWN BECAUSE OF A RED LIGHT, THE ENGINE RPM WENT WAY UP, MAYBE AROUND 4,000 RPM. I PRESSED THE CLUTCH TO AVOID THE CAR JERKING FORWARD AND HITTING THE CAR IN FRONT OF ME. THIS WAS THE THIRD TIME THIS ACTUALLY HAPPENED. I BOUGHT THE CAR NEW AND HAVE ONLY OWN…

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WHEN DOWNSHIFTING (MANUAL TRANSMISSION) FROM 3RD TO 2ND AS I WAS SLOWING DOWN BECAUSE OF A RED LIGHT, THE ENGINE RPM WENT WAY UP, MAYBE AROUND 4,000 RPM. I PRESSED THE CLUTCH TO AVOID THE CAR JERKING FORWARD AND HITTING THE CAR IN FRONT OF ME. THIS WAS THE THIRD TIME THIS ACTUALLY HAPPENED. I BOUGHT THE CAR NEW AND HAVE ONLY OWNED IT 5 MONTHS. *TR

NHTSA ODI #10487778

200 miles · Aug 8, 2012
EnginePower Train

THE CAR SOMETIMES SURGES DURING DOWNSHIFTING. I WILL BE DRIVING IN MODERATE TRAFFIC IN THIRD GEAR. THE TRAFFIC SLOWS, AND I LET IN THE CLUTCH AND APPLY THE BRAKE. WHEN THE TRAFFIC STARTS TO PICK UP AGAIN, I AM GOING TOO SLOW FOR THIRD, SO I SHIFT INTO SECOND AND LET THE CLUTCH OUT. MY RIGHT FOOT IS JUST RESTING LIGHTLY ON …

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THE CAR SOMETIMES SURGES DURING DOWNSHIFTING. I WILL BE DRIVING IN MODERATE TRAFFIC IN THIRD GEAR. THE TRAFFIC SLOWS, AND I LET IN THE CLUTCH AND APPLY THE BRAKE. WHEN THE TRAFFIC STARTS TO PICK UP AGAIN, I AM GOING TOO SLOW FOR THIRD, SO I SHIFT INTO SECOND AND LET THE CLUTCH OUT. MY RIGHT FOOT IS JUST RESTING LIGHTLY ON THE GAS PEDAL. THE CAR HAS NOT BEEN IDLING FAST, BUT AS SOON AS THE CLUTCH IS ENGAGED, THE ENGINE SUDDENLY ROARS AND THE CAR LEAPS FORWARD, EVEN THOUGH I HAVE NOT PRESSED THE GAS AT ALL. I LET IN THE CLUTCH AGAIN TO AVOID AN ACCIDENT. WHEN I LET IT OUT AGAIN, IT WORKS NORMALLY. THIS HAPPENS ONCE, TWICE, OR NOT AT ALL IN A 40-MILE ROUND TRIP OUT OF TOWN AND BACK. IT ALSO HAPPENS FREQUENTLY WHEN I MAKE A LEFT TURN WITHOUT STOPPING, BUT WHERE I NEED TO SLOW AND DOWNSHIFT. I COAST INTO THE TURN WITH THE CLUTCH PEDAL IN, SHIFT DOWN, AND ATTEMPT TO LET THE CLUTCH OUT WHEN COMING OUT OF THE TURN. I WOULD EXPECT THE CAR TO SLOW WHEN I SHIFT DOWN UNLESS I AM PRESSING THE ACCELERATOR, BUT SOMETHING OTHER THAN ME IS GIVING IT GAS. IT IS IMPOSSIBLE TO PREDICT WHEN THIS WILL HAPPEN, AND IT NEVER HAPPENS TWICE IN A ROW. I HAVE MADE IT HAPPEN ON PURPOSE, BUT I THINK THAT WAS PURE LUCK. IT HAPPENS WHEN DOWNSHIFTING INTO ANY GEAR, BUT BECAUSE OF THE HEAVY TRAFFIC IN OUR AREA, IT ENDS UP USUALLY BEING THIRD TO SECOND. IT HAS HAPPENED TO ME WHEN DOWNSHIFTING INTO THIRD OR FOURTH ALSO. *TR

