NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
13 reportsClear category filterMileage unknown · Mar 25, 2026
EngineFuel/propulsion SystemPower Train
My 2016 Subaru Outback CVT transmission has exhibited an intermittent jerking and grabbing sensation when accelerating from a stop, worse when cold, since at least February 2023. This is a known defect covered under Subaru warranty extension bulletin 16-115-18. February 2023 — An authorized Subaru dealer documented the complaint…
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My 2016 Subaru Outback CVT transmission has exhibited an intermittent jerking and grabbing sensation when accelerating from a stop, worse when cold, since at least February 2023. This is a known defect covered under Subaru warranty extension bulletin 16-115-18. February 2023 — An authorized Subaru dealer documented the complaint in writing. The technician stated the vehicle never warmed up during the test drive and dismissed the concern. The CVT issue was never repaired. I was never informed of Subaru's CVT warranty extension program. February 17 2026 — seven days before my warranty expiration — the same authorized Subaru dealer physically identified and documented a CVT oil pump cover leak. The same jerking complaint was again documented in writing. No repairs were made and the warranty expired one week later. The CVT defect has been physically confirmed by an authorized Subaru dealer within the warranty period and Subaru of America has denied my warranty claim in writing. This issue presents a safety concern. The unpredictable jerking and hesitation when accelerating from a stop creates dangerous situations in traffic, particularly at intersections and when merging. The vehicle is available for inspection upon request. Subaru chose to handle this known widespread defect as a quiet warranty extension rather than a mandatory recall despite hundreds of owners reporting identical symptoms.
NHTSA ODI #11727074
Mileage unknown · Oct 21, 2024
EngineFuel/propulsion SystemService Brakes
The left front drive axel cracked while we were driving on an overpass connecting two highways. We didn’t hit or bump anything. The car just stopped, like the brakes were slammed on, except the brakes didn’t work. As we were on an incline, the car started rolling backwards, but fortunately the emergency brake worked. It happened…
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The left front drive axel cracked while we were driving on an overpass connecting two highways. We didn’t hit or bump anything. The car just stopped, like the brakes were slammed on, except the brakes didn’t work. As we were on an incline, the car started rolling backwards, but fortunately the emergency brake worked. It happened so abruptly, I wasn’t able to fully pull off the road and my children in the back seat were screaming for their lives as truck after truck whizzed by rattling our car with their horns blaring missing us by inches. The police and fire trucks eventually blocked us from traffic until we could get a tow. The engine worked, but we couldn’t get into any gear. The mechanic said it must’ve been a faulty part to have gone like that. When the axel broke, it damaged the front differential and the transmission so the car isn’t very drivable. On a less dramatic note, a month earlier, both back doors stopped working on the same day!! The child locks failed and the doors couldn’t be opened. I consider this a safety hazard, so we spent $$$ to fix it. As we take good care of our car, I am very curious why it’s failing so spectacularly all at once.
NHTSA ODI #11621014
Mileage unknown · Sep 12, 2023
Fuel/propulsion SystemCrash
As I was pulling slowly into a parking spot in a busy lot that serves a lot of small businesses, my Subaru suddenly accelerated forward, over the concrete parking bumper and raised sidewalk area, and into the side of the building. While I was uninjured and had no passengers in the vehicle, the car sustained damage to the apron a…
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As I was pulling slowly into a parking spot in a busy lot that serves a lot of small businesses, my Subaru suddenly accelerated forward, over the concrete parking bumper and raised sidewalk area, and into the side of the building. While I was uninjured and had no passengers in the vehicle, the car sustained damage to the apron and tire area on front passenger side of the car. The airbag did not inflate. Tiling on the exterior of the building was impacted, but not greatly damaged, and I had been able to avoid the plate glass entry to the business. A few customers were greatly alarmed by the Subaru's proximity to their lunch tables by the windows. I was able to put the vehicle into reverse and carefully move it off the sidewalk. I exited the car and went in to share my insurance information with the empathetic employees and manager of the business. I was able to drive my vehicle about two blocks to a larger lot, so that the towing company my husband contacted could access it, but not for several hours. The vehicle was taken to an auto body shop where it remains until they are finished with it. The claims people seem to have reached the conclusion that since I was driving, I must be at fault in this accident. I immediately, and still, continue to think over that incident, trying to determine how parking carefully and without distraction could turn into such a collision. I believe that I am not to blame. In reading the reports that have been made to your agency on Subarus of this vintage, there are marked similarities to the narratives on sudden unintended acceleration caused by Subaru equipment faults. I have lost confidence in what has been my favorite car. I'm hoping that some clear path exists for me to drive it again without anxiety.
