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 reports
93,700 miles · Aug 14, 2020
Unknown Or Other
MUTIPLE TIMES WHEN THE CAR IS STOPPED AND PUT INTO PARK,REGARDLESS OF WHERE, THE KEY WILL NOT COME OUT OF THE IGNITION. THE SWITCH CAN BE TURNED OFF, BUT THE KEY WILL NOT COME OUT OF THE IGNITION. THE GEAR SHIFT HAS TO BE MANIPULATED MULTIPLE TIMES BETWEEN DRIVE AND PARK IN ORDER TO EVER REMOVE THE KEY. THIS MAKES IT QUITE DIFFI…
Read full complaint
MUTIPLE TIMES WHEN THE CAR IS STOPPED AND PUT INTO PARK,REGARDLESS OF WHERE, THE KEY WILL NOT COME OUT OF THE IGNITION. THE SWITCH CAN BE TURNED OFF, BUT THE KEY WILL NOT COME OUT OF THE IGNITION. THE GEAR SHIFT HAS TO BE MANIPULATED MULTIPLE TIMES BETWEEN DRIVE AND PARK IN ORDER TO EVER REMOVE THE KEY. THIS MAKES IT QUITE DIFFICULT TO RUN ERRANDS OR TO TAKE A TRIP, NOT KNOWING IF THE ABILITY TO REMOVE THE KEY WILL BE POSSIBLE. AND, OF COURSE, IF THE KEY HAS TO BE LEFT IN, THE POSSIBILITY OF THEFT WOULD BE GREAT. CAR IS NOT RECOGNIZING THE GEAR SHIFT IS IN PARK. ON ONE OCCASION, I HAD TO LEAVE THE KEY IN THE CAR IN MY DRIVEWAY, BUT THIS RUNS THE BATTERY DOWN. DEALER WHERE I AM TAKING CAR TO BE REPAIRED AS WELL AS THE SUBARU OF AMERICA CONTACT, ADVISED ME THIS IS A REGULAR OCCURRENCE AND SUBARU IS WELL AWARE OF WHAT IS HAPPENING. I FEEL THIS SHOULD BE PUT ON THE RECALL STATUS! THIS HAS HAPPENED ON MULTIPLE OCCASIONS SINCE BUYING THE CAR ON JUNE 5, 2020. TODAY'S DATE IS 08/14/20. REPAIR WILL BE MADE MONDAY, 08/17/20.
NHTSA ODI #11349304
93,700 miles · Aug 14, 2020
Electrical SystemPower Train
TL* THE CONTACT OWNS A 2017 SUBARU OUTBACK. THE CONTACT STATED THAT THE GEAR BOX FAILED TO RECOGNIZE WHEN THE VEHICLE WAS IN PARK WHICH CAUSED THE KEY TO NOT BE ABLE TO BE REMOVED FROM THE IGNITION. THERE WAS NO WARNING. THE VEHICLE WAS TAKEN TO THE SUBARU OF KENNESAW DEALER LOCATED AT 905 ERNEST W. BARRETT PKWY NW, KENNESAW, GA…
Read full complaint
TL* THE CONTACT OWNS A 2017 SUBARU OUTBACK. THE CONTACT STATED THAT THE GEAR BOX FAILED TO RECOGNIZE WHEN THE VEHICLE WAS IN PARK WHICH CAUSED THE KEY TO NOT BE ABLE TO BE REMOVED FROM THE IGNITION. THERE WAS NO WARNING. THE VEHICLE WAS TAKEN TO THE SUBARU OF KENNESAW DEALER LOCATED AT 905 ERNEST W. BARRETT PKWY NW, KENNESAW, GA 30144, WHERE IT WAS STATED THAT THE FAILURE WAS A KNOWN ISSUE AND SCHEDULED AN APPOINTMENT FOR THE CONTACT. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THERE WERE MULTIPLE COMPLAINTS ABOUT THE FAILURE AND THAT THE DEALER WOULD BE CONTACTED. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 93,700.*DT*DT CONSUMER WAS REIMBURSED FOR THE REPAIR.*JB
