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 reports
10,000 miles · Dec 16, 2015
Visibility/wiper
DURING A RECENT TRIP TO COLORADO, THE FRONT WINDSHIELD ON MY NEW 2015 SUBARU OUTBACK DEVELOPED A DOZEN SMALL PITS IN THE EXTERIOR GLASS SURFACE FROM CONTACT WITH VERY TINY PEBBLES. TWO OF THE PITS HAVE DEVELOPED LARGE CRACKS THAT HAVE GROWN TO LENGTHS EXCEEDING 15 INCHES. THE TINY PEBBLE STRIKES SHOULD NOT HAVE CAUSED SUCH PIT…
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DURING A RECENT TRIP TO COLORADO, THE FRONT WINDSHIELD ON MY NEW 2015 SUBARU OUTBACK DEVELOPED A DOZEN SMALL PITS IN THE EXTERIOR GLASS SURFACE FROM CONTACT WITH VERY TINY PEBBLES. TWO OF THE PITS HAVE DEVELOPED LARGE CRACKS THAT HAVE GROWN TO LENGTHS EXCEEDING 15 INCHES. THE TINY PEBBLE STRIKES SHOULD NOT HAVE CAUSED SUCH PITS BASED ON MY EXTENSIVE DRIVING EXPERIENCE. I BELIEVE THERE TO BE A DEFECT IN THE GLASS ITSELF, MAKING IT UNUSUALLY BRITTLE. THE PEBBLE STRIKES OCCURRED WHILE DRIVING AT HIGHWAY SPEEDS (I.E. 55-65 MPH) ON PAVED ROADWAYS. THE TEMPERATURE OUTSIDE DURING THE PEBBLE STRIKES, WHICH TOOK PLACE OVER SEVERAL DAYS OF DRIVING, RANGED FROM 20 TO 45 DEGREES F. THE CRACKS APPEAR TO STILL BE GROWING.
NHTSA ODI #10810785
6,000 miles · Dec 11, 2015
Service Brakes
WHEN APPLYING THE BREAKS SOMETIMES MY FOOT HITS THE GAS PEDAL. 2ND. OUTBACK I PURCHASED .NEVER HAPPENED BEFORE. HAD CAR SINCE 21 MAY 2015 HAPPENED APPROX. 4 TIMES.
NHTSA ODI #10809659
19,000 miles · Nov 23, 2015
Electrical SystemUnknown Or OtherVisibility/wiper
PURCHASED THE 2015 OUTBACK IN SEPT. 2014. TOOK TO BACK TO DEALERSHIP SERVICE DEPT. OCTOBER. 24, 2014 BECAUSE OF LOUD POPPING NOISE AROUND WINDSHIELD ESPECIALLY WHEN BLUETOOTH PHONE CONNECTED. THEY COULD NOT FIND ANY PROBLEMS. POPPING NOISE AROUND WINDSHIELD CONTINUED FROM TIME TO TIME. TOOK BACK TO DEALER JULY 29, 2015 FOR POP…
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PURCHASED THE 2015 OUTBACK IN SEPT. 2014. TOOK TO BACK TO DEALERSHIP SERVICE DEPT. OCTOBER. 24, 2014 BECAUSE OF LOUD POPPING NOISE AROUND WINDSHIELD ESPECIALLY WHEN BLUETOOTH PHONE CONNECTED. THEY COULD NOT FIND ANY PROBLEMS. POPPING NOISE AROUND WINDSHIELD CONTINUED FROM TIME TO TIME. TOOK BACK TO DEALER JULY 29, 2015 FOR POPPING NOISE AROUND WINDSHIELD AND POOR RADIO AM RECEPTION. THEY REPLACED THE RADIO BUT AM RADIO RECEPTION STILL NOT GREAT. GOT IN THE OUTBACK ON NOV 17, 2015 AND THERE WAS A 5" CRACK ON THE BOTTOM OF THE WINDSHIELD SLIGHTLY RIGHT OF THE CENTER. A COUPLE OF WEEKS BEFORE THIS I WAS DRIVING AND HEARD A VERY LOUD