June 1st 2021 I went to park in a parking space at a local mall. My truck instead of stopping it accelerated out of control jumped two stone curbs, drove though a fence and landed into a swamp. Call Toyota and they have opened a new case # 210602000065. Police report # 21-374-AC. This isn't the first time that this has happen w…
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June 1st 2021 I went to park in a parking space at a local mall. My truck instead of stopping it accelerated out of control jumped two stone curbs, drove though a fence and landed into a swamp. Call Toyota and they have opened a new case # 210602000065. Police report # 21-374-AC. This isn't the first time that this has happen with this truck. It happen in Aug 2019. I contacted Toyota case number 1908060035. They sent out EAA Engineering Analysis Ass. out who did a ACM.CDRX file a month later. Toyota came back said they couldn't find anything wrong and my case was closed. Another incident in winter of 2016 where my truck was stopped and it accelerated on its own and It drove in the 4 way intersection where it caused an accident. lots of damage to cars. Toyota was contacted and they sent me to a dealer for repairs. Dealership has records of my truck coming in since I owned it with complaints of Truck not moving at all to all of sudden to acceleration on its own.
NHTSA ODI #11419346
137,000 miles · Aug 18, 2020
EngineSuspensionUnknown Or Other
I BROUGHT TRUCK TO TOYOTA DEALERSHIP AS PART OF RUSTED FRAME RECALL TO BE VERIFIED. THEY STATED TRUCK WAS NOT RUSTED ENOUGH UNDERNEATH FOR TOYOTA TO APPROVE RECALL. THAT WAS A COUPLE OF MONTHS AGO. I HAVE RECENTLY BROUGHT IT TO A FEW MECHANICS TO DO SOME WORK ON A/C AS THE A/C STOPPED WORKING AND THAT REFUSE TO WORK ON IT AS…
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I BROUGHT TRUCK TO TOYOTA DEALERSHIP AS PART OF RUSTED FRAME RECALL TO BE VERIFIED. THEY STATED TRUCK WAS NOT RUSTED ENOUGH UNDERNEATH FOR TOYOTA TO APPROVE RECALL. THAT WAS A COUPLE OF MONTHS AGO. I HAVE RECENTLY BROUGHT IT TO A FEW MECHANICS TO DO SOME WORK ON A/C AS THE A/C STOPPED WORKING AND THAT REFUSE TO WORK ON IT AS THE TRUCK IS SO RUSTED UNDERNEATH!! THEY SAID IT WOULD CRUMBLE. NOT EVEN WORTH IT.
NHTSA ODI #11350058
91,000 miles · May 11, 2020
Engine
MY 2012 TACOMA WARNING LIGHT 1) ENGINE AND 2 TRAC OFF WARNING LIGHT CAME ON AND LOST POWER GOING 65 MPH ON FREEWAY AND WOULD NOT GO OVER 25 MPH (DANGEROUS!). OBD-II SCANNER DISPLAYED ERROR CODE CHECK P2442 INDICATING FAULTY AIR INJECTION PUMPS AND/OR AIR SWITCHING VALVES. *TR
NHTSA ODI #11324105
103,000 miles · Apr 11, 2020
Engine
ON MY 2012 TACOMA THE CODE P2440 AND P2442 WHICH REPRESENT A STUCK OPEN VALVE IN THE SECONDARY AIR INJECTION SYSTEM. UPON MY RESEARCH INTO THIS ISSUE ON FORUMS I HAVE LEARNED THIS IS A COMMON PROBLEM WITH THE TOYOTA SYSTEMS PARTICULARLY THE 2012 TACOMA. THE COST OF THE PART IS ABOUT 400 TO 500 DOLLARS FOR THE VALVES AND ANOTHER …
