IllustrationEXCESSIVE EXHAUST ENTERING PASSENGER CABIN ANYTIME THE ENGINE IS RUNNING BECAUSE OF CRACK IN FLEX PIPE ON THE EXHAUST MANIFOLD THAT OCCURRED WITH LESS THAN 60K MILES.
2015 Subaru Outback
Owner reports · Recalls · Investigations
More warning signs than most Outback years
Owner complaints for the 2015 Subaru Outback are substantially higher than the model-year median of 207.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all Outback years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
1810–25K
6925–50K
5350–75K
2675–100K
8100–150K
6150K+
343 reports with mileage · 167 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.
- Visibility/wiper. Review the 130 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 127 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine. Review the 47 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
20 crash reports5 fire reports13 injury reports
What owners actually said
510 reportsWHILE PARKED OUTSIDE IN THE DRIVEWAY DURING WINTER, A CRACK APPEARED AT THE VERY BOTTOM OF THE WINDSHIELD ON THE PASSENGER SIDE. NOTHING KNOWINGLY HIT THE WINDSHIELD, AND I SEE AND FEEL NO KIND OF IMPACT POINT. THE CRACK EXTENDED UPWARD AND THEN SPREAD TOWARD THE DRIVER'S SIDE OVER THE NEXT FEW DAYS. I HAVE CONTACTED A SUBARU DE…
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WHILE PARKED OUTSIDE IN THE DRIVEWAY DURING WINTER, A CRACK APPEARED AT THE VERY BOTTOM OF THE WINDSHIELD ON THE PASSENGER SIDE. NOTHING KNOWINGLY HIT THE WINDSHIELD, AND I SEE AND FEEL NO KIND OF IMPACT POINT. THE CRACK EXTENDED UPWARD AND THEN SPREAD TOWARD THE DRIVER'S SIDE OVER THE NEXT FEW DAYS. I HAVE CONTACTED A SUBARU DEALER ASKING THEM WHAT SUBARU'S POLICY IS REGARDING WINDSHIELD REPLACEMENTS ON 2015 OUTBACKS. I AM WAITING FOR THEIR REPLY.
WINDSHIELD CRACKED FROM BASE OF WINDSHIELD RUNS THROUGH HEATING ELEMENT AND WIPER AREA. DOES NOT APPEAR TO BE CAUSED BY PEBBLE IMPACT OR POSSIBLY EXTREMELY MINOR ONE AND SPREAD IMMEDIATELY
THE CAR WOULD STALL WHEN COASTING TO A STOP LIGHT OR STOP SIGN A FEW TIMES AND HAVE BEEN BACK TO THE DEALER AND CAN'T REPLICATED THE PROBLEM. THIS IS A DANGEROUS SITUATION AND CAN CAUSE AN UNSAFE AND HUGE ACCIDENT WITH MY FAMILY. THE CAR WOULD DIE WHILE IN DRIVE AND SOMETIMES CAN'T BE RESTARTED. IT'S HAPPENING AGAIN AND AFRAID…
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THE CAR WOULD STALL WHEN COASTING TO A STOP LIGHT OR STOP SIGN A FEW TIMES AND HAVE BEEN BACK TO THE DEALER AND CAN'T REPLICATED THE PROBLEM. THIS IS A DANGEROUS SITUATION AND CAN CAUSE AN UNSAFE AND HUGE ACCIDENT WITH MY FAMILY. THE CAR WOULD DIE WHILE IN DRIVE AND SOMETIMES CAN'T BE RESTARTED. IT'S HAPPENING AGAIN AND AFRAID TO DRIVE THE CAR SINCE THE DEALER WILL SAY NOTHING IS WRONG WITH THE CAR. IT LOOKS LIKE IT'S RELATED TO IDLE BEING LOW OR THE CVT ACTING UP WHEN TAKING THE FOOT OFF THE GAS PEDAL AND TRY TO ACCELERATE FROM A DEAD STOP OR COASTING TO A STOP. THIS HAPPENED A FEW TIMES DURING FACTORY WARRANTY WINDOW.
THE SRVD (BLIND SPOT) NOT WORKING INDICATOR LIGHT COMES ON--MEANING THE BLIND SPOT MECHANISM WILL NOT WORK. I HAVE TURNED THE CAR OFF AND STARTED AGAIN WHICH MAY ELIMINATE THE PROBLEM. THERE HAVE BEEN OTHER PUBLISHED COMPLAINTS AS DETAILED IN CONSUMER FORUMS ON THE INTERNET. THE BLIND SPOT LIGHT ON THE OUTSIDE MIRRORS WILL W…
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THE SRVD (BLIND SPOT) NOT WORKING INDICATOR LIGHT COMES ON--MEANING THE BLIND SPOT MECHANISM WILL NOT WORK. I HAVE TURNED THE CAR OFF AND STARTED AGAIN WHICH MAY ELIMINATE THE PROBLEM. THERE HAVE BEEN OTHER PUBLISHED COMPLAINTS AS DETAILED IN CONSUMER FORUMS ON THE INTERNET. THE BLIND SPOT LIGHT ON THE OUTSIDE MIRRORS WILL WILL NOT WORK IF THE SRVD IS NOT FUNCTIONING.
