Toyota frame rusting recall is cut off at 2010. I have a 2013 that the bed is rusting out because of the plastic Toyota branded beds the factory installed when it was new. The frame and rear axle also show rusting. I am paying out if pocket to stay safe.
2013 Toyota Tundra
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2013 Toyota Tundra do not stand out strongly from the model-year median of 144.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all Tundra 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
64 reports with mileage · 21 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.
- Engine. Review the 23 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Fuel/propulsion System. Review the 13 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 11 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
Structure complaints
7 reportsI HAVE NOTICED PREVIOUS RECALLS FROM OLDER MODEL TOYOTA TRUCKS DUE RUST OCCURRING TO FRAMES AND BEDS. CURRENTLY, THERE IS NO RECALL FOR MY 2013 TUNDRA SPECIFIC TO THIS. HOWEVER, IT SEEMS LIKE THE FRAME RUST ISSUES CONTINUED PAST THE EARLIER RECALL. MY TRUCK IS 2013 TOYOTA TUNDRA WITH APPROX 35,000 MILES. THERE IS RUST ON THE…
Read full complaint
I HAVE NOTICED PREVIOUS RECALLS FROM OLDER MODEL TOYOTA TRUCKS DUE RUST OCCURRING TO FRAMES AND BEDS. CURRENTLY, THERE IS NO RECALL FOR MY 2013 TUNDRA SPECIFIC TO THIS. HOWEVER, IT SEEMS LIKE THE FRAME RUST ISSUES CONTINUED PAST THE EARLIER RECALL. MY TRUCK IS 2013 TOYOTA TUNDRA WITH APPROX 35,000 MILES. THERE IS RUST ON THE FRAME AND BUBBLING THROUGH MY TRUCK BED LINER. FROM FORBES I NOTICED THERE WAS A $3.4 BILLION RECALL FOR TOYOTA TRUCKS AND SUVS FROM 2005-2010. FROM FURTHER RESEARCH ON VARIOUS FORUMS, I NOTICED OTHERS HAVING SIMILAR ISSUES. I SPOKE TO TOYOTA, THEY STATED THERE IS NO RECALL FOR MY YEAR TRUCK. I WILL SHARE SOME PHOTOS FROM RUST BUBBLING THROUGH THE TRUCK BED. IF YOU WOULD LIKE ADDITIONAL PHOTOS I WOULD BE HAPPY TO SHARE. I REALLY AM UNSURE THE NEXT COARSE OF ACTION. I HAVE NEVER SUBMITTED ANYTHING TO NHTSA BEFORE. I WOULD LOVE FOR YOU TO RESEARCH THIS FURTHER TO DETERMINE IF A RECALL COULD BE ISSUED. I WOULD BE HAPPY TO ANSWER ANY QUESTIONS YOU MAY HAVE. THANK YOU, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
TL* THE CONTACT OWNS A 2013 TOYOTA TUNDRA. WHILE DRIVING 30 MPH, THE SPARE TIRE CARRIER DETACHED FROM THE VEHICLE AND CAUSED THE SPARE TIRE TO STRIKE THE BOTTOM OF THE VEHICLE AND ROLL AWAY. THE VEHICLE WAS TAKEN TO ANDERSON TOYOTA (LOCATED AT 6510 SHOWPLACE AVE, LAKE HAVASU CITY, AZ 86404, (928) 764-2886) WHERE IT WAS DIAGNOSED…
Read full complaint
TL* THE CONTACT OWNS A 2013 TOYOTA TUNDRA. WHILE DRIVING 30 MPH, THE SPARE TIRE CARRIER DETACHED FROM THE VEHICLE AND CAUSED THE SPARE TIRE TO STRIKE THE BOTTOM OF THE VEHICLE AND ROLL AWAY. THE VEHICLE WAS TAKEN TO ANDERSON TOYOTA (LOCATED AT 6510 SHOWPLACE AVE, LAKE HAVASU CITY, AZ 86404, (928) 764-2886) WHERE IT WAS DIAGNOSED THAT THE SPARE TIRE CARRIER NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 126,035.