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ON MY 2012 TACOMA THE CODE P2440 AND P2442 WHICH REPRESENT A STUCK OPEN VALVE IN THE SECONDARY AIR INJECTION SYSTEM. UPON MY RESEARCH INTO THIS ISSUE ON FORUMS I HAVE LEARNED THIS IS A COMMON PROBLEM WITH THE TOYOTA SYSTEMS PARTICULARLY THE 2012 TACOMA. THE COST OF THE PART IS ABOUT 400 TO 500 DOLLARS FOR THE VALVES AND ANOTHER 500 DOLLARS FOR THE SECONDARY AIR INJECTION PUMP. THE FAILURE WILL PLACE THE VEHICLE INTO A LIMP MODE AND HAS TO BE FIXED IN ORDER TO THE TRUCK TO KEEP ON GOOD WORKING CONDITION. IT SEEMS LIKE THIS ERROR HAS AFFECTED MANY TACOMA OWNERS. *TR
NHTSA ODI #11320809
68,381 miles · Jan 27, 2020
Engine
TWO DASHBOARD LIGHTS ILLUMINATED AT THE SAME TIME: THE CHECK ENGINE LIGHT AND THE TRAC OFF LIGHT. AT FIRST I REALLY DIDN'T NOTICE MUCH OF A DIFFERENCE BUT AFTER 2 DAYS I EXPERIENCED SIGNIFICANT POWER LOSS. I WOULD PULL OUT INTO TRAFFIC OK UNTIL ABOUT 20MPH THEN HAVE NO POWER. IT CRAWLED WHILE TRYING TO GET UP TO SPEED. I READ ON…
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TWO DASHBOARD LIGHTS ILLUMINATED AT THE SAME TIME: THE CHECK ENGINE LIGHT AND THE TRAC OFF LIGHT. AT FIRST I REALLY DIDN'T NOTICE MUCH OF A DIFFERENCE BUT AFTER 2 DAYS I EXPERIENCED SIGNIFICANT POWER LOSS. I WOULD PULL OUT INTO TRAFFIC OK UNTIL ABOUT 20MPH THEN HAVE NO POWER. IT CRAWLED WHILE TRYING TO GET UP TO SPEED. I READ ON THE INTERNET THAT IF YOU DISCONNECT THE BATTERY AND OPEN THE GAS CAP THE LIGHTS WOULD GO OUT AND THE PROBLEM WOULD GO AWAY. I DID THIS AND IT WORKED; OR SO I THOUGHT. I THEN LEFT FOR AN HOUR TRIP (I KNOW DUMB) AND WITHIN 15 MINS THE LIGHTS CAME BACK ON AND I COULDN'T GET THE TRUCK OVER 60MPH ON A MAJOR HIGHWAY. I ACTUALLY STOPPED AT A REST STOP AND DISCONNECTED THE BATTERY AND REMOVED THE GAS CAP. AGAIN THIS SHUT OFF THE LIGHTS BUT ONLY FOR ABOUT 5 MINS. THEN THE POWER LOSS WAS BACK. TOOK TO MY LOCAL MECHANIC WHO I TRUST AND HE SAID IT WAS A KNOWN PROBLEM THAT WAS SOMETHING CALLED A TECHNICAL SERVICE BULLETIN BUT NOT YET A RECALL. APPARENTLY THE TUNDRA AND SEQUOIA ARE RECALLED FOR THIS PROBLEM BUT NOT THE TACOMA. I DON'T GET IT. I WAS TOLD TO KEEP MY RECEIPTS ($1,870.68) RIGHT AFTER CHRISTMAS THANK YOU, AND HOPEFULLY ONE DAY GET REIMBURSED IF IT BECOMES A RECALL. I CAN ONLY HOPE THIS IS A NO INTEREST INVESTMENT INTO MY FUTURE. *TR
NHTSA ODI #11302208
91,500 miles · Dec 31, 2019
Engine
FAILURE OF THE SECONDARY AIR INJECTION SYSTEM P2440 AND P2442, WHILE THE VEHICLE WAS MOVING ONTO A CITY STREET FROM A PARKING LOT. WHEN ACCELERATING IMMEDIATELY THERE WAS A DECREASE IN POWER AND THE CHECK ENGINE LIGHT ALONG WITH THE "TRAC OFF" LIGHT ILLUMINATING SIMULTANEOUSLY. THE VEHICLE HAS A NOW MAXIMUM SPEED OF AROUND 55 MP…
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FAILURE OF THE SECONDARY AIR INJECTION SYSTEM P2440 AND P2442, WHILE THE VEHICLE WAS MOVING ONTO A CITY STREET FROM A PARKING LOT. WHEN ACCELERATING IMMEDIATELY THERE WAS A DECREASE IN POWER AND THE CHECK ENGINE LIGHT ALONG WITH THE "TRAC OFF" LIGHT ILLUMINATING SIMULTANEOUSLY. THE VEHICLE HAS A NOW MAXIMUM SPEED OF AROUND 55 MPH AND EXTREMELY SLOW TO ACCELERATE BEING ALMOST DANGEROUS ON BUSIER ROADS. AFTER BEING CHECK OUT BY A THE DEALER IT WAS FOUND TO BE THE SECONDARY AIR INJECTION SYSTEM WHICH IS COVERED BY AN EXTENDED WARRANTY BUT PARTS ARE ON BACK-ORDER.