NHTSA ODI #11544150
Mileage unknown · Jan 27, 2023
EngineFuel/propulsion SystemUnknown Or OtherCrashInjury
I was in a parking lot at a near-complete stop. I needed to nose the car about 18 inches to move it all the way into the spot. I lightly touched the accelerator to inch the car forward, and it shot forward as if some outside force had stomped on the accelerator. The car jumped the sidewalk and slammed into the wall of the buildi…
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I was in a parking lot at a near-complete stop. I needed to nose the car about 18 inches to move it all the way into the spot. I lightly touched the accelerator to inch the car forward, and it shot forward as if some outside force had stomped on the accelerator. The car jumped the sidewalk and slammed into the wall of the building. The car inner body bent and the car is totaled. The airbags did not inflate. The passenger in the passenger seat sustained a fractured sternum and two broken ribs from going into the seatbelt. The driver sustained a sore neck and dizziness.
NHTSA ODI #11503955
Mileage unknown · Aug 1, 2022
Electrical SystemFuel/propulsion SystemService BrakesCrash
This incident occurred on Friday July 29, 2022 @ 5pm. I was pulling into a parking space while my foot was on the brake I proceeded to put the car in park when the car suddenly lunged forward into the concrete patio of the Market/Store. I was in disbelief at what just happened. I would happily make my car available for inspect…
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This incident occurred on Friday July 29, 2022 @ 5pm. I was pulling into a parking space while my foot was on the brake I proceeded to put the car in park when the car suddenly lunged forward into the concrete patio of the Market/Store. I was in disbelief at what just happened. I would happily make my car available for inspection. I want to find out what is wrong with the car. I believe this could happen again and I am fearful for my life and the lives of others. I was so lucky that the table and chairs were roped off that evening for some reason. People could have been sitting or walking there at the time of this incident. This incident has not been reproduced or confirmed by the dealer or independent service center. I brought the car to the Subaru dealer for them to do a diagnostic test and any other things needed to give me some answers & repairs. I was told no issues were found. They also told me they would like to have my car for a week so they could drive it & do more test. I asked for a loaner and they said they could not do that. I can’t afford to rent a car for a week. And I feel they will come back to me with the same answer of not being able to find an issue. I have had this car for almost 3 years and I park by putting my foot on the brake and then shift into park. There was a malfunction! What it was I don’t know. But I do know something went very wrong with the vehicle. There was never any warning lamps, messages or other symptoms of the problem prior to this failure.
NHTSA ODI #11477046
Mileage unknown · Feb 11, 2022
Fuel/propulsion SystemUnknown Or Other
on 2/8/22 I brought my car in for service to an independent repair shop. The service was for the 120k standard service. I had been noticing exhaust smells. They checked the exhaust and found "exhaust leak from center exhaust flange, and exhaust leave from exhaust manifold". They recommended a complete replacement of the exhaus…
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on 2/8/22 I brought my car in for service to an independent repair shop. The service was for the 120k standard service. I had been noticing exhaust smells. They checked the exhaust and found "exhaust leak from center exhaust flange, and exhaust leave from exhaust manifold". They recommended a complete replacement of the exhaust manifold "under Subaru recall". They printed the recall for me. It is WUJ-95. Which recalls 2015-2016 outbacks for this issue. When I contacted the dealer they indicated my vehicle was not under this recall. Subaru Customer care indicated the same as did your website. Subaru said that the recall was initiated by NHTSA and that until NHTSA indicated my vehicle was included in the recall they would not repair it. My vehicle has exactly the same issue as what was found for the recall. The only thing I can assume is that my actual 2016 Subaru outback was manufactured after 9/30/15. I cannot find the exact date of manufacture so cannot tell if that is the issue. However, that actual manufacture date should not be controlling as my 2016 outback has exactly the same issue as the recall. If 2016 outbacks manufactured after 9/30/15 have this same issue they should be included in this recall. I am asking you to review this issue and include my vehicle in the recall.