VIBRATION IN GAS PEDAL,STEERING WHEEL AND FLOOR BOARD EVERY TIME THE ACCELERATOR IS ENGAGED. HAVE CARRIED TO THE DEALER FOUR TIMES. WAS TOLD TODAY 11/26/2014 THAT IT IS HARMONIC VIBRATIONS.I ASKED WHERE WAS IT COMING FROM BUT WAS NOT PROVIDED ANY ANSWERS.I AM CONCERNED BECAUSE IT INVOLVES THE GAS PEDAL AND THE FACT THAT THE DEAL…
Read full complaint
VIBRATION IN GAS PEDAL,STEERING WHEEL AND FLOOR BOARD EVERY TIME THE ACCELERATOR IS ENGAGED. HAVE CARRIED TO THE DEALER FOUR TIMES. WAS TOLD TODAY 11/26/2014 THAT IT IS HARMONIC VIBRATIONS.I ASKED WHERE WAS IT COMING FROM BUT WAS NOT PROVIDED ANY ANSWERS.I AM CONCERNED BECAUSE IT INVOLVES THE GAS PEDAL AND THE FACT THAT THE DEALER WILL NOT TELL ME THE SOURCE OF THE VIBRATIONS ,IF THEY KNOW.I ALSO CALLED TOYOTA CORP.AND FILED A CLAIM BUT WAS TOLD IF DEALER AND ENGINEERS SAID THERE WAS NO PROBLEM,MY ONLY RECOURSE WOULD BE A CLAIM WITH NHTSA. *TR
ON 08/22/14, I HAD BEEN TO THE LOCAL TOYOTA DEALERSHIP TO HAVE MY OIL CHANGED. I ASKED THEM TO LOOK AT THE BRAKES BECAUSE THERE WAS A TERRIBLE VIBRATION AND THE BRAKES HAVE NOT STOPPED WELL SINCE I BOUGHT THE TRUCK. THEY SAID THE TRUCK NEEDED NEW BRAKES, ROTORS AND PADS ALL THE WAY AROUND. I WAS SUPPOSED TO TAKE IT BACK ON 08…
Read full complaint
ON 08/22/14, I HAD BEEN TO THE LOCAL TOYOTA DEALERSHIP TO HAVE MY OIL CHANGED. I ASKED THEM TO LOOK AT THE BRAKES BECAUSE THERE WAS A TERRIBLE VIBRATION AND THE BRAKES HAVE NOT STOPPED WELL SINCE I BOUGHT THE TRUCK. THEY SAID THE TRUCK NEEDED NEW BRAKES, ROTORS AND PADS ALL THE WAY AROUND. I WAS SUPPOSED TO TAKE IT BACK ON 08/29/14. ON 08/28/14 WHILE DRIVING ON A CLEAR ROAD WITH NO RAIN OR CLOUDS I WENT TO STOP AND I PUSHED THE BRAKES TO THE FLOOR WITH BOTH FEET AND THE TRUCK DID NOT STOP AND I HIT ANOTHER CAR. I HAVE FILED A COMPLAINT WITH TOYOTA AND THEY FINALLY ORDERED AN INSPECTOR TO GET THE BLACK BOX FROM MY TRUCK. HE HAS NOT CALLED TO SCHEDULE THIS AND IT IS 3 WEEKS LATER. I HAVE LEFT MESSAGE AFTER MESSAGE. I BELIEVE THE BRAKES ARE FAULTY WITH THE TRUCK. THERE IS NO REASON AT 9000 MILES ON A NEW TRUCK THAT IT SHOULD NEED NEW BRAKES, ROTORS AND PAD ALL THE WAY AROUND. NOW I AM WAITING ON ENGINEERING ANALYSIS ASSOCIATION TO CONTACT ME TO SET UP AN INSPECTION OF MY TRUCK. NO ONE IS WILLING TO HELP ME GET INFORMATION, NOT TOYOTA AND NOT EAA. *TR
THE BODY OF THE TRUCK IS DESIGNED TO ALLOW RODENTS/MICE INTO THE CAB WHERE THEY CAN CHEW THE WIRING WHICH WILL LEAD TO A VARIETY OF PROBLEMS. THE TRUCK CURRENTLY HAS ABOUT 3300 MILES ON IT. WHEN I CONTACTED THE DEALER THEY SAID YEAH ALL THESE TRUCKS HAVE THIS, WHAT HAS BEEN DAMAGED SO WE CAN GET IT IN FOR REPAIR. I ASKED IF …
Read full complaint
