NHTSA owner reports · September 18, 2026 snapshot.
Unknown Or Other complaints
108 reportsClear category filter65,000 miles · Dec 30, 2018
StructureUnknown Or Other
WE WERE DRIVING OUR 2015 SUBARU OUTBACK AT ABOUT 55MPH ON US20, THE TEMPERATURE WAS IN THE MID 30'S, IN EAST OREGON WHEN OUR SUNROOF SPONTANEOUSLY EXPLODED. THERE WERE NO OTHER VEHICLES AROUND AND THERE WAS NO IMPACT FROM FOREIGN OBJECTS. THERE WAS A LOUD, DISTRACTING, BANG FOLLOWED BY A CLOUD OF SHATTERED GLASS COMING FROM THE …
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WE WERE DRIVING OUR 2015 SUBARU OUTBACK AT ABOUT 55MPH ON US20, THE TEMPERATURE WAS IN THE MID 30'S, IN EAST OREGON WHEN OUR SUNROOF SPONTANEOUSLY EXPLODED. THERE WERE NO OTHER VEHICLES AROUND AND THERE WAS NO IMPACT FROM FOREIGN OBJECTS. THERE WAS A LOUD, DISTRACTING, BANG FOLLOWED BY A CLOUD OF SHATTERED GLASS COMING FROM THE BACK OF THE CAR. THE SUNROOF COVER WAS CLOSED AND THE TEMPERED GLASS FRAGMENTS COLLECTED IN THE WELL AND RATTLED AROUND FOR THE REMAINING 3 1/2 HOURS OF OUR JOURNEY.
NHTSA ODI #11164079
40,000 miles · Dec 13, 2018
Unknown Or Other
WINDSHIELD CRACK APPEARED WITHOUT OBVIOUS CAUSE.
NHTSA ODI #11161273
65,000 miles · Nov 16, 2018
EngineUnknown Or OtherInjury
EXHAUST SYSTEM ISSUE. EXHAUST MAINFOLD LEAK AT CATALYST CONVERTER. FOR OUR OUTBACK WE NOTICED A SIGNIFICANT LEVELS OF EXHAUST FUMES IN PASSENGER CABIN. THEY WERE NO INDICATION OF FAILURE OF EXHAUST SYSTEM OR CATALYST CONVERTER ON THE CAR. BUT WE ARE GETTING SOME MUCH FUMES SMELL WHEN WE STOPPED AT THE TRAFFIC SIGNAL OR PARKING …
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EXHAUST SYSTEM ISSUE. EXHAUST MAINFOLD LEAK AT CATALYST CONVERTER. FOR OUR OUTBACK WE NOTICED A SIGNIFICANT LEVELS OF EXHAUST FUMES IN PASSENGER CABIN. THEY WERE NO INDICATION OF FAILURE OF EXHAUST SYSTEM OR CATALYST CONVERTER ON THE CAR. BUT WE ARE GETTING SOME MUCH FUMES SMELL WHEN WE STOPPED AT THE TRAFFIC SIGNAL OR PARKING LOT. IT ALL MOST MADE US SICK. LUCKILY I GOT IT CHECKED AT THE SERVICE CENTER AND THEY FIND THE LEAK. THIS IS POTENTIALLY A VERY RISKY THING FOR PEOPLE WHO DON'T NOTICE THE SMELL MIGHT GET SLOW POISONED WITH CARBON MONOXIDE OR OTHER ELEMENTS IN EXHAUST FUMES. THERE MAY BE DIRECT INJURY FROM THIS ISSUE BUT AS I SAID I WAS ALMOST GOT SICK BECAUSE OF FUMES. FOR PEOPLE WITH PZEV VEHICLE, THE EXHAUST SYSTEM IS COVERED UNDER WARRANTY. PLEASE BRING THIS ISSUE WITH MANUFACTURING. FOR PEOPLE OUT THERE IF YOU NOTICE A LOUD EXHAUST NOTE AT START OF YOUR VEHICLE OR SMALL RATTLING NOISE WHEN WE YOU ACCELERATE AFTER A COMPLETE STOP, IT MIGHT BE YOUR EXHAUST SYSTEM, PLEASE GET IT CHECKED AS SOON AS POSSIBLE. PS ATTACHED IS THE DIAGNOSIS REPORT FROM DEALER SERVICE CENTER BE SAFE OUT THERE !! THANK YOU.
NHTSA ODI #11152117
500,000 miles · Oct 5, 2018
Unknown Or Other
THE PIPES THAT CONNECT TO MANIFOLD TO MUFFLER NEED TO BE REPLACED AFTER 50,000 MILES. SUBARU SAID THIS IS NOT COVERED UNDER WARRANT, BECAUSE IT IS NOT THE MANIFOLD.