NHTSA ODI #11451505
30,000 miles · Oct 7, 2020
Fuel/propulsion System
WHEN THE CAR IS STARTED UP ON A COLD MORNING IT IDLES TOO FAST AND LURCHES DANGEROUSLY WHEN PUT INTO DRIVE. I HAVE TO HOLD THE CAR BACK WITH FIRM BRAKING. I HAVE HAD NUMEROUS CLOSE CALLS OVER THE LAST FOUR YEARS THAT I HAVE OWNED THE CAR. THE CAR IS A 2016 OUTBACK 3.6 R WITH A 6 CYLINDER ENGINE.
NHTSA ODI #11363155
50,000 miles · Jan 2, 2019
EngineFuel/propulsion System
ON TWO OCCASIONS WHILE DRIVING ON THE INTERSTATE AT 65-75 MPH WITH NO WARNING THE GAS PEDAL STOPPED RESPONDING TO INPUTS. WHILE MANEUVERING THE VEHICLE TO THE SHOULDER OF THE ROAD THROUGH TRAFFIC THE ENGINE SHUTOFF. ON ONE OCCASION I WAS ABLE TO RESTART THE VEHICLE AND ON THE SECOND OCCASION IT WOULD NOT RESTART. AFTER TOWING…
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ON TWO OCCASIONS WHILE DRIVING ON THE INTERSTATE AT 65-75 MPH WITH NO WARNING THE GAS PEDAL STOPPED RESPONDING TO INPUTS. WHILE MANEUVERING THE VEHICLE TO THE SHOULDER OF THE ROAD THROUGH TRAFFIC THE ENGINE SHUTOFF. ON ONE OCCASION I WAS ABLE TO RESTART THE VEHICLE AND ON THE SECOND OCCASION IT WOULD NOT RESTART. AFTER TOWING THE VEHICLE TO A REPAIR SHOP THE VEHICLE STARTED UP AND RAN WITH NO ISSUES. NO CHECK ENGINE LIGHTS WERE EVER DISPLAYED. THE BATTERY WAS WORKING FINE AND FULLY CHARGED. THE CAR IS IN PERFECT MECHANICAL SHAPE WITH ALL REGULAR SERVICE PERFORMED. THE GAS REMAINING AT TIME OF INCIDENT WAS APPROXIMATELY 1/4 TANK FULL. THE CAUSE IS UNKNOWN TO ME.
NHTSA ODI #11164684
350 miles · Jul 13, 2018
EngineFuel/propulsion SystemVehicle Speed Control
AFTER STOPPING AT A STOP SIGN ON A CITY STREET, I TRIED TO ACCELERATE BUT THERE WAS A LONG HESITATION FOLLOWED BY A SURGE OF POWER. THIS HAPPENED ON 2 OCCASIONS. I HAD THE SALES MAN DRIVE THE VEHICLE AND ALSO THE SERVICE MANAGER DROVE IT FOR 1 WEEK - NEITHER TIMES DID THIS ISSUE REPEAT ITSELF. THE DEALERSHIP DID NOT HAVE ANY …
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AFTER STOPPING AT A STOP SIGN ON A CITY STREET, I TRIED TO ACCELERATE BUT THERE WAS A LONG HESITATION FOLLOWED BY A SURGE OF POWER. THIS HAPPENED ON 2 OCCASIONS. I HAD THE SALES MAN DRIVE THE VEHICLE AND ALSO THE SERVICE MANAGER DROVE IT FOR 1 WEEK - NEITHER TIMES DID THIS ISSUE REPEAT ITSELF. THE DEALERSHIP DID NOT HAVE ANY KNOWLEDGE OF THIS TYPE OF PROBLEM. I REFUSED TO DRIVE THIS VEHICLE AND RETURNED IT TO THE SUBARU DEALER IN BERLIN, CT.
