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2011 MERCEDES-BENZ C300

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2011 MERCEDES-BENZ C300 do not stand out strongly from the model-year median of 259.

About this comparison →

When problems were reported

Mileage at the reported incident

141 reports with mileage · 339 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 250 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Suspension. Review the 60 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Structure. Review the 49 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

15 crash reports6 fire reports11 injury reports

What owners actually said

480 reports
114,000 miles · Sep 6, 2022
Suspension

I was driving down the road when a deer ran out into the roadway ahead of me. I applied the brake firmly and hear a "pop" and the car suddenly changed lanes. I was able to recover without much of an incident but applying the brakes from that point on caused the car to "steer" into a new direction. I took the vehicle out to a fr…

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I was driving down the road when a deer ran out into the roadway ahead of me. I applied the brake firmly and hear a "pop" and the car suddenly changed lanes. I was able to recover without much of an incident but applying the brakes from that point on caused the car to "steer" into a new direction. I took the vehicle out to a friends farm and jacked it up to find that on this car with zero other corrosion issues that the mounting point for one of the rear suspension arms had rusted at the weld and broken off the sub frame. I should note that the rest of the underbody was inspected and the rear subframe is the only place that has any corrosion. Research into this issue over the past few months has lead me to countless people being affected by the same issues. This is not an isolated case and it needs to be addressed by the manufacturer before it causes a fatal accident (if it has not already).

NHTSA ODI #11482982

157,000 miles · Aug 30, 2022
Structure

The contact owns a 2011 Mercedes-Benz C300. The contact stated while having a routine brake service performed, the contact was informed that the driver’s side rear subframe was rusted. The contact was informed that the failure might puncture the fuel tank. The vehicle was not repaired. The manufacturer was informed of the failur…

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The contact owns a 2011 Mercedes-Benz C300. The contact stated while having a routine brake service performed, the contact was informed that the driver’s side rear subframe was rusted. The contact was informed that the failure might puncture the fuel tank. The vehicle was not repaired. The manufacturer was informed of the failure but provided no assistance. The failure mileage was approximately 157,000.

NHTSA ODI #11482098

Mileage unknown · Aug 28, 2022
Suspension

Manufactory defect on w204 Chassis Mercedes Benz rear sub frame rusting allowing control arm to brake free affecting safety and drivability control loss, which has or could lead to severe accident. There no recalls for this defect and is a common issue with materials on back order for the rear sub frame, vehicle Is not drivable …

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Manufactory defect on w204 Chassis Mercedes Benz rear sub frame rusting allowing control arm to brake free affecting safety and drivability control loss, which has or could lead to severe accident. There no recalls for this defect and is a common issue with materials on back order for the rear sub frame, vehicle Is not drivable until frame is replaced.

NHTSA ODI #11481664

Mileage unknown · Aug 26, 2022
Fuel/propulsion System

I started to smell gas after filling my tank. Once the gas level went down, the odor disappeared. I took car to dealer who said car needs new gas tank (issue on top of tank) and cost is approx $5K for parts and labor. I started reading about same exact issue on same C300 model and year 2011. I was advised that car with high mile…

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I started to smell gas after filling my tank. Once the gas level went down, the odor disappeared. I took car to dealer who said car needs new gas tank (issue on top of tank) and cost is approx $5K for parts and labor. I started reading about same exact issue on same C300 model and year 2011. I was advised that car with high mileage of 114,000 was not worth repairing even though there are no dents, cosmetically very nice, new tires, always dealer maintained. I have the dealer inspection paperwork

NHTSA ODI #11481477

Mileage unknown · Aug 26, 2022
Suspension

My C300 2011 is having rear suspension problem which is unsafe to drive. I took in my car for my usual maintenance check and was told by the mechanic that the rear left driver side suspension is rusted and rotated out, to the point that it can break off and cause an accident. As Mercedes product, even the mechanic was surprised …

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My C300 2011 is having rear suspension problem which is unsafe to drive. I took in my car for my usual maintenance check and was told by the mechanic that the rear left driver side suspension is rusted and rotated out, to the point that it can break off and cause an accident. As Mercedes product, even the mechanic was surprised to see this happen on this car. Not surprised the dealer told me there is no recall at this time. I am still waiting for a quote but from what I've seen other people complaining with the same exact issue in same make and model. I have attached pictures just in case.