POPPING NOISE. IT MADE ME JUMP AS I THOUGHT THE WINDSHIELD WAS GOING TO SHATTER BUT NOTHING HAPPENED. I HAD RECEIVED A LETTER FROM SUBARU ABOUT WINDSHIELD CRACKING PROBLEMS SO I CONTACTED THE DEALERSHIP. I TOOK IT IN SO THEY COULD TAKE A PICTURE. AT THAT TIME I ALSO REPORTED PROBLEMS WITH THE DEFROSTER NOT KEEPING THE WINDSHIELD CLEAR ESPECIALLY ON RAINY DAYS AND NIGHTS. THIS PROBLEM WITH THE DEFROSTER HAS OCCURRED SEVERAL TIMES AND IT WAS I THE LOWER PORTION OF THE WINDSHIELD. I THOUGHT THE SUBARU HAD ELECTRICAL L ISSUES BECAUSE OF THE POPPING, POOR AM RADIO RECEPTION AND THE DEFROSTER. NOW THE WINDSHIELD! THIS IS MY FIRST SUBARU AND POSSIBLY LAST IF THE PROBLEMS PERSIST. ALL OF THE INCIDENTS HAPPENED WHILE DRIVING BUT WHEN I DISCOVERED THE CRACK IT WAS PARKED IN THE GARAGE. CRACK US NOW ABOUT 9".
NHTSA ODI #10806357
27,000 miles · Nov 17, 2015
Unknown Or Other
I HAVE HAD THIS CAR FOR 1 YEAR AND HAVE HAD 3 WINDSHIELDS CRACK. I HAVE NEVER HAD A CAR THAT HAD THIS MANY INCIDENTS WITH CRACKED WINDSHIELDS
NHTSA ODI #10794385
3,500 miles · Nov 14, 2015
Visibility/wiper
SMALL PEBBLE STRUCK WINDSHIELD PASSENGER SIDE AT EDGE ADJACENT TO HEATING ELEMENT AT LEVEL OF MID WINDSHIELD. THIS LEFT A SMALL SHALLOW PIT IN OUTER GLASS. 12 HOURS LATER A CRACK DEVELOPED AT THE WINDSHIELD EDGE AND EXTENDED 12 INCHES TOWARD THE MIDDLE OF THE WINDSHIELD WHICH IS SLOWLY EXTENDING
NHTSA ODI #10790396
4,000 miles · Nov 10, 2015
Visibility/wiper
WHILE DRIVING ON THE HIGHWAY, A SMALL ROCK HIT OUR WINDSHIELD IN THE PASSENGER SIDE DEICER AREA. WE HAVE RECEIVED A NOTICE THAT SUBARU KNOWS THERE IS AN ISSUE WITH WINDSHIELDS CRACKING AT THE DEICER AREA, BUT THE LOCAL DEALER STATES THAT OUR CRACK INITIATED ABOVE THE AREA FOR WHICH THEY ACCEPT RESPONSIBILITY. THE DEICER AREA ON …
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WHILE DRIVING ON THE HIGHWAY, A SMALL ROCK HIT OUR WINDSHIELD IN THE PASSENGER SIDE DEICER AREA. WE HAVE RECEIVED A NOTICE THAT SUBARU KNOWS THERE IS AN ISSUE WITH WINDSHIELDS CRACKING AT THE DEICER AREA, BUT THE LOCAL DEALER STATES THAT OUR CRACK INITIATED ABOVE THE AREA FOR WHICH THEY ACCEPT RESPONSIBILITY. THE DEICER AREA ON OUR WINDSHIELD EXTENDS ABOVE THE SPOT WHERE THE ROCK HIT, BUT SUBARU IS TRYING TO LIMIT RESPONSIBILITY TO A LOWER AREA. VISIBILITY IS A HIGHLY IMPORTANT COMPONENT OF SAFE DRIVING. THE DEICER AREA WAS NOT APPLIED BY TWO DIFFERENT MANUFACTURING PROCESSES WHEN IT IS A FEW INCHES APART. SUBARU IS TRYING TO LIMIT LIABILITY FOR A DESIGN OR MANUFACTURING FLAW. WE BELIEVE THAT SHOULD NOT BE ALLOWED.