THE BODY OF THE TRUCK IS DESIGNED TO ALLOW RODENTS/MICE INTO THE CAB WHERE THEY CAN CHEW THE WIRING WHICH WILL LEAD TO A VARIETY OF PROBLEMS. THE TRUCK CURRENTLY HAS ABOUT 3300 MILES ON IT. WHEN I CONTACTED THE DEALER THEY SAID YEAH ALL THESE TRUCKS HAVE THIS, WHAT HAS BEEN DAMAGED SO WE CAN GET IT IN FOR REPAIR. I ASKED IF IT WAS COVERED UNDER WARRANTY AND THEY SAID NO. COATING THE WIRING WITH A SOY (MOUSE FOOD) BASED PRODUCT IS INSANITY UNLESS YOU'RE TRYING TO INCREASE YOUR REPAIR BUSINESS. THERE ARE 16 COMPUTERS IN THIS TRUCK THAT CONTROL EVERYTHING. WHEN THE WIRING IS DAMAGED BECAUSE OF THIS DESIGN FLAW ALL SORTS OF MALFUNCTIONS WILL OCCUR THAT INCLUDE STEERING, ENGINE QUITTING, BRAKES FAILING, THROTTLE, LIGHTS, ETC. THE DEALER IS VERY AWARE OF THE PROBLEM AND SPECIALIZES IN FIXING IT TO THE TUNE OF ABOUT $200 SO FAR. I HAVEN'T HAD A WIRING PROBLEM BECAUSE OF MICE BUT OTHERS HAVE. THIS VERY FUNNY (TO THE DEALER0 PROBLEM WILL EVENTUALLY KILL PEOPLE IF IT HASN'T ALREADY. *TR
I PURCHASED THE VEHICLE BRAND NEW FROM JOE PECHELES TOYOTA IN WASHINGTON, NC. I DISCOVERED DENTS IN THE ROOF 5 DAYS AFTER PURCHASE. THE ROOF SOMETIMES VIBRATES AND MAKES NOISE WHEN DRIVEN. YOU CAN PLACE YOUR HAND ALMOST ANYWHERE ON THE ROOF AND IT CAVITATES. I CONTACTED THE DEALER AND TOYOTA'S CUSTOMER CARE. I WAS TOLD IN AN EM…
Read full complaint
I PURCHASED THE VEHICLE BRAND NEW FROM JOE PECHELES TOYOTA IN WASHINGTON, NC. I DISCOVERED DENTS IN THE ROOF 5 DAYS AFTER PURCHASE. THE ROOF SOMETIMES VIBRATES AND MAKES NOISE WHEN DRIVEN. YOU CAN PLACE YOUR HAND ALMOST ANYWHERE ON THE ROOF AND IT CAVITATES. I CONTACTED THE DEALER AND TOYOTA'S CUSTOMER CARE. I WAS TOLD IN AN EMAIL BY THEIR CUSTOMER CARE DEPARTMENT SUPERVISOR [XXX] THAT THIS IS NOT A SAFETY ISSUE. I HAD A MEETING WITH DISTRICT SERVICE MANAGER [XXX] AND JOE PECHELES GENERAL MANAGER [XXX] ON FEB. 17, 2014. I WAS SHOWN A DIAGRAM OF THE ROOF AND THE SUPPORT BRACES. THE INTERIOR LINER WAS REMOVED AND [XXX] LOOKED AT THE SUPPORT BRACES AND TOLD ME THE ROOF MET MANUFACTURING SPECIFICATIONS AND THAT THEY COULD NOT ACCOUNT FOR THE DENTS AND THE CAVITATING. HE SUGGESTED THAT MAYBE SOMETHING HEAVY WAS PLACED ON THE ROOF TO CAUSE THE DENTS EVEN THOUGH THERE IS NO EVIDENCE TO MATCH HIS CLAIM, NO SCRATCHES, SCRAPES, THE PAINT IS PERFECT, THE INDENTS ARE NOT LOCATED IN A SPECIFIC AREA. HE STATED ALL TOYOTA TUNDRA'S WITH A SUN ROOF ARE MANUFACTURED THE SAME. WHEN THE INTERIOR LINER WAS REMOVED I PLACED MY HAND ON THE ROOF JUST ABOVE THE SUPPORT BRACES AND THE ROOF FLEXES WHERE IT'?S SUPPOSED TO BE SUPPORTED MOST, THE METAL IS VERY THIN. THERE WAS NO AUTO BODY MECHANIC TO ANSWER ANY OF MY CONCERNS DURING THIS MEETING AND THEY CONVENIENTLY HAD NO OTHER TUNDRA WITH A SUNROOF TO COMPARE WITH MINE. EARLIER WHEN I WAS COMMUNICATING WITH TOYOTA CUSTOMER CARE I TOOK THE VEHICLE TO AN AUTO BODY SHOP. I WAS TOLD THE ROOF WAS NOT STRUCTURALLY SUPPORTED PROPERLY AND THEY GAVE ME AN ESTIMATE TO PROPERLY FIX IT. I EMAILED THIS INFORMATION TO THEIR CUSTOMER CARE DEPARTMENT AND NO MENTION HAS BEEN MADE BY TOYOTA ABOUT THE FINDINGS. I FEEL THIS IS A SAFETY ISSUE AND IF THIS TRUCK FLIPS OVER THE ROOF WILL OFFER NO PROTECTION TO THE OCCUPANTS. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