NHTSA ODI #11133523
44,000 miles · Jun 9, 2018
EngineService BrakesUnknown Or Other
WHILE PARKING THE CAR AT AN OPEN PARKING LOT IN SHOPPING CENTER AT LOW SPEED (<5MPH) THE ENGINE SURGED SUDDENLY AND THE VEHICLE ACCELERATED UNCONTROLLABLY. IT REQUIRED TREMENDOUS PRESSURE ON BRAKE TO EVENTUALLY OVERRIDE THE ENGINE.
NHTSA ODI #11100658
30,000 miles · May 19, 2018
EnginePower TrainUnknown Or Other
AFTER 2 YEARS OF OWNERSHIP ON MY BRAND NEW SUBARU OUTBACK 2015, I HAVE NOTICED A LOUD SQUEAKY SOUND COMING FROM THE ENGINE WHEN I START MY CAR AFTER IT RAINED/SNOWED. THE SOUND WOULD GO AWAY AFTER A FEW MINUTES, HOWEVER, IT DIDN'T SEEM NORMAL. I TOOK THE CAR TO THE DEALERSHIP TO HAVE IT CHECKED OUT. THE DEALERSHIP TOLD ME THAT N…
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AFTER 2 YEARS OF OWNERSHIP ON MY BRAND NEW SUBARU OUTBACK 2015, I HAVE NOTICED A LOUD SQUEAKY SOUND COMING FROM THE ENGINE WHEN I START MY CAR AFTER IT RAINED/SNOWED. THE SOUND WOULD GO AWAY AFTER A FEW MINUTES, HOWEVER, IT DIDN'T SEEM NORMAL. I TOOK THE CAR TO THE DEALERSHIP TO HAVE IT CHECKED OUT. THE DEALERSHIP TOLD ME THAT NOTHING IS WRONG AND IT IS PERFECTLY FINE. HOWEVER, THE SQUEAKY NOISE STILL OCCURS AFTER RAIN/SNOW. IT SEEMS TO ME THAT WATER IS LEAKING INTO A BELT WHEN IT'S NOT SUPPOSE TO AND IT IS CAUSING THE NOISE WHEN THE ENGINE IS STARTED. SUBARU NEEDS TO LOOK INTO THIS ISSUE BECAUSE THIS PROBLEM ONLY HAPPENS AFTER IT RAINS/SNOWS AND CANNOT BE REPLICATED WHEN THE CAR IS BROUGHT TO THE DEALERSHIP. THEREFORE, IT IS HARD TO HAVE THIS ISSUE FIXED.
NHTSA ODI #11096820
23,000 miles · Mar 6, 2018
Air BagsPower TrainUnknown Or OtherCrashInjury
UNEXPECTED ACCELERATION AFTER PARKING, JUMP CURB INTO TREE, CAUSING $7,000 IN DAMAGE. AIR BAGS DID NOT DEPLOY, BOTH MYSELF AND PASSENGER HIT KNEES ON DASH, EVEN WITH OUR SEAT BELTS STILL ON. HAD OTHER COMPUTER ISSUES EARLIER THAT DAY, BACK UP SENSORS DIDN'T WORK WHILE BACKING CAR RIGHT BEHIND MINE. CAR HAS NOW BEEN AT SUBARU FOR…
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UNEXPECTED ACCELERATION AFTER PARKING, JUMP CURB INTO TREE, CAUSING $7,000 IN DAMAGE. AIR BAGS DID NOT DEPLOY, BOTH MYSELF AND PASSENGER HIT KNEES ON DASH, EVEN WITH OUR SEAT BELTS STILL ON. HAD OTHER COMPUTER ISSUES EARLIER THAT DAY, BACK UP SENSORS DIDN'T WORK WHILE BACKING CAR RIGHT BEHIND MINE. CAR HAS NOW BEEN AT SUBARU FOR A MONTH, WAITING FOR ENGINEERS RESULTS AFTER THEIR INSPECTION 2/14/2018
NHTSA ODI #11076432
25,000 miles · Feb 27, 2018
Unknown Or OtherInjury
THE SUNROOF ON THE VEHICLE EXPLODED RANDOMLY. CAUSING GLASS TO GO EVERYWHERE ALL OVER THE CAR WHILE ON THE FREEWAY.