NHTSA ODI #11111266
8,000 miles · Nov 27, 2016
Fuel/propulsion SystemPower Train
3RD OCCURRENCE: WHILE DRIVING ON A STATE HIGHWAY, VEHICLE JERKED, ALL WARNING LIGHTS CAME ON AND VEHICLE LOST MOVEMENT WITH RESISTANCE. TOWED TO DEALER. *TR
NHTSA ODI #10928155
Official recalls
4Dec 19, 2019
Subaru of America, Inc. (Subaru) is recalling certain 2016-2017 Outback vehicles. A replacement air bag control module may have been installed that is not compatible with the passenger air bag module, possibly affecting air bag deployment.
Consequence & remedy
Consequence: In the event of a crash necessitating passenger frontal air bag deployment, the air bag may not deploy properly, increasing the risk of injury.
Remedy: Subaru will notify owners, and dealers will replace the passenger air bag module, free of charge. The recall began February 3, 2020. Owners may contact Subaru customer service at 1-844-373-6614. Subaru's number for this recall is WUX-09.
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.
Nov 24, 2015
Subaru of America, Inc. (Subaru) is recalling certain model year 2016 Legacy vehicles manufactured October 24, 2015, to November 16, 2015, and Outback vehicles manufactured October 24, 2015, to November 17, 2015. Due to the improper tightening of the securing nuts, the drive shaft may separate from the rear differential.
Consequence & remedy
Consequence: If the drive shaft detaches from the rear differential, it may strike the fuel tank and result in a fuel leak, increasing the risk of a fire.
Remedy: Subaru has notified owners, and dealers will inspect the fastening nuts, and tighten or replace them, as necessary, free of charge. The recall began on December 10, 2015. Owners may contact Subaru customer service at 1-856-488-8500. Subaru's number for this recall is WQV-57.
Additional source detail variants (2)
Power Train:driveline:differential Unit
Subaru of America, Inc. (Subaru) is recalling certain model year 2016 Legacy vehicles manufactured October 24, 2015, to November 16, 2015, and Outback vehicles manufactured October 24, 2015, to November 17, 2015. Due to the improper tightening of the securing nuts, the drive shaft may separate from the rear differential.
Consequence: If the drive shaft detaches from the rear differential, it may strike the fuel tank and result in a fuel leak, increasing the risk of a fire.
Remedy: Subaru has notified owners, and dealers will inspect the fastening nuts, and tighten or replace them, as necessary, free of charge. The recall began on December 10, 2015. Owners may contact Subaru customer service at 1-856-488-8500. Subaru's number for this recall is WQV-57.
Power Train:driveline:driveshaft
Subaru of America, Inc. (Subaru) is recalling certain model year 2016 Legacy vehicles manufactured October 24, 2015, to November 16, 2015, and Outback vehicles manufactured October 24, 2015, to November 17, 2015. Due to the improper tightening of the securing nuts, the drive shaft may separate from the rear differential.
Consequence: If the drive shaft detaches from the rear differential, it may strike the fuel tank and result in a fuel leak, increasing the risk of a fire.
Remedy: Subaru has notified owners, and dealers will inspect the fastening nuts, and tighten or replace them, as necessary, free of charge. The recall began on December 10, 2015. Owners may contact Subaru customer service at 1-856-488-8500. Subaru's number for this recall is WQV-57.
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: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.
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.
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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