IllustrationDEAD BATTERY REQUIRING TOW SERVICE TO CHARGE BATTERY 4/2018 AND 5/2018. REPLACED BATTERY UNDER WARRANTY AFTER TESTING AT SUBARU 5/2018. DEAD BATTERY REQUIRING TOWING COMPANY CHARGE TIMES IN 5/2020 AND REPLACED BATTERY ON 5/14/2020. DEAD BATTERY NOW AGAIN IN 4/2021 REQUIRING TOWING COMPANY BATTERY CHARGE.
2017 Subaru Outback
Owner reports · Recalls · Investigations
More warning signs than most Outback years
Owner complaints for the 2017 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
2040–25K
20725–50K
7750–75K
2075–100K
6100–150K
2150K+
516 reports with mileage · 401 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.
- Electrical System. Review the 391 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Visibility/wiper. Review the 205 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. 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.
32 crash reports3 fire reports17 injury reports
What owners actually said
917 reportsSAFETY DEFECT OPERATOR DATA: BLIND SPOT INDICATOR IS ONLY PRESENTED ON EXTERNAL REVIEW MIRROR. DATA SHOULD BE PROVIDED IN CENTER INSTRUMENT CLUSTER RATHER THAN HAVING TO DEFLECT FOCUS FROM DIRECTION OF TRAVEL.
VEHICLE DESIGN SAFETY DEFECT: AFTER LOCKING DOORS WHILE SEATED IN VEHICLE MUST SELECT UNLOCK TO EXIT VEHICLE. IN AN EMERGENCY SAFETY DICTATES THAT PULLING DOOR OPEN LEVER WOULD OPEN DOOR IN ONE ACTION.
I RECENTLY PURCHASED A 2017 SUBARU OUTBACK. IT DEVELOPED RANDOM SMALL CHIPS IN THE WINDSHIELD IN 4 DIFFERENT SPOTS ON THE WINDSHIELD I WAS DRIVING ON A SMALL NEIGHBORHOOD STREET, WHEN I NOTICED SPECS ON MY WINDSHIELD THAT WOULD NOT COME OFF UPON FURTHER INSPECTION I CAME TO REALIZE THEY WERE TINY CHIPS IN THE GLASS. I HAVE NO …
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I RECENTLY PURCHASED A 2017 SUBARU OUTBACK. IT DEVELOPED RANDOM SMALL CHIPS IN THE WINDSHIELD IN 4 DIFFERENT SPOTS ON THE WINDSHIELD I WAS DRIVING ON A SMALL NEIGHBORHOOD STREET, WHEN I NOTICED SPECS ON MY WINDSHIELD THAT WOULD NOT COME OFF UPON FURTHER INSPECTION I CAME TO REALIZE THEY WERE TINY CHIPS IN THE GLASS. I HAVE NO EXPLANATION AS TO HOW THOSE GOT THERE I WAS NOT IMPACTED BY ANYTHING FLYING AT MY WINDSHIELD. I HAD TO PAY OUT OF POCKET TO FIX ONE CHIP THAT GOT BIG ENOUGH TO POSSIBLY CRACK THE OTHER 3 I WAS TOLD BY THE SAFELIGHT EMPLOYEE THAT I WOULD GET LOTS OF THEM AND I DIDN'T NEED TO DO ANYTHING UNTIL THEY CHIPPED OR CRACKED DEEPER. HE INFORMED ME THAT THE SUBARU GLASS IS VERY THIN AND CHIPS AND CRACKS EASILY HE HAS MANY SUBARU'S THAT COME IN FOR THIS PROBLEM. THE WAY THE CHIPS ARE STARTING OUT VERY TINY AND HOW THEY ARE SPACED OUT LEADS ME TO BELIEVE THIS IS SOMETHING SUBARU SHOULD BE MADE AWARE AND RECALL AND REPLACE. MY HUSBAND JUST PURCHASED A CROSS TREK AND NO SURPRISE AFTER INSPECTING HIS WINDSHIELD WE FOUND TWO VERY TINY SMALL CHIPS IN DIFFERENT LOCATIONS ON HIS WINDSHIELD. I WAS TOLD TO TRY AND KEEP MY WINDSHIELD COOL AND OUT OF THE SUN TO TRY AND PREVENT ANYMORE CHIPPING OR CRACKING. IF I HAD KNOWN THE SUBARU OUTBACK HAD THIS DEFECT I NEVER WOULD HAVE PURCHASED THIS CAR.