NHTSA ODI #11292261
46,000 miles · May 18, 2019
Engine
WHILE ON A ROAD TRIP I HAD MY CHECK ENGINE LIGHT COME ON WHILE ON THE HIGHWAY DUE TO DEFECTIVE SECONDARY INJECTION VALVES BEING STUCK CLOSED/OPEN. THE CODES I HAD FOR THIS ISSUE IS P2440 AND P2442. IN MY CASE THIS ISSUE MADE MY TRUCK GO INTO LIMP MODE WHICH IS OFTEN A LOSS OF POWER IN THE ENGINE AND SOMETIMES A RESTRICTION IN ON…
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WHILE ON A ROAD TRIP I HAD MY CHECK ENGINE LIGHT COME ON WHILE ON THE HIGHWAY DUE TO DEFECTIVE SECONDARY INJECTION VALVES BEING STUCK CLOSED/OPEN. THE CODES I HAD FOR THIS ISSUE IS P2440 AND P2442. IN MY CASE THIS ISSUE MADE MY TRUCK GO INTO LIMP MODE WHICH IS OFTEN A LOSS OF POWER IN THE ENGINE AND SOMETIMES A RESTRICTION IN ONE'S ABILITY TO SHIFT THE TRUCK. LUCKILY THE HIGHWAY WAS NOT BUSY AT THE TIME THIS HAPPENED, BUT IF IT WERE I WOULD BELIEVE THAT IT WOULD BE A VERY UNSAFE THING TO HAPPEN GOING 70 MPH. THE PARTS DO HAVE AN EXTENDED WARRANTY UNTIL 2022 IF I REMEMBER RIGHT, BUT IT SEEMS LIKE TOYOTA IS NOT INTERESTED IN RECALLING THESE PARTS EVEN AFTER THEY HAVE KNOWN FOR MANY YEARS THAT THESE PARTS ARE DEFECTIVE. I HAVE DONE QUITE A BIT OF RESEARCH AND FOUND ISSUES WITH THESE PARTS GOING BACK TO 2013.
NHTSA ODI #11208428
86,000 miles · May 2, 2019
EngineVehicle Speed Control
I WAS ON THE THE HIGHWAY TODAY AND SUDDENLY I LOST POWER AND WON'T PASS SPEEDS OVER 40 MPH VERY DANGEROUS HAVE HEARD THIS HAPPEND TO A LOT OF TACOMAS/ TUNDRAS AND HAS TO DO SOMETHING WITH THE EMISSIONS I THINK I NEED A NEW DIVERTER VALVE WHICH TOYOTA SHOULD COVER
NHTSA ODI #11205143
Mileage unknown · May 1, 2019
Engine
HAVING TROUBLE WITH MY VEHICLES SECONDARY AIR INJECTION SYSTEM, REPLACEMENT PARTS ARE SUPER EXPENSIVE AND HAVE SEEN MANY PEOPLE HAVE THE SAME ISSUE, SEEMS LIKE A NON-RELIABLE COMPONENT. ALWAYS GET THE FAULT CODES P2440 AND P2442. I STRONGLY BELEIVE THAT THIS IS A DEFECTIVE COMPONENT.
NHTSA ODI #11205116
103,000 miles · Apr 29, 2019
Engine
CIL AND TRAC ILLUMINATION WITH CODES P2440 AND P2442 CAUSED THE ENGINE TO GO TO LIMP MODE WITH LOSS OF POWER
Southeast Toyota Distributors, LLC (SET) is recalling certain 2011-2016 Toyota Tacoma and 4Runner vehicles equipped with accessory hood scoops installed by SET or SET dealers. The adhesive attaching the hood scoop may weaken, allowing the hood scoop to detach from the vehicle.