NHTSA ODI #11349271
30,000 miles · Aug 13, 2020
Electrical System
THE CAR DIES VERY QUICKLY. WE BOUGHT THE VEHICLE BRAND NEW, AND IT ONLY TOOK ABOUT A YEAR BEFORE THE CAR STARTED DYING FOR NO REASON. WE REPLACED THE BATTERY, BUT THE CAR WOULD STILL DRAIN THE BATTERY OVERNIGHT. WE TOOK TO OUR MECHANIC AND HE CANNOT FIND WHAT IS DRAWING THE ENERGY. NOW, IF WE LEAVE THE DOORS OPEN FOR MORE TH…
Read full complaint
THE CAR DIES VERY QUICKLY. WE BOUGHT THE VEHICLE BRAND NEW, AND IT ONLY TOOK ABOUT A YEAR BEFORE THE CAR STARTED DYING FOR NO REASON. WE REPLACED THE BATTERY, BUT THE CAR WOULD STILL DRAIN THE BATTERY OVERNIGHT. WE TOOK TO OUR MECHANIC AND HE CANNOT FIND WHAT IS DRAWING THE ENERGY. NOW, IF WE LEAVE THE DOORS OPEN FOR MORE THAN 10 MINUTES THE CAR WILL DIE. IT IS COMPLETELY UNRELIABLE AT THIS POINT, AND I HAVE HAD TO PURCHASE A TRAVEL "JUMPER" KIT IN ORDER TO NOT GET STRANDED. IT SEEMS VERY RANDOM HOW IT WILL DIE. IT CAN JUST BE SITTING IN THE GARAGE OVERNIGHT (FROM 5 PM TO 8 AM), WITH NOTHING RUNNING, NO DOORS OPEN, NO LIGHTS ON, BUT WILL BE FULLY DRAINED.
NHTSA ODI #11349029
20,000 miles · Aug 12, 2020
Visibility/wiper
THE WINDSHIELD JUST CRACKED BY ITSELF WHILE NOT MOVING. I GOT IN THE CAR TO START IT AND HEARD A CRACK. IT STARTED AT THE BOTTOM OF THE WINDSHIELD BEHIND THE TRIM AND WENT UP THE WINDSHIELD ABOUT 10 INCHES. SENSE THEN IT HAS SPREAD.
NHTSA ODI #11348936
24,000 miles · Aug 9, 2020
Electrical System
THE BATTERY DOES NOT LAST LONG AND DOES NOT ALWAYS HOLD ITS CHARGE. IT HAS COMPLETELY LOST ITS CHARGE MULTIPLE TIMES FROM THE SECOND DAY I OWNED IT. IN LESS THAN A YEAR THE CAR HAS HAD A DRAINED BATTERY FOR NO APPARENT REASON. THE VEHICLE HAS CONSISTENTLY LOST ITS CHARGE WHILE STATIONARY. AT SOME TIMES IT IS OFF AND WILL NOT TUR…
Read full complaint
THE BATTERY DOES NOT LAST LONG AND DOES NOT ALWAYS HOLD ITS CHARGE. IT HAS COMPLETELY LOST ITS CHARGE MULTIPLE TIMES FROM THE SECOND DAY I OWNED IT. IN LESS THAN A YEAR THE CAR HAS HAD A DRAINED BATTERY FOR NO APPARENT REASON. THE VEHICLE HAS CONSISTENTLY LOST ITS CHARGE WHILE STATIONARY. AT SOME TIMES IT IS OFF AND WILL NOT TURN ON. OTHER TIMES IT HAS BEEN ON AND PARKED AND SUDDENLY TURNS OFF. THE DEALERSHIP SERVICE DEPARTMENT CAN NOT DETERMINE THE REASON.