NHTSA ODI #11075352
23,000 miles · Dec 16, 2017
Unknown Or OtherCrash
PULLING INTO A PARKING SPACE, STOPPING WHEN VEHICLE ACCELERATED AT HIGH SPEED JUMPED CURB AN HIT A TREE, HAPPENED IN A COUPLE SECONDS. ## VIN PASSED ## SUBARU OUTBACK 2015 ##
NHTSA ODI #11055040
30 miles · Nov 29, 2017
Air BagsUnknown Or OtherVehicle Speed ControlCrashInjury
THIS CONCERNS A 2015 SUBARU OUTBACK LIMITED 6 CYLINDER. AT APPROX 21,000 MI I WAS SLOWING TO SPEED TO PARK IN A PUBLIC PARKING SPACE ON A CITY STREET AND THE OUTBACK SUDDEN ACCELERATION. THE OUTBACK HIT A CITY METAL POST/SIGN, JUMPED THE CURB AND COLLIDED WITH A BUILDING AND DAMAGING A STORE FRONT WITH GREAT FORCE. THE AIRBAG…
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THIS CONCERNS A 2015 SUBARU OUTBACK LIMITED 6 CYLINDER. AT APPROX 21,000 MI I WAS SLOWING TO SPEED TO PARK IN A PUBLIC PARKING SPACE ON A CITY STREET AND THE OUTBACK SUDDEN ACCELERATION. THE OUTBACK HIT A CITY METAL POST/SIGN, JUMPED THE CURB AND COLLIDED WITH A BUILDING AND DAMAGING A STORE FRONT WITH GREAT FORCE. THE AIRBAGS DID NOT DEPLOY AND THE AUTOMATIC COLLISION PREVENTION FAILED TO WORK. ONCE BEFORE THE CAR HAD AN ACCELERATION SURGE WHILE DRIVING A PUBLIC CITY STREET AT LOW SPEED BUT DID NOT HIT ANYTHING. PRIOR TO THE ACCIDENT I'VE ALSO EXPERIENCED SLIGHT HESITATION IN ACCELERATION WHEN I FIRST ACCELERATE FROM A STATIONARY POSITION AND PROBABLY UNRELATED, THE GEAR SHIFT OFTEN GETS STUCK IN PARK AND I HAVE TO USE FORCE THE GEAR SHIFT TO REVERSE. HAVING TROUBLE WITH TURNING NECK FROM SIDE TO SIDE AND NEED TO SEE DOCTOR FOR EVALUATION SO, NOT SURE IF THIS IS CONSIDERED INJURY?
NHTSA ODI #11051133
Official recalls
5May 11, 2016
Subaru of America, Inc. (Subaru) is recalling certain model year 2016-2017 Legacy and Outback vehicles manufactured February 29, 2016, to May 6, 2016. The steering column on the affected vehicles may have been improperly machined, and as a result, turning the steering wheel may have no effect on the direction of the wheels.
Consequence & remedy
Consequence: The loss of steering ability would increase the risk of a crash.
Remedy: Subaru will notify owners, and dealers will inspect the lot number on the steering column, replacing the steering column, as necessary, free of charge. The recall began May 13, 2016. Owners may contact Subaru customer service at 1-800-782-2783 or by visiting http://www.wtd65.service-campaign.com. Subaru's number for this recall is WTD-65. Note: Until the vehicles have been inspected, owners are advised not to drive their vehicles.
Apr 27, 2016
Subaru of America, Inc. (Subaru) is recalling certain model year 2015 Legacy and Outback vehicles manufactured on July 20, 2015. The brake fluid used in these vehicles may contain excess moisture which may adversely affect the performance of the electronic stability control system. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 126, "Electronic Stability Control Systems."
Consequence & remedy
Consequence: Poor performance of the electronic stability control system when it is activated may result in a loss of vehicle control, increasing the risk of a crash.
Remedy: Subaru will notify owners, and dealers will perform an ABS activation, then flush and replace the brake fluid, free of charge. The recall began on May 20, 2016. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WTC-64.
Aug 10, 2015
Subaru of America, Inc. (Subaru) is recalling certain 2015 and 2016 model year Subaru Legacy 4-Door and Outback vehicles manufactured July 3, 2015, to July 27, 2015. Transmission oil may leak from a deformed seal cap on the propeller shaft yoke.
Consequence & remedy
Consequence: If the transmission oil leaks onto the exhaust pipe, there is a possible risk of fire.
Remedy: Subaru will notify owners, and dealers will replace the propeller shaft, free of charge. The recall began on August 28, 2015. Owners may contact 1-800-782-2783. Subaru's number for this recall is WQU-56.
Additional source detail variants (2)
Power Train:driveline:driveshaft
Subaru of America, Inc. (Subaru) is recalling certain 2015 and 2016 model year Subaru Legacy 4-Door and Outback vehicles manufactured July 3, 2015, to July 27, 2015. Transmission oil may leak from a deformed seal cap on the propeller shaft yoke.
Consequence: If the transmission oil leaks onto the exhaust pipe, there is a possible risk of fire.