Consequence & remedy
Consequence: If the hood scoop detaches, it may become a road hazard, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will mechanically fasten the scoop to the hood, free of charge. The recall began on September 1, 2017. Owners may contact SET customer service at 1-954-429-2000. SET's number for this recall is SET17B.
Additional source detail variants (2)
Equipment
Southeast Toyota Distributors, LLC (SET) is recalling certain 2011-2016 Toyota Tacoma and 4Runner vehicles equipped with accessory hood scoops installed by SET or SET dealers. The adhesive attaching the hood scoop may weaken, allowing the hood scoop to detach from the vehicle.
Consequence: If the hood scoop detaches, it may become a road hazard, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will mechanically fasten the scoop to the hood, free of charge. The recall began on September 1, 2017. Owners may contact SET customer service at 1-954-429-2000. SET's number for this recall is SET17B.
Structure:body:hood:hinge And Attachments
Southeast Toyota Distributors, LLC (SET) is recalling certain 2011-2016 Toyota Tacoma and 4Runner vehicles equipped with accessory hood scoops installed by SET or SET dealers. The adhesive attaching the hood scoop may weaken, allowing the hood scoop to detach from the vehicle.
Consequence: If the hood scoop detaches, it may become a road hazard, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will mechanically fasten the scoop to the hood, free of charge. The recall began on September 1, 2017. Owners may contact SET customer service at 1-954-429-2000. SET's number for this recall is SET17B.
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2008-2014 FJ Cruiser and Tacoma vehicles equipped with accessory wheels and tires installed by Toyota or dealers prior to the vehicle's first sale. The affected vehicles may list incorrect spare tire size and/or cold tire inflation information on the tire placard. As such, these vehicles fail to comply with Federal Motor Vehicle Safety Standard No. 110, "Tire Selection and Rims for Passenger Cars."
Consequence & remedy
Consequence: If the spare tire is inflated to the incorrect pressure provided on the placard, tire failure may occur while it is being driven on, increasing the risk of a crash.
Remedy: For the involved vehicles, overlay stickers to correct the tire placard will either be mailed to owners or provided to dealers for placement over the incorrect information on the placard. The recall is expected to begin in September 2014. Owners may contact Toyota customer service at 1-800-331-4331.
Toyota is recalling certain model year 2012 and 2013 Toyota Tacoma and Lexus RX350 vehicles and certain model year 2012 Toyota Rav4 vehicles. In the affected vehicles, the brake system contains a brake actuator that adjusts the fluid pressure of each wheel cylinder. An electrical component within the actuator may experience an increased resistance resulting in the illumination of various warning lights, including those for the Vehicle Stability Control (VSC) system, Antilock Brake System (ABS), and Traction Control system.
Consequence & remedy
Consequence: If this occurs, these systems could become inoperative, reducing the directional control assistance, increasing the risk of a crash.
Remedy: Toyota will notify owners, and Toyota and Lexus dealers will update the software for the Skid Control electronic control unit, free of charge. The recall began on March 28, 2014. Owners may contact Toyota at 1-800-331-4331.
Additional source detail variants (2)
Electronic Stability Control (esc)
Toyota is recalling certain model year 2012 and 2013 Toyota Tacoma and Lexus RX350 vehicles and certain model year 2012 Toyota Rav4 vehicles. In the affected vehicles, the brake system contains a brake actuator that adjusts the fluid pressure of each wheel cylinder. An electrical component within the actuator may experience an increased resistance resulting in the illumination of various warning lights, including those for the Vehicle Stability Control (VSC) system, Antilock Brake System (ABS), and Traction Control system.
Consequence: If this occurs, these systems could become inoperative, reducing the directional control assistance, increasing the risk of a crash.
Remedy: Toyota will notify owners, and Toyota and Lexus dealers will update the software for the Skid Control electronic control unit, free of charge. The recall began on March 28, 2014. Owners may contact Toyota at 1-800-331-4331.
Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module
Toyota is recalling certain model year 2012 and 2013 Toyota Tacoma and Lexus RX350 vehicles and certain model year 2012 Toyota Rav4 vehicles. In the affected vehicles, the brake system contains a brake actuator that adjusts the fluid pressure of each wheel cylinder. An electrical component within the actuator may experience an increased resistance resulting in the illumination of various warning lights, including those for the Vehicle Stability Control (VSC) system, Antilock Brake System (ABS), and Traction Control system.
Consequence: If this occurs, these systems could become inoperative, reducing the directional control assistance, increasing the risk of a crash.
Remedy: Toyota will notify owners, and Toyota and Lexus dealers will update the software for the Skid Control electronic control unit, free of charge. The recall began on March 28, 2014. Owners may contact Toyota at 1-800-331-4331.
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2012-2013 Tacoma vehicles equipped with 18" Maverick Alloy Wheels. In the affected vehicles, the spare tire requires the use of a different style of lug nut to attach it to the vehicle than the other wheels use. These lug nuts were not provided with the vehicle.
Consequence & remedy
Consequence: If the spare tire/wheel is installed on the vehicle using the lug nuts from another wheel, damage to the wheel could result and may eventually lead to a loose wheel, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will: (a) Install a Warning Label on the spare tire/wheel, (b) supply a bag containing proper spare wheel lug nuts, and (c) place an Owner's Manual Addendum in the vehicle's glove box. The recall began on January 23, 2014. Owners may contact SET at 1-954-429-2000.
Southeast Toyota is recalling certain model year 2008 and 2010-2013 Toyota Tundra, 2010-2012 Rav4, 2012 Toyota Sequoia, 2010-2011 Toyota Corolla, 2010-2011 Toyota Camry and Camry Hybrid, 2010-2013 Toyota Highlander and Highlander Hybrid, 2010-2013 Toyota FJ Cruiser, 2011 Toyota Land Cruiser, 2010-2013 Toyota Venza, 2010-2011 Toyota 4Runner, 2010-2013 Toyota Tacoma, 2011-2012 Toyota Sienna, 2012 Toyota Prius, 2013 Scion FR-S, 2011 Scion XD, 2011 Scion XB, and 2012 Scion TC vehicles. These vehicles were sold with labels that were outside the allowable one percent of accuracy of actual weight added. Thus, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) Number 110, "Tire Selection and Rims."
Consequence & remedy
Consequence: An inaccurate label could lead to owners overloading their vehicles and tires. An overloaded vehicle can result in a tire failure which may result in a vehicle crash, personal injury, or property damage.
Remedy: Southeast Toyota will notify owners and provide a corrected label with instructions concerning its installation. A small group of the affected vehicles will need additonal remedies which are still being developed. The recall began on May 28, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.
Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.
Consequence & remedy
Consequence: If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.
Remedy: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.
Additional source detail variants (2)
Seats
Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.
Consequence: If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.
Remedy: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.
Air Bags:frontal:sensor/control MODULE-INACTIVE
Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.
Consequence: If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.
Remedy: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.
GULF STATES TOYOTA (GST) IS RECALLING CERTAIN MODEL YEAR 2012 TACOMA TRUCKS. THE TIRE AND LOADING INFORMATION PLACARD ON EACH VEHICLE CONTAINS INACCURATE SPARE TIRE SIZE AND COLD INFLATION PRESSURE INFORMATION. THUS, THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110,TIRE SELECTION AND RIMS.
Consequence & remedy
Consequence: AN INCORRECT PLACARD COULD LEAD TO IMPROPER SPARE TIRE USE OR REPLACEMENT WHICH COULD RESULT IN A TIRE FAILURE, INCREASING THE RISK OF A CRASH.
Remedy: GST WILL NOTIFY OWNERS, AND SEND EACH OWNER A CORRECTED PLACARD, FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 5, 2012. OWNERS MAY CONTACT GULF STATES TOYOTA, INC. AT 1-713-744-3465.
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
EA19001 · Electrical Overstress
Opened Apr 19, 2019 · Closed Sep 19, 2024
Status: closed (inferred from source dates) · Air Bags: Air Bag/restraint Control Module
The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect. During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW. The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications. The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU. In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment. FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle. Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW. These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes. An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time. In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU. This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners. Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW. The risk associated with the ASIC is equally shared among all OEMS involved in the investigation. The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage. There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation. The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU. If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC. Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC. All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled. In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024. With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.
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