NHTSA ODI #10789553
1,000 miles · Nov 6, 2015
Electrical SystemFire
TL* THE CONTACT OWNS A 2015 SUBARU OUTBACK. THE CONTACT STATED THAT THERE WAS A CHEMICAL ODOR IN THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER TO BE INSPECTED; HOWEVER, THE MECHANIC WAS UNABLE TO DETERMINE ORIGIN OF THE ODOR. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILUR…
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TL* THE CONTACT OWNS A 2015 SUBARU OUTBACK. THE CONTACT STATED THAT THERE WAS A CHEMICAL ODOR IN THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER TO BE INSPECTED; HOWEVER, THE MECHANIC WAS UNABLE TO DETERMINE ORIGIN OF THE ODOR. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 1,000.
NHTSA ODI #10788825
8,300 miles · Nov 4, 2015
Visibility/wiper
MY WINDSHIELD CRACKED WHILE ON THE HIGHWAY. I DID NOT SEE OR HEAR A STONE HIT. 3 OTHER PEOPLE WERE IN THE CAR WHEN A 10 INCH CRACK APPEARED FROM THE DRIVER SIDE CORNER POST TOWARD THE MIDDLE. NO ONE SAW OR HEARD A STONE HIT. I CAME HOME AND RESEARCHED IT AND THERE ARE MANY COMPLAINTS ON THE OUTBACK FORUM ABOUT HOW EASILY THEIR…
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MY WINDSHIELD CRACKED WHILE ON THE HIGHWAY. I DID NOT SEE OR HEAR A STONE HIT. 3 OTHER PEOPLE WERE IN THE CAR WHEN A 10 INCH CRACK APPEARED FROM THE DRIVER SIDE CORNER POST TOWARD THE MIDDLE. NO ONE SAW OR HEARD A STONE HIT. I CAME HOME AND RESEARCHED IT AND THERE ARE MANY COMPLAINTS ON THE OUTBACK FORUM ABOUT HOW EASILY THEIR WINDSHIELDS BROKE. I THINK IT IS A SAFETY ISSUE IF SO MANY OF SUBARU'S NEW WINDSHIELDS ARE CRACKING SO EASILY.
NHTSA ODI #10788422
Mileage unknown · Nov 1, 2015
Steering
THE CAR DOES NOT DRIVE STRAIT , WANDERING LEFT AND RIGHT AT ALL THE TIME FROM THE DAY ONE .CHECKED ALIGNMENT AT THE DEALER - NO PROBLEMS . SO I AM VERY CONCERN ABOUT MY SAFETY AND CAN'T EVEN THINK HOW IT'S GONNA BE ON THE SNOW ( I LIVE IN THE NORTHWEST )
NHTSA ODI #10787525
24,500 miles · Oct 26, 2015
Unknown Or Other
THE WINDSHIELD CRACKED EARLIER THIS YEAR AND HAD TO BE REPLACED. THE CRACK EXTENDED FROM THE UPPER RIGHT TO THE DRIVERS SIDE. LAST WEEK A ROCK HIT MY WINDSHIELD AND WITHIN MINUTES A 2 FOOT CRACK APPEARED (EXTENDS FROM UPPER RIGHT TO THE MIDDLE). THE CRACK IS CONTINUING TO GROW. I'M CONCERNED THERE IS A SAFETY ISSUE WITH THE …
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THE WINDSHIELD CRACKED EARLIER THIS YEAR AND HAD TO BE REPLACED. THE CRACK EXTENDED FROM THE UPPER RIGHT TO THE DRIVERS SIDE. LAST WEEK A ROCK HIT MY WINDSHIELD AND WITHIN MINUTES A 2 FOOT CRACK APPEARED (EXTENDS FROM UPPER RIGHT TO THE MIDDLE). THE CRACK IS CONTINUING TO GROW. I'M CONCERNED THERE IS A SAFETY ISSUE WITH THE WINDSHIELD.
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.
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.
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.
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.
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.
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
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.
Illustration