NHTSA ODI #11481426

142,000 miles · Aug 25, 2022
Fuel System, Gasoline

The contact's client owns a 2011 Mercedes-Benz C300. The contact stated that the vehicle's owner had complained of an abnormal fuel odor coming from the vehicle. There was no warning light illuminated. Upon inspecting the vehicle, the contact discovered that fuel was spraying out of the fuel pump onto the exhaust. The contact w…

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The contact's client owns a 2011 Mercedes-Benz C300. The contact stated that the vehicle's owner had complained of an abnormal fuel odor coming from the vehicle. There was no warning light illuminated. Upon inspecting the vehicle, the contact discovered that fuel was spraying out of the fuel pump onto the exhaust. The contact was able to replace the fuel pump and correct the failure. Upon investigation, the contact discovered NHTSA Campaign Number: 12V557000 (Fuel System, Gasoline) which he linked to the failure. The dealer nor the manufacturer had yet to be notified of the failure. The vehicle had been repaired. The failure mileage was approximately 142,000.

NHTSA ODI #11481256

12,800 miles · Aug 24, 2022
Fuel System, Gasoline

The contact owns a 2011 Mercedes-Benz C300. The contact stated that after refueling the vehicle and driving a short distance, there was a burning odor coming from inside and outside the vehicle. The traction control warning light was illuminated. The contact had taken the vehicle to a certified mechanic who replaced the fuel cab…

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The contact owns a 2011 Mercedes-Benz C300. The contact stated that after refueling the vehicle and driving a short distance, there was a burning odor coming from inside and outside the vehicle. The traction control warning light was illuminated. The contact had taken the vehicle to a certified mechanic who replaced the fuel cabinet. The burning odor persisted. The contact was informed that the failure was related to NHTSA Campaign Number: 12V557000 (Fuel System, Gasoline) however, the VIN was not included. The manufacturer was made aware of the failure. The approximate failure mileage 12,800.

NHTSA ODI #11481021

Mileage unknown · Aug 23, 2022
Exterior Lighting

The driver side rear tail light wiring melted the tailight housing. This component was already replaced as part of a previous recall, but apparently Mercedes is not properly fixing the issue. They refuse to fix it for free, because they already "addressed" the recall. Looks like they are putting cars back on the street that coul…

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The driver side rear tail light wiring melted the tailight housing. This component was already replaced as part of a previous recall, but apparently Mercedes is not properly fixing the issue. They refuse to fix it for free, because they already "addressed" the recall. Looks like they are putting cars back on the street that could catch fire.

NHTSA ODI #11480828

Mileage unknown · Aug 21, 2022
Structure

I am contacting you about a certified pre-owned car I had purchased from Mercedes Benz Cincinnati. Following my most recent routine maintenance visit to the dealer, I received an email from Mercedes stating that they had identified that the rear subframe on my Mercedes C300 4Matic needed replacement and it was not safe to drive.…

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I am contacting you about a certified pre-owned car I had purchased from Mercedes Benz Cincinnati. Following my most recent routine maintenance visit to the dealer, I received an email from Mercedes stating that they had identified that the rear subframe on my Mercedes C300 4Matic needed replacement and it was not safe to drive. It turns out that the two joints on the subframe were corroded. This type of a problem is not expected for a professionally maintained certified car by Mercedes that is at 58,481 miles. The issue has nothing to do with standard wear and tear, or user negligence, and it stems from the material used in the specific component. There is no other area on the vehicle that is displaying even the slightest amount of corrosion. The mechanic said that this is to do with the properties of the materials selected for the manufactured part, they have been seeing many cars of the same year with the same exact problem, and if the subframe joints were to break while the car is in motion, it could potentially cause a fatal accident. There were no warning lamps, message or symptoms of the problem prior to the failure. I contacted Mercedes and asked them to address this problem. After months of back and forth, I was told there were no safety recalls, and the car was out of standard warranty period. I was also told that the part was not currently available (and was on back order). As you may know, the subframe's job is to distribute high local loads over a wider area of the body structure and its failure could result in fatal accidents. The internet is full of customer complaints on this issue, yet there are no safety recalls issued.