NHTSA ODI #11344212
23,973 miles · Aug 8, 2020
Electrical System
BATTERY DIED IN 2019 AFTER OWNING CAR FOR ~2YRS AS IT FAILED BATTERY LOAD TEST. BATTERY REPLACED APRIL 2019. IN JULY 2020, THE CAR FAILED TO START (STATIONARY) AGAIN REQUIRING A CHARGE / JUMP. TOOK CAR IN TODAY ON 8/8/20 AND IT FAILED BATTERY LOAD TEST AGAIN AND BATTERY WAS REPLACED AGAIN UNDER WARRANTY. THIS APPEARS TO BE…
Read full complaint
BATTERY DIED IN 2019 AFTER OWNING CAR FOR ~2YRS AS IT FAILED BATTERY LOAD TEST. BATTERY REPLACED APRIL 2019. IN JULY 2020, THE CAR FAILED TO START (STATIONARY) AGAIN REQUIRING A CHARGE / JUMP. TOOK CAR IN TODAY ON 8/8/20 AND IT FAILED BATTERY LOAD TEST AGAIN AND BATTERY WAS REPLACED AGAIN UNDER WARRANTY. THIS APPEARS TO BE A COMMON PROBLEM WITH SUBARUS AND SUBARU NEEDS TO ADDRESS AS THIS CAN LEAVE CONSUMERS IN BAD/DIFFICULT SITUATIONS.
NHTSA ODI #11344054
45,000 miles · Jul 30, 2020
Unknown Or Other
WON'T LET ME REMOVE THE KEY WHEN IN PARK. DIAGNOSIS IS THE SHIFTER PLATE ASSEMBLY NEEDS REPLACED.
NHTSA ODI #11342334
33,000 miles · Jul 29, 2020
Visibility/wiper
I PURCHASED MY 2017 OUTBACK BRAND NEW FROM THE DEALERSHIP IN 2017 AND IN THE THREE YEARS OF OWNING IT, I HAVE HAD TO REPLACE THE WINDSHIELD 3 TIMES. I HAVE NEVER HAD A CAR WHERE THE WINDSHIELD APPEARS TO CRACK FOR NO REASON OR BY THE SLIGHTEST TOUCH OF LOOSE GRAVEL. EACH TIME THE WINDSHIELD CRACKS I HAVE BEEN IN MOTION, ON A HIG…
Read full complaint
I PURCHASED MY 2017 OUTBACK BRAND NEW FROM THE DEALERSHIP IN 2017 AND IN THE THREE YEARS OF OWNING IT, I HAVE HAD TO REPLACE THE WINDSHIELD 3 TIMES. I HAVE NEVER HAD A CAR WHERE THE WINDSHIELD APPEARS TO CRACK FOR NO REASON OR BY THE SLIGHTEST TOUCH OF LOOSE GRAVEL. EACH TIME THE WINDSHIELD CRACKS I HAVE BEEN IN MOTION, ON A HIGHWAY GOING SPEEDS OF ABOUT 60MPH. THE CRACK WILL START SMALL AND THEN SPREAD VERY RAPIDLY WITHIN A MATTER OF MINUTES, THUS MAKING IT IMPOSSIBLE TO GET THE CRACK FILLED BEFORE IT SPREADS.
NHTSA ODI #11342090
62,000 miles · Jul 29, 2020
Electrical System
CANNOT REMOVE KEY FROM IGNITION ONCE VEHICLE IS TURNED OFF AND PUT IN PARK. REFERENCE SUBARU SERVICE BULLETIN 16-112-18R.
NHTSA ODI #11341997
40,000 miles · Jul 28, 2020
Unknown Or Other
BATTERY SEEMS TO BE DRAINING FOR NO REASON. MY CURRENT BATTERY IS 2 MONTHS OLD AND WAS STONE DEAD THIS MORNING(TUESDAY) IN MY CARPORT. I HAD NOT DRIVEN IT SINCE SATURDAY, BUT THE SATURDAY TRIP WAS ABOUT 100 MILES.
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 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.
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.
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
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