SECOND WINDSHIELD CRACK IN 10 DAYS. WHILE DRIVING ON INTERSTATE IN THE RAIN, I TURNED ON THE FRONT DE-FOGGER. APPROX 20 SECONDS LATER THE WINDSHIELD CRACKED FROM THE CENTER BOTTOM UP AND TOWARD THE DRIVERS SIDE. CRACK CURRENTLY EXTENDS UP ABOUT 8 INCHES. AS BEFORE, THERE WAS NO STRIKE THAT CAUSED THIS AND PAVEMENT WAS CLEAN AND …
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SECOND WINDSHIELD CRACK IN 10 DAYS. WHILE DRIVING ON INTERSTATE IN THE RAIN, I TURNED ON THE FRONT DE-FOGGER. APPROX 20 SECONDS LATER THE WINDSHIELD CRACKED FROM THE CENTER BOTTOM UP AND TOWARD THE DRIVERS SIDE. CRACK CURRENTLY EXTENDS UP ABOUT 8 INCHES. AS BEFORE, THERE WAS NO STRIKE THAT CAUSED THIS AND PAVEMENT WAS CLEAN AND SMOOTH. THIS WAS A NEW SUBARU BRANDED WINDSHIELD THAT WAS INSTALLED LITERALLY 4 DAYS AGO. GOING BACK IN TO THE SERVICE DEPT FOR REPAIR AS SOON AS POSSIBLE.
NHTSA ODI #10862777
2,578 miles · May 3, 2016
Visibility/wiper
CAR HAD 2578 MILES ON IT. WHILE PARKED OVERNIGHT WINDSHIELD CRACKED STARTING AT PASSENGER SIDE AND EXTENDING APPROXIMATELY 12 INCHES TOWARD DRIVER SIDE. WENT IMMEDIATELY TO THE LOCAL SUBARU SERVICE DEPT AND THEY DETERMINED THAT IT WOULD BE COVERED UNDER WARRANTY DUE TO NO EVIDENCE OF A STRIKE CAUSING IT. WINDSHIELD WAS REPLACED …
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CAR HAD 2578 MILES ON IT. WHILE PARKED OVERNIGHT WINDSHIELD CRACKED STARTING AT PASSENGER SIDE AND EXTENDING APPROXIMATELY 12 INCHES TOWARD DRIVER SIDE. WENT IMMEDIATELY TO THE LOCAL SUBARU SERVICE DEPT AND THEY DETERMINED THAT IT WOULD BE COVERED UNDER WARRANTY DUE TO NO EVIDENCE OF A STRIKE CAUSING IT. WINDSHIELD WAS REPLACED WITH SUBARU BRANDED PART 6 DAYS LATER THROUGH SUBARU BUT BY THEN THE CRACK HAD GROWN TO APPROX. 18INCHS.
NHTSA ODI #10862769
1,973 miles · Apr 25, 2016
Visibility/wiper
VEHICLE PURCHASED NEW 2/25/2016. 1990 MILEAGE. CRACKS DEVELOPED WHILE DRIVING AT 70MPH. NO SOUNDS OF STONES HITTING GLASS AT ANY TIME DURING DRIVE. STOPPED TO WASH WINDSHIELD AT GAS STOP. DID NOT NOTICE CRACKS UNTIL LATER IN DRIVE. AC WAS TURNED ON & OFF DURING DRIVE, IF THAT MADE A DIFFERENCE. DRIVEN 500 MILES IN MODESTLY WARM …
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VEHICLE PURCHASED NEW 2/25/2016. 1990 MILEAGE. CRACKS DEVELOPED WHILE DRIVING AT 70MPH. NO SOUNDS OF STONES HITTING GLASS AT ANY TIME DURING DRIVE. STOPPED TO WASH WINDSHIELD AT GAS STOP. DID NOT NOTICE CRACKS UNTIL LATER IN DRIVE. AC WAS TURNED ON & OFF DURING DRIVE, IF THAT MADE A DIFFERENCE. DRIVEN 500 MILES IN MODESTLY WARM SUNNY WEATHER IN 8 HRS THAT DAY,4/24/2016. CRACK PROGRESSED TO DRIVERS LINE OF SITE WITHIN ONE HOURS TIME. WAS INFORMED BY SUBARU DEALER NOT COVERED BY WARRANTY. REPAIR IS MY EXPENSE.