NHTSA ODI #11480406

Mileage unknown · Aug 20, 2022
Suspension

I am reporting a big safety hazard issue on these Mercedes C300 model year 2011. The suspense bracket just breaking off with obvious no visible issues. The suspension support bracket is got rotted with rust from inside out and broke off while driving on the highway. The issue was obvious when I braked suddenly and the car just …

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I am reporting a big safety hazard issue on these Mercedes C300 model year 2011. The suspense bracket just breaking off with obvious no visible issues. The suspension support bracket is got rotted with rust from inside out and broke off while driving on the highway. The issue was obvious when I braked suddenly and the car just pulled itself to the right side. This could easily cause an accident. I reported the incident to Mercedes and they told me to report to NHSTA and they cannot do anything. Once home and jacked up the vehicle I found that the bracket was completely off the frames and it did hit the gas tank causing a dent in the tank (a big safety issue) seam. I googled the issue and it seems like it is a known issue with these models and Mercedes have not recalled or fixed this issue on any vehicle. I have attached pictures of the broken bracket. Thank you

NHTSA ODI #11480326

Official recalls

6

19V010000 · Air Bags:frontal:passenger Side:inflator Module

Jan 9, 2019

Mercedes-Benz USA, LLC (MBUSA) is recalling certain 2014 C250, C300 4Matic, C350, C63 AMG, E350 4Matic Coupe, E350 Cabrio, E350 Coupe, SLS AMG Cabrio, SLS AMG Coupe, 2014-2015 C250 Coupe, C350 4Matic Coupe, C350 Coupe, C63 AMG Coupe, GLK 350, GLK250 BlueTec 4Matic, GLK350 RWD, 2015-2017 E400 4Matic Coupe, E400 Cabrio, E400 Coupe, 2014-2017 E550 Cabrio, and 2014-2016 E550 Coupe vehicles 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, MBUSA is recalling certain 2012-2014 C250, E350 4Matic Coupe, SLS AMG Cabrio, 2012-2015 C250 Coupe, C350 4Matic Coupe, C350 Coupe, C63 AMG Coupe, 2011 C300, 2011-2014 C300 4Matic, C350, C63 AMG, E350 Cabrio, E350 Coupe, SLS AMG Coupe, 2015-2016 E400 4Matic Coupe, E400 Cabrio, E400 Coupe, 2011-2016 E550 Cabrio, E550 Coupe, 2011-2015 GLK350 4Matic, GLK350 RWD, and 2013-2015 GLK250 BlueTec 4Matic vehicles 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." MBUSA is also recalling certain 2012-2014 C250, E350 4Matic Coupe, SLS AMG Cabrio 2012-2015 C250 Coupe, C350 4Matic Coupe, C350 Coupe, C63 AMG Coupe, 2010-2011 C300, 2010-2014 C300 4Matic, C350, C63 AMG, E350 Coupe, 2011-2014 E350 Cabrio, SLS AMG Coupe, 2015-2016 E400 4Matic Coupe, E400 Cabrio, E400 Coupe, 2016-2017 E550 Cabrio, 2010-2016 E550 Coupe, 2010-2015 GLK350 4Matic, GLK350 RWD, and 2013-2015 GLK250 BlueTec 4Matic vehicles ever registered in the states of AK, CO, CT, ID, IA, ME, MA, MI, MN, MO, NH, NY, ND, OR, RI, SD, UT, VT, WA, WI and WY or "Zone C." These vehicles are equipped with air bag inflators assembled as part of the passenger frontal air bag modules that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.

Consequence & remedy

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

Remedy: MBUSA will notify owners, and dealers will replace the passenger frontal air bag module, free of charge. The recall began March 29, 2019. Owners may contact MBUSA customer service at 1-800-367-6372.