THE WINDOW CRACKED FROM THE INSIDE STARTING ON THE BOTTOM OF THE FRONT WINDOW. THERE ARE ALSO MULTIPLE CRACKS ON OTHER PARTS OF THE WINDOWS.
I AM EXPERIENCING REPEATED BATTERY DRAIN LEAVING THE VEHICLE UNABLE TO START. THE DEALER SAYS I AM LEAVING SOMETHING ELECTRICAL "ON" WHEN I PARK IT. IT HAS GOTTEN SO BAD THAT I CARRY A STARTER JUMP PACK BATTERY TO GET IT GOING WHEN THE BATTERY GOES DEAD. THE ORIGINAL EQUIPMENT BATTERY RATING IS 200 COLD CRANK AMPS BELOW THE STAN…
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I AM EXPERIENCING REPEATED BATTERY DRAIN LEAVING THE VEHICLE UNABLE TO START. THE DEALER SAYS I AM LEAVING SOMETHING ELECTRICAL "ON" WHEN I PARK IT. IT HAS GOTTEN SO BAD THAT I CARRY A STARTER JUMP PACK BATTERY TO GET IT GOING WHEN THE BATTERY GOES DEAD. THE ORIGINAL EQUIPMENT BATTERY RATING IS 200 COLD CRANK AMPS BELOW THE STANDARD OF 550 CCA SEEN IN MOST CARS. THIS PROBLEM HAS BEEN GOING ON SINCE I FIRST PURCHASED THE VEHICLE NEW.
HAVE THE CAR 5 YEARS, HAVE HAD TO REPLACE THE BATTERY NOW TWICE. ONCE AT 2 YEARS AND ONCE A YEAR AND A HALF LATER. I OWN A 2014 VW BEETLE AND STILL HAVE NOT HAD TO REPLACE THE BATTERY.
THE HEADLIGHTS (HID WITH AUTO-LEVELING) ARE POINTED DANGEROUSLY LOW. THEY DO NOT ILLUMINATE THE ROAD AHEAD FAR ENOUGH. A DRIVER WOULD HAVE VERY LITTLE TIME TO REACT, GIVEN THIS LIMITED ILLUMINATION DISTANCE. SUBARU DEALERSHIPS ARE ADAMANT THE HEADLIGHTS ARE ADJUSTED TO SPECIFICATIONS. THERE ARE MANY COMPLAINTS ABOUT THIS ISSUE A…
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THE HEADLIGHTS (HID WITH AUTO-LEVELING) ARE POINTED DANGEROUSLY LOW. THEY DO NOT ILLUMINATE THE ROAD AHEAD FAR ENOUGH. A DRIVER WOULD HAVE VERY LITTLE TIME TO REACT, GIVEN THIS LIMITED ILLUMINATION DISTANCE. SUBARU DEALERSHIPS ARE ADAMANT THE HEADLIGHTS ARE ADJUSTED TO SPECIFICATIONS. THERE ARE MANY COMPLAINTS ABOUT THIS ISSUE ALL OVER THE INTERNET FROM OWNERS, AND THE DEALERSHIPS I'VE MENTIONED THIS ISSUE TO HAVE EXPLAINED THEY ARE AWARE OF THE COMPLAINTS, BUT THERE IS NOTHING THEY CAN DO. I AM VERY WORRIED FOR OUR SAFETY AND FOR THE PEDESTRIANS/VEHICLES WE WOULD NOT SEE IN TIME TO STOP. WE PURCHASED THIS VEHICLE NEW, AND THIS IS NOT A NEW ISSUE. I HAVE TRIED TO ADDRESS IT FOR SEVERAL YEARS. WHEN THE VEHICLE IS ACCELERATING FROM A STOPLIGHT, FOR EXAMPLE, THE HEADLIGHTS ARE BASICALLY FINE (GIVEN THE SHIFT OF WEIGHT TO THE REAR WHICH HAS THE FRONT OF THE VEHICLE AIMED A BIT HIGHER), BUT AS SOON AS THE VEHICLE LEVELS OUT, THE ISSUE IS VERY EVIDENT. THE AUTOMATIC HIGH BEAM FEATURE SIMPLY DOES NOT COMPENSATE, AS THE AUTOMATIC HIGH BEAMS ARE NOT INTUITIVE ENOUGH TO PERFECTLY ACTIVATE AND STAY ACTIVATED EVERY TIME (IT MISREADS SURROUNDING STREET LIGHTS, FOR EXAMPLE, AS ONCOMING HEADLIGHTS VERY EASILY.