NHTSA ODI #10861402
6,000 miles · Apr 9, 2016
Visibility/wiper
WINDSHIELD CRACKED WHILE SITTING IN A PARKING AREA. THERE WAS A SMALL CHIP IN THE DEICER AREA WHERE THE CRACK BEGAN. HOWEVER, IT APPEARS THE STRIKE WAS MINOR AND WOULD HAVE BEEN EASILY REPAIRED BEFORE SPREADING. ALREADY HAD ONE CHIP REPAIRED FOR ANOTHER MINOR STRIKE. WINDSHIELD APPEARS TO BE EXCESSIVELY FRAGILE WHICH COULD R…
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WINDSHIELD CRACKED WHILE SITTING IN A PARKING AREA. THERE WAS A SMALL CHIP IN THE DEICER AREA WHERE THE CRACK BEGAN. HOWEVER, IT APPEARS THE STRIKE WAS MINOR AND WOULD HAVE BEEN EASILY REPAIRED BEFORE SPREADING. ALREADY HAD ONE CHIP REPAIRED FOR ANOTHER MINOR STRIKE. WINDSHIELD APPEARS TO BE EXCESSIVELY FRAGILE WHICH COULD RESULT IN A MAJOR SAFETY PROBLEM. DEALER IS WILLING TO REPAIR, BUT I AM CONCERNED ABOUT THE QUALITY OF GLASS BEING USED IN THE SUBARU.
NHTSA ODI #10854576
150 miles · Apr 4, 2016
Visibility/wiper
WINDSHIELD CRACKED WITHIN FIRST 150 MILES/48 HOURS OF OWNERSHIP OF THE NEW CAR. A VERY SMALL PIECE OF GRAVEL HIT THE WINDSHIELD NEAR THE PASSENGER SIDE WIPER BLADE. IT BARELY MADE ANY NOISE. ON ANY OTHER CAR I'VE OWNED, IT LIKELY WOULD NOT HAVE DAMAGED THE WINDSHIELD AT ALL. IT LEFT A STAR ON THE OUTBACK, WHICH TURNED INTO A FOO…
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WINDSHIELD CRACKED WITHIN FIRST 150 MILES/48 HOURS OF OWNERSHIP OF THE NEW CAR. A VERY SMALL PIECE OF GRAVEL HIT THE WINDSHIELD NEAR THE PASSENGER SIDE WIPER BLADE. IT BARELY MADE ANY NOISE. ON ANY OTHER CAR I'VE OWNED, IT LIKELY WOULD NOT HAVE DAMAGED THE WINDSHIELD AT ALL. IT LEFT A STAR ON THE OUTBACK, WHICH TURNED INTO A FOOT LONG CRACK WITHIN 30 SECONDS. SITTING OVERNIGHT THE CRACK DOUBLED IN SIZE. A WINDSHIELD WHICH FAILS UNDER TYPICAL DAY-TO-DAY CONDITIONS IS NOT ACCEPTABLE.
NHTSA ODI #10853243
1,000 miles · Mar 21, 2016
Visibility/wiper
I BOUGHT A 2016 SUBARU OUTBACK ON MARCH 5TH, 2016. AFTER TWO WEEKS I TOOK A TRIP DOWN TO ATLANTA AND BACK TO KNOXVILLE, TN. I WAS DRIVING ON I-75 AND GOING 70MPH. I HEARD NO SOUND NOR DID I SEE A ROCK OR DEBRIS HIT MY WINDSHIELD, BUT ALL OF A SUDDEN I SAW A CRACK APPEAR. WITHIN AN HOUR OF HOME THIS CRACK GREW FROM ABOUT 3 INCHE…
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I BOUGHT A 2016 SUBARU OUTBACK ON MARCH 5TH, 2016. AFTER TWO WEEKS I TOOK A TRIP DOWN TO ATLANTA AND BACK TO KNOXVILLE, TN. I WAS DRIVING ON I-75 AND GOING 70MPH. I HEARD NO SOUND NOR DID I SEE A ROCK OR DEBRIS HIT MY WINDSHIELD, BUT ALL OF A SUDDEN I SAW A CRACK APPEAR. WITHIN AN HOUR OF HOME THIS CRACK GREW FROM ABOUT 3 INCHES TO 5 INCHES. I CALLED SUBARU OF AMERICA AND ALL THEY TOLD ME WAS 'CRACKS HAPPEN.'