NHTSA ODI #10469613

8,300 miles · Jul 4, 2012
Power Train

DRIVING HOME LAST NIGHT (ON THE FREEWAY) AT APPROXIMATELY 9:45 PM I ATTEMPTED TO ACCELERATE TO MAKE A LANE CHANGE. I NOTICED THE CAR WASN'T MOVING ANY FASTER THE ONLY THING I HEARD WAS THE ENGINE GUNNING. THE CAR WAS SLOWING DOWN IN VERY FAST TRAFFIC AND I IMMEDIATELY PUT MY HAZARDS ON WHILE TRYING TO MOVE THE GEAR SHIFT WHICH W…

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DRIVING HOME LAST NIGHT (ON THE FREEWAY) AT APPROXIMATELY 9:45 PM I ATTEMPTED TO ACCELERATE TO MAKE A LANE CHANGE. I NOTICED THE CAR WASN'T MOVING ANY FASTER THE ONLY THING I HEARD WAS THE ENGINE GUNNING. THE CAR WAS SLOWING DOWN IN VERY FAST TRAFFIC AND I IMMEDIATELY PUT MY HAZARDS ON WHILE TRYING TO MOVE THE GEAR SHIFT WHICH WAS STUCK. ITS A MIRACLE THAT I DIDN'T GET HIT TRYING TO GET TNATE TO HAVE IT APOENHIS VEHICLE OVER TO THE RIGHT SHOULDER WHICH I EVENTUALLY DID. I REMOVED A SMALL COVER BESIDE THE GEAR SHIFT INSERTED A SCREWDRIVER IN THE HOLE AND WAS ABLE TO RELEASE THE SHIFT. I PUT IT IN PARK, TURNED THE CAR OFF FOR ABOUT A MINUTE. STARTED THE CAR AND SHIFTED IT TO DRIVE BUT THE CAR JERKED BACK AND THE GEAR SHIFT IS STUCK AGAIN. I HAD TO BE TOWED HOME. THIS WAS A VERY DANGEROUS AND FRIGHTENING SITUATION FOR A MALE ADULT AND WOULD HATE TO HAVE THIS HAPPEN TO A SINGLE MOTHER WITH CHILDREN IN THE CAR. THIS IS NOT THE ONLY TIME THE GEARS HAVE LOCKED. I WAS FORTUNATE TO HAVE IT HAPPEN IN MY DRIVEWAY AND WAS ABLE TO UNLOCK WITH THE METHOD I DESCRIBED ABOVE. I FEEL THIS REALLY SHOULD BE LOOKED INTO. *JS

NHTSA ODI #10464194

2,700 miles · Apr 23, 2012
Electronic Stability Control (esc)Power Train

I WAS DRIVING A STEADY 55 MPH ON THE FREEWAY ON A DRY SUNNY DAY WITH MY WIFE AND KIDS. THE ROADS WERE SMOOTH AND DRY, AND THE GAS TANK WAS 1/2 FULL. THE CAR WAS 3 MONTHS OLD WITH 2700 MILES ON IT. THE CAR SUDDENLY LOST POWER AND STARTED TO DECELERATE. THE ENGINE WAS STILL RUNNING, BUT PRESSING THE GAS PEDAL HAD NO EFFECT ON …

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

NHTSA ODI #10456191

Official recalls

1

16V644000 · Structure:body:hatchback/liftgate

Sep 6, 2016

Mazda North American Operations (Mazda) is recalling certain model year 2010-2013 Mazda3 and Mazdaspeed3 vehicles manufactured November 18, 2008, to June 8, 2013, 2012-2015 Mazda5 vehicles manufactured October 26, 2010, to June 22, 2015, 2016 CX-3 vehicles manufactured June 1, 2015, to December 26, 2015, and 2013-2016 CX-5 vehicles manufactured December 15, 2011, to December 26, 2015. On the affected vehicles, the lift gate support struts may corrode, possibly causing the struts to break and/or the lift gate to drop unexpectedly.

Consequence & remedy

Consequence: If the lift gate falls unexpectedly, it may hit the user, increasing their risk of injury.

Remedy: Mazda dealers will replace the both lift gate supports, free of charge, however parts are not currently available. The recall began April 2017. Owners may contact Mazda customer service at 1-800-222-5500. Mazda's number for this recall is 9916H.

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.