THIS CAR HAS HAD REPEATED ELECTRICAL ISSUES. THE CAR IS ON IT'S THIRD BATTERY IN 4 YEARS. SUUBARU PAID FOR THE LAST "AFTERMARKET" BATTERY BASED ON MY REQUEST AND NUMEROUS COMPLAINTS FROM OTHERS. THE SAFETY ISSUE CAME UP FROM THE LAST PROBLEM: THE KEY WAS STUCK IN THE IGNITION. THIS TOO IS A COMMON PROBLEM. THE DEALER REPLA…
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THIS CAR HAS HAD REPEATED ELECTRICAL ISSUES. THE CAR IS ON IT'S THIRD BATTERY IN 4 YEARS. SUUBARU PAID FOR THE LAST "AFTERMARKET" BATTERY BASED ON MY REQUEST AND NUMEROUS COMPLAINTS FROM OTHERS. THE SAFETY ISSUE CAME UP FROM THE LAST PROBLEM: THE KEY WAS STUCK IN THE IGNITION. THIS TOO IS A COMMON PROBLEM. THE DEALER REPLACED THE SENSOR IN THE GEAR SHIFT MECHANISM TO FIX THIS PROBLEM. THE SAFETY ISSUE IS OWNERS ARE POSTING WORKAROUNDS ON LINE TO GET AROUND THIS PROBLEM. THE WORKAROUNDS GET AROUND THE ISSUE. HOWEVER, BY DISCONNECTING WIRES THE KEY CAN BE REMOVED IN ANY POSITION, INCLUDING WHILE THE CAR IS IN GEAR AND MOVING. THAT IS CLEARLY A POTENTIAL PROBLEM. THIS REPAIR WAS MADE APPROXIMATELY THREE WEEKS AGO. TWO DAYS AGO THE BATTERY WAS COMPLETELY DEPLETED AND THE TAILGATE WOULD NOT FUNCTION. I BROUGHT THIS TO SUBARU'S ATTENTION. THIS TIME THEY SAID I WAS OUT OF WARRANTY AND THEY WOULD NOT ASSIST (I WAS OUT OF WARRANTY ON THE IGNITION SWITCH AND BATTERY ISSUES). I BELIEVE THERE IS A FUNDAMENTAL PROBLEM IN THIS GENERATION OF SUBARU'S THAT NEEDS TO BE INVESTIGATED. A SIMPLE SEARCH OF THE SUBARU OUTBACK FORUM FOR KEY RELEASE PROBLEMS WILL VERIFY MY ASSERTION. SUBARU NEEDS TO COME CLEAN ON THE ELECTRICAL ENGINEERING DEFICIENCIES IMPACTING SAFETY AND RELIABILITY.
BATTERY KEEPS DRAINING EVEN AFTER BEING REPLACED KEY SENSOR ALSO ALWAYS GOES OFF THAT KEY IS NOT IN CAR WHEN DRIVING
Official recalls
419V910000 · Air Bags: Air Bag/restraint Control Module
Dec 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.
16V716000 · Air Bags:knee Bolster; Steering:column
Oct 6, 2016
Subaru of America, Inc. (Subaru) is recalling certain model year 2017 Legacy and Outback vehicles manufactured September 21, 2016, to September 23, 2016. In the affected vehicles, the knee guard bracket may not be properly attached to the steering beam assembly.