17V177000 · Air Bags:frontal:sensor/control MODULE-INACTIVE ; Electrical System:software

Mar 14, 2017

Mercedes-Benz USA, LLC (MBUSA) is recalling certain 2016 AMG GT-S, GLC300, CLA250 and GLE300d 4Matic vehicles, 2013 C250, E350 BlueTec and G63 AMG vehicles, 2008-2014 C300 vehicles, 2013-2014 C300 4Matic and ML350 4Matic vehicles, 2009 C350 vehicles, 2014 CLS550, E350 4Matic, E350 Coupe 4Matic, E350 Wagon 4Matic, GLK350 and SL550 vehicles, 2012 CLS550 4Matic vehicles, 2012-2016 E350 vehicles, 2016-2017 GL450 4Matic vehicles, 2012-2014 ML350 4Matic BlueTec vehicles, 2015 S550, S550 4Matic and C300 4Matic Sedan vehicles, 2015-2016 C300 Sedan vehicles, and 2017 SL63 AMG vehicles. Various control units on these vehicles may have been updated with incorrect software, potentially affecting the correct deployment of the air bags in the event of a crash.

Consequence & remedy

Consequence: If the air bags do not deploy as intended in the event of a crash, there would be an increased risk of injury in the event of a crash.

Remedy: MBUSA will notify owners, and dealers will update software in the affected control units, free of charge. The recall began April 21, 2017. Owners may contact MBUSA customer service at 1-800-367-6372.

Additional source detail variants (2)

Electrical System:software

Mercedes-Benz USA, LLC (MBUSA) is recalling certain 2016 AMG GT-S, GLC300, CLA250 and GLE300d 4Matic vehicles, 2013 C250, E350 BlueTec and G63 AMG vehicles, 2008-2014 C300 vehicles, 2013-2014 C300 4Matic and ML350 4Matic vehicles, 2009 C350 vehicles, 2014 CLS550, E350 4Matic, E350 Coupe 4Matic, E350 Wagon 4Matic, GLK350 and SL550 vehicles, 2012 CLS550 4Matic vehicles, 2012-2016 E350 vehicles, 2016-2017 GL450 4Matic vehicles, 2012-2014 ML350 4Matic BlueTec vehicles, 2015 S550, S550 4Matic and C300 4Matic Sedan vehicles, 2015-2016 C300 Sedan vehicles, and 2017 SL63 AMG vehicles. Various control units on these vehicles may have been updated with incorrect software, potentially affecting the correct deployment of the air bags in the event of a crash.

Consequence: If the air bags do not deploy as intended in the event of a crash, there would be an increased risk of injury in the event of a crash.

Remedy: MBUSA will notify owners, and dealers will update software in the affected control units, free of charge. The recall began April 21, 2017. Owners may contact MBUSA customer service at 1-800-367-6372.

Air Bags:frontal:sensor/control MODULE-INACTIVE

Mercedes-Benz USA, LLC (MBUSA) is recalling certain 2016 AMG GT-S, GLC300, CLA250 and GLE300d 4Matic vehicles, 2013 C250, E350 BlueTec and G63 AMG vehicles, 2008-2014 C300 vehicles, 2013-2014 C300 4Matic and ML350 4Matic vehicles, 2009 C350 vehicles, 2014 CLS550, E350 4Matic, E350 Coupe 4Matic, E350 Wagon 4Matic, GLK350 and SL550 vehicles, 2012 CLS550 4Matic vehicles, 2012-2016 E350 vehicles, 2016-2017 GL450 4Matic vehicles, 2012-2014 ML350 4Matic BlueTec vehicles, 2015 S550, S550 4Matic and C300 4Matic Sedan vehicles, 2015-2016 C300 Sedan vehicles, and 2017 SL63 AMG vehicles. Various control units on these vehicles may have been updated with incorrect software, potentially affecting the correct deployment of the air bags in the event of a crash.

Consequence: If the air bags do not deploy as intended in the event of a crash, there would be an increased risk of injury in the event of a crash.

Remedy: MBUSA will notify owners, and dealers will update software in the affected control units, free of charge. The recall began April 21, 2017. Owners may contact MBUSA customer service at 1-800-367-6372.