NHTSA ODI #10850872
125 miles · Mar 20, 2016
Visibility/wiper
THE DAY AFTER DRIVING THE NEW CAR HOME FROM THE DEALERSHIP, A CRACK APPROXIMATELY 12 INCHES IN LENGTH APPEARED IN THE WINDSHIELD. THE CRACK WAS NOT NOTICED UNTIL THE VEHICLE WAS STATIONARY AND HAD NOT MOVED FOR ABOUT 24 HOURS. THE CRACK STARTED AT THE EXTREME EDGE OF THE WINDSHIELD ON THE PASSENGER SIDE TOWARD THE TOP AND CURVED…
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THE DAY AFTER DRIVING THE NEW CAR HOME FROM THE DEALERSHIP, A CRACK APPROXIMATELY 12 INCHES IN LENGTH APPEARED IN THE WINDSHIELD. THE CRACK WAS NOT NOTICED UNTIL THE VEHICLE WAS STATIONARY AND HAD NOT MOVED FOR ABOUT 24 HOURS. THE CRACK STARTED AT THE EXTREME EDGE OF THE WINDSHIELD ON THE PASSENGER SIDE TOWARD THE TOP AND CURVED DOWN.
NHTSA ODI #10850657
11,000 miles · Mar 11, 2016
Visibility/wiper
WHEN DRIVING ABOUT 60MPH ON A SMOOTH FLAT HIGHWAY, A SMALL CLICK WAS HEARD. DIDN'T THINK ANYTHING OF IT AT FIRST. AFTER ABOUT 10 MORE MINUTES OF DRIVING I HEARD A LOUD POP. A 8 INCH VERTICAL CRACK STARTED ON THE WINDSHIELD. IT STARTED LOW, BY THE WIPERS, AROUND THE MID-LINE OF THE WINDSHIELD. THE CRACK HAS CONTINUALLY GROWN AND …
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WHEN DRIVING ABOUT 60MPH ON A SMOOTH FLAT HIGHWAY, A SMALL CLICK WAS HEARD. DIDN'T THINK ANYTHING OF IT AT FIRST. AFTER ABOUT 10 MORE MINUTES OF DRIVING I HEARD A LOUD POP. A 8 INCH VERTICAL CRACK STARTED ON THE WINDSHIELD. IT STARTED LOW, BY THE WIPERS, AROUND THE MID-LINE OF THE WINDSHIELD. THE CRACK HAS CONTINUALLY GROWN AND IS NOW RUNNING HORIZONTALLY ACROSS THE DRIVER-SIDE.
NHTSA ODI #10846084
2,100 miles · Feb 24, 2016
Visibility/wiper
WHILE THE CAR WAS GARAGED WITH THE GARAGE DOOR CLOSED, IT DEVELOPED AT ROUGHLY 12" CRACK RUNNING FROM THE RIGHT (PASSENGER SIDE) PILLAR. THERE IS NO ROCK STRIKE OR OTHER IMPACT, NOR HAD THERE BEEN ONE PRIOR TO IT BEING GARAGED. IT DEVELOPED OVERNIGHT.
NHTSA ODI #10837939
2,000 miles · Feb 3, 2016
Visibility/wiper
DURING A RECENT TRIP TO FLORIDA, THE FRONT WINDSHIELD ON MY NEW 2016 SUBARU OUTBACK DEVELOPED OVER HALF A DOZEN SMALL PITS IN THE EXTERIOR GLASS SURFACE FROM CONTACT WITH VERY TINY PEBBLES. 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 GLA…
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DURING A RECENT TRIP TO FLORIDA, THE FRONT WINDSHIELD ON MY NEW 2016 SUBARU OUTBACK DEVELOPED OVER HALF A DOZEN SMALL PITS IN THE EXTERIOR GLASS SURFACE FROM CONTACT WITH VERY TINY PEBBLES. 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 LOW SPEEDS ON HIGHWAY OFF RAMPS. THE TEMPERATURE OUTSIDE DURING THE PEBBLE STRIKES, WHICH TOOK PLACE OVER SEVERAL DAYS OF DRIVING, RANGED FROM 60 TO 85 DEGREES F. THE DEALER EXAMINED THE WINDSHIELD AND SAID THERE WAS NOTHING INFERIOR ABOUT IT.
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.
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 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.
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
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.
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