Remedy: Subaru will notify owners, and dealers will replace the propeller shaft, free of charge. The recall began on August 28, 2015. Owners may contact 1-800-782-2783. Subaru's number for this recall is WQU-56.
Power Train:automatic Transmission
Subaru of America, Inc. (Subaru) is recalling certain 2015 and 2016 model year Subaru Legacy 4-Door and Outback vehicles manufactured July 3, 2015, to July 27, 2015. Transmission oil may leak from a deformed seal cap on the propeller shaft yoke.
Consequence: If the transmission oil leaks onto the exhaust pipe, there is a possible risk of fire.
Remedy: Subaru will notify owners, and dealers will replace the propeller shaft, free of charge. The recall began on August 28, 2015. Owners may contact 1-800-782-2783. Subaru's number for this recall is WQU-56.
Jun 12, 2015
Subaru of America, Inc. (Subaru) is recalling certain model year 2015 Legacy vehicles manufactured March 10, 2014, to April 16, 2015, Outback vehicles manufactured February 24, 2014, to April 16, 2015, Impreza vehicles manufactured September 9, 2014, to April 14, 2015, XV Crosstrek vehicles manufactured October 16, 2014, to April 15, 2015, and 2016 WRX vehicles manufactured March 23, 2015, and equipped with the Eyesight Driver Assist System. If the switch that activates the brake lights fails, the automatic pre-collision braking component of the driver assist system will not function.
Consequence & remedy
Consequence: If the automatic pre-collision braking system does not function as intended, the vehicle will not react to an obstacle in its path, increasing the risk of a crash.
Remedy: Subaru will notify owners, and dealers will reprogram the driver assist system, free of charge. The recall began on July 20, 2015. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WQS-54.
Additional source detail variants (2)
Forward Collision Avoidance: Crash Imminent Braking
Subaru of America, Inc. (Subaru) is recalling certain model year 2015 Legacy vehicles manufactured March 10, 2014, to April 16, 2015, Outback vehicles manufactured February 24, 2014, to April 16, 2015, Impreza vehicles manufactured September 9, 2014, to April 14, 2015, XV Crosstrek vehicles manufactured October 16, 2014, to April 15, 2015, and 2016 WRX vehicles manufactured March 23, 2015, and equipped with the Eyesight Driver Assist System. If the switch that activates the brake lights fails, the automatic pre-collision braking component of the driver assist system will not function.
Consequence: If the automatic pre-collision braking system does not function as intended, the vehicle will not react to an obstacle in its path, increasing the risk of a crash.
Remedy: Subaru will notify owners, and dealers will reprogram the driver assist system, free of charge. The recall began on July 20, 2015. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WQS-54.
Exterior Lighting:brake Lights:switch
Subaru of America, Inc. (Subaru) is recalling certain model year 2015 Legacy vehicles manufactured March 10, 2014, to April 16, 2015, Outback vehicles manufactured February 24, 2014, to April 16, 2015, Impreza vehicles manufactured September 9, 2014, to April 14, 2015, XV Crosstrek vehicles manufactured October 16, 2014, to April 15, 2015, and 2016 WRX vehicles manufactured March 23, 2015, and equipped with the Eyesight Driver Assist System. If the switch that activates the brake lights fails, the automatic pre-collision braking component of the driver assist system will not function.
Consequence: If the automatic pre-collision braking system does not function as intended, the vehicle will not react to an obstacle in its path, increasing the risk of a crash.
Remedy: Subaru will notify owners, and dealers will reprogram the driver assist system, free of charge. The recall began on July 20, 2015. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WQS-54.
Sep 19, 2014
Subaru of America, Inc. (Subaru) is recalling certain model year 2015 Outback vehicles manufactured January 22, 2014, to August 18, 2014, and equipped with a Subaru accessory trailer hitch assembly. During installation, the trailer hitch mounting nuts may have been overtightened, potentially resulting in failure of the trailer hitch mounting studs.
Consequence & remedy
Consequence: The mounting nut(s) may not provide sufficient force to remain attached to the studs or the studs themselves might break. If this were to happen while a trailer is being towed, the driver might not be able to operate the vehicle as desired or the trailer may detach from the vehicle. Either situation could increase the risk of a crash.
Remedy: Subaru will notify owners, and dealers will replace all eight mounting nuts for the trailer hitch assembly, and will inspect all eight mounting studs for damage, free of charge. The recall began on October 7, 2014. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WQN-50.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1EA21002 · Desiccated Air Bag Inflator Rupture
Opened Sep 17, 2021 · No close date supplied
Status: open (inferred from source dates) · Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:passenger Side:inflator Module
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.
Additional source detail variants (2)
Air Bags:frontal:driver Side:inflator Module
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.
Air Bags:frontal:passenger Side:inflator Module
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.
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