16V363000 · Air Bags:frontal:passenger Side:inflator Module

May 26, 2016

Mercedes-Benz USA, LLC (MBUSA) is recalling certain model year 2008-2011 C300 Sedan, C300 4matic Sedan, C350 Sedan, C63 AMG Sedan vehicles, 2010-2011 GLK350, GLK350 4-Matic and E350 Coupe vehicles, 2011 SLS AMG, E350 Convertible, E550 Coupe and E550 Convertible vehicles originally sold, or ever registered, in 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, unless included in "Zone A" above, MBUSA is recalling certain model year 2008 C300 Sedan, C350 Sedan, C63 AMG Sedan and C300 4-Matic Sedan vehicles originally sold, or ever registered, in 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." Vehicles not originally sold or ever registered in either Zones A or B are not subject to this safety recall. 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. In the event of a crash necessitating deployment of the front air bags, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.

Consequence & remedy

Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.

Remedy: MBUSA will notify owners, and dealers will replace the passenger frontal air bag modules, free of charge. Owners were sent an interim notification October 2016. A second notice will be mailed when remedy parts are available. Owners may contact MBUSA customer service at 1-877-496-3691.

16V081000 · Air Bags:frontal:driver Side:inflator Module

Feb 11, 2016

Mercedes-Benz USA, LLC. (MBUSA) is recalling certain model year 2009-2010 ML320 BlueTec 4Matic, GL320 BlueTec 4Matic and R320 CDI 4Matic, 2011 E350 Cabriolet and E550 Cabriolet, 2009-2011 ML350, ML350 4Matic, ML550 4Matic, ML63 AMG, and C63 AMG, 2010-2011 ML450 4Matic Hybrid, E350 Coupe, E350 4Matic, E550 Coupe, E550 4Matic, and E63 AMG, 2011-2012 GL350 BlueTec 4Matic and R350 BlueTec 4Matic, 2009-2012 GL450 4Matic, GL550 4Matic and R350 4Matic, 2007-2008 SLK280, SLK350, and SLK55 AMG, 2011-2014 SLS AMG Coupe, 2012 SLS AMG Cabriolet, 2013-2014 SLS AMG GT and SLS AMG GT Cabriolet, 2005 C230 Kompressor and C320, 2006-2007 C230, 2006-2011 C350, 2008-2011 C300 and C300 4Matic, 2010-2012 GLK350 and GLK350 4Matic and 2007-2008 Chrysler Crossfire vehicles. Upon deployment of the driver's frontal air bag, excessive internal pressure may 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: MBUSA will their notify owners, and Fiat Chrysler will notify the affected Chrysler owners. Dealers for the respective brands will replace the driver's frontal air bag module, free of charge. This recall began November 2016. Mercedes-Benz owners may contact MBUSA customer service at 1-800-367-6372 and Chrysler owners may contact Fiat Chrysler customer service at 1-800-853-1403.

14V177000 · Exterior Lighting:tail Lights

Apr 11, 2014

Mercedes-Benz USA, LLC (Mercedes) is recalling certain model year 2008-2011 C300, C300 4Matic, C350, and C63 AMG vehicles manufactured January 26, 2007, through July 13, 2011. In the affected vehicles, a poor electrical ground connection may result in the dimming or failure of the tail lights.

Consequence & remedy

Consequence: Dimming or failure of the tail lights reduces the ability to warn other motorists of the driver's intentions of stopping or turning, increasing the risk of a crash.

Remedy: Mercedes will notify owners, and dealers will replace the bulb holders if not previously updated and replace any corroded connectors, free of charge. The recall began on August, 18, 2014. Owners may contact Mercedes at 1-800-367-6372.

12V557000 · Fuel System, Gasoline

Dec 3, 2012

Mercedes-Benz is recalling certain model year 2011-2012 S400, S550, S550 4Matic, S63 AMG, C300, C300 4Matic, E350, GLK350, GLK350 4Matic, CL550 4Matic, and CL63 AMG vehicles manufactured from April 18, 2011, through July 12, 2011. Due to an irregularity stemming from the molding process of the fuel filter flange, the fuel filter flange may crack when operated in high temperatures.

Consequence & remedy

Consequence: If the fuel filter flange cracks, it will leak fuel which may lead to a fire if an external ignition source is present.

Remedy: Mercedes-Benz will notify owners, and dealers will replace the fuel filter, free of charge. The recall campaign is expected to begin in February 2013. Owners may contact Mercedes-Benz at 1-800-367-6372.

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.