PLEASE READ UPLOAD DOCUMENTS. MY 2015 SUBARU OUTBACK BEGAN SHOWING SIGNS OF EXCESSIVE OIL CONSUMPTION IN THE SUMMER 2018. APPARENTLY THIS WAS A KNOWN PROBLEM WITH SUBARU AND CLASS ACTION LAWSUIT WAS FILED AGAINST SUBARU FOR MODELS MADE PRIOR TO 2015. MY VEHICLE FAILED A OIL CONSUMPTION TEST IN THE FALL OF 2018. I WAS TOLD BY WHI…
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PLEASE READ UPLOAD DOCUMENTS. MY 2015 SUBARU OUTBACK BEGAN SHOWING SIGNS OF EXCESSIVE OIL CONSUMPTION IN THE SUMMER 2018. APPARENTLY THIS WAS A KNOWN PROBLEM WITH SUBARU AND CLASS ACTION LAWSUIT WAS FILED AGAINST SUBARU FOR MODELS MADE PRIOR TO 2015. MY VEHICLE FAILED A OIL CONSUMPTION TEST IN THE FALL OF 2018. I WAS TOLD BY WHITE BEAR SUBARU IF THE VEHICLE FAILED AN OIL CONSUMPTION TEST SUBARU OF AMERICA WOULD PAY TO HAVE A NEW SHORT BLOCK INSTALLED DUE TO THIS ONGOING ENGINE DEFECT. HOWEVER, SUBARU OF AMERICA REFUSED TO PAY THE FULL AMOUNT TO HAVE A NEW SHORT BLOCK INSTALLED AS EVEN THOUGH MY CAR WAS MAKE IN 2014 IT IS TECHNICALLY A 2015 THAT THE CLASS ACTION LAWSUIT ONLY PROTECTED CONSUMERS OF MODELS PRIOR TO 2015. ALSO, IN THE FALL OF 2018 THE INTERIOR OF THIS VEHICLE BEGAN TO HAVE A EXHAUST SMELL AND WAS MAKING ME FEEL SICK. THEY DETERMINED THAT PART OF THE EXHAUST SYSTEM WAS BROKEN BUT TOLD ME NOT TO HAVE IT FIXED BEFORE THE NEW SHORT BLOCK WAS INSTALLED AND THE EXHAUST SYSTEM WOULD JUST BECOME CLOGGED WITH THE OIL THE CAR WAS BURNING. I WENT AHEAD HAD HAD THE REPAIR DONE ANYWAY AS THE EXHAUST AIR WAS TERRIBLE.
FUEL DOOR DOES NOT OPEN TO ALLOW ACCESS TO GAS CAP. I WAS LOW ON GAS AND COULD NOT FILL THE TANK BECAUSE I COULD NOT ACCESS THE GAS CAP.
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.
TL* THE CONTACT OWNS A 2015 SUBARU OUTBACK. WHEN THE CONTACT ENTERED THE VEHICLE, THE WINDSHIELD CRACKED WITHOUT IMPACT. THE VEHICLE WAS TAKEN TO RELIABLE SUBARU (438 INGRAM MILL RD, SPRINGFIELD, MO 65802, 855-983-7578) WHO STATED THAT A PHOTO WOULD BE PROVIDED TO THE MANUFACTURER TO MAKE A DETERMINATION. THE VEHICLE WAS NOT DI…
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TL* THE CONTACT OWNS A 2015 SUBARU OUTBACK. WHEN THE CONTACT ENTERED THE VEHICLE, THE WINDSHIELD CRACKED WITHOUT IMPACT. THE VEHICLE WAS TAKEN TO RELIABLE SUBARU (438 INGRAM MILL RD, SPRINGFIELD, MO 65802, 855-983-7578) WHO STATED THAT A PHOTO WOULD BE PROVIDED TO THE MANUFACTURER TO MAKE A DETERMINATION. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS CONTACTED AND PROVIDED CASE NUMBER: TL1-38506103544. THE FAILURE MILEAGE WAS 75,000.
WINDSHIELD CRACK APPEARED WITHOUT OBVIOUS CAUSE.
Official recalls
516V292000 · Steering:column
May 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.
16V251000 · Electronic Stability Control (esc)
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.
15V502000 · Power Train:automatic Transmission; Power Train:driveline:driveshaft
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.
15V366000 · Exterior Lighting:brake Lights:switch; Forward Collision Avoidance: Crash Imminent Braking
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.
14V577000 · Trailer Hitches
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.