Consequence & remedy
Consequence: If the knee guard is not properly attached and the driver is not wearing a seatbelt, the knee guard may not be able to properly restrain the driver's lower body in the event of a crash, increasing the risk of injury.
Remedy: Subaru will notify owners, and dealers will inspect the knee guard welding on each vehicle's steering beam, replacing the beam as necessary, free of charge. The recall began November 14, 2016. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WTL-72.
Additional source detail variants (2)
Air Bags:knee Bolster
Subaru of America, Inc. (Subaru) is recalling certain model year 2017 Legacy and Outback vehicles manufactured September 21, 2016, to September 23, 2016. In the affected vehicles, the knee guard bracket may not be properly attached to the steering beam assembly.
Consequence: If the knee guard is not properly attached and the driver is not wearing a seatbelt, the knee guard may not be able to properly restrain the driver's lower body in the event of a crash, increasing the risk of injury.
Remedy: Subaru will notify owners, and dealers will inspect the knee guard welding on each vehicle's steering beam, replacing the beam as necessary, free of charge. The recall began November 14, 2016. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WTL-72.
Steering:column
Subaru of America, Inc. (Subaru) is recalling certain model year 2017 Legacy and Outback vehicles manufactured September 21, 2016, to September 23, 2016. In the affected vehicles, the knee guard bracket may not be properly attached to the steering beam assembly.
Consequence: If the knee guard is not properly attached and the driver is not wearing a seatbelt, the knee guard may not be able to properly restrain the driver's lower body in the event of a crash, increasing the risk of injury.
Remedy: Subaru will notify owners, and dealers will inspect the knee guard welding on each vehicle's steering beam, replacing the beam as necessary, free of charge. The recall began November 14, 2016. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WTL-72.
16V576000 · Service Brakes, Hydraulic:foundation Components:disc:caliper; Suspension
Aug 3, 2016
Subaru of America, Inc. (Subaru) is recalling certain model year 2017 Outback vehicles manufactured June 20, 2016, to June 23, 2016. The affected vehicles may have improperly tightened attaching bolts for the front left and right brake calipers, wheel hubs, and the right stabilizer clamp.
Consequence & remedy
Consequence: If any of the front brake caliper, wheel hub or stabilizer clamp attaching bolts loosen or detach, the related components would also become loose and may detach possibly making the vehicle unstable and reducing the braking capability. These conditions would increase the risk of a crash.
Remedy: Subaru has notified owners, and dealers will inspect the bolts for proper torque, and replace any loose bolts, free of charge. The recall began on August 8, 2016. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WTE-66.
Additional source detail variants (2)
Service Brakes, Hydraulic:foundation Components:disc:caliper
Subaru of America, Inc. (Subaru) is recalling certain model year 2017 Outback vehicles manufactured June 20, 2016, to June 23, 2016. The affected vehicles may have improperly tightened attaching bolts for the front left and right brake calipers, wheel hubs, and the right stabilizer clamp.
Consequence: If any of the front brake caliper, wheel hub or stabilizer clamp attaching bolts loosen or detach, the related components would also become loose and may detach possibly making the vehicle unstable and reducing the braking capability. These conditions would increase the risk of a crash.
Remedy: Subaru has notified owners, and dealers will inspect the bolts for proper torque, and replace any loose bolts, free of charge. The recall began on August 8, 2016. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WTE-66.
Suspension
Subaru of America, Inc. (Subaru) is recalling certain model year 2017 Outback vehicles manufactured June 20, 2016, to June 23, 2016. The affected vehicles may have improperly tightened attaching bolts for the front left and right brake calipers, wheel hubs, and the right stabilizer clamp.
Consequence: If any of the front brake caliper, wheel hub or stabilizer clamp attaching bolts loosen or detach, the related components would also become loose and may detach possibly making the vehicle unstable and reducing the braking capability. These conditions would increase the risk of a crash.
Remedy: Subaru has notified owners, and dealers will inspect the bolts for proper torque, and replace any loose bolts, free of charge. The recall began on August 8, 2016. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WTE-66.
16V292000 · 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.
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.