Official recalls
521V920000 · Steering:hydraulic Power Assist System; Steering:rack And Pinion
Nov 23, 2021
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2008-2022 Sequoia and 2007-2021 Tundra vehicles. The power steering gear assembly may have been manufactured incorrectly, which can result in an oil leak.
Consequence & remedy
Consequence: An oil leak may cause a sudden loss of power steering assist, increasing the risk of a crash.
Remedy: Dealers will inspect and replace the power steering gear assembly as necessary, free of charge. Owner notification letters were mailed on January 21, 2022. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's numbers for this recall are 21TB10 and 21TA10.
Additional source detail variants (2)
Steering:hydraulic Power Assist System
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2008-2022 Sequoia and 2007-2021 Tundra vehicles. The power steering gear assembly may have been manufactured incorrectly, which can result in an oil leak.
Consequence: An oil leak may cause a sudden loss of power steering assist, increasing the risk of a crash.
Remedy: Dealers will inspect and replace the power steering gear assembly as necessary, free of charge. Owner notification letters were mailed on January 21, 2022. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's numbers for this recall are 21TB10 and 21TA10.
Steering:rack And Pinion
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2008-2022 Sequoia and 2007-2021 Tundra vehicles. The power steering gear assembly may have been manufactured incorrectly, which can result in an oil leak.
Consequence: An oil leak may cause a sudden loss of power steering assist, increasing the risk of a crash.
Remedy: Dealers will inspect and replace the power steering gear assembly as necessary, free of charge. Owner notification letters were mailed on January 21, 2022. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's numbers for this recall are 21TB10 and 21TA10.
17V311000 · Wheels:lugs/nuts/bolts/studs
May 11, 2017
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2013-2017 Toyota Tundra and Sequoia vehicles accessorized with Southeast Toyota accessory 20-inch Rockstar wheels installed by Southeast Toyota or a Southeast Toyota dealer. The Rockstar wheels were installed with lugnuts that may crack and detach.
Consequence & remedy
Consequence: Lugnuts that crack and detach may cause the wheels to separate from the vehicle, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will install new replacement lugnuts, free of charge. The recall began June 23, 2017. Owners may contact SET customer service at 1-866-405-4226. SET's number for this recall is SET17A.
14V429000 · Wheels:lugs/nuts/bolts/studs
Jul 16, 2014
Gulf States Toyota, Inc. (GST) is recalling certain model year 2013-2014 Toyota Tundra vehicles modified by GST as part of certain vehicle packages to be equipped with a combination of non-Toyota-brand 20-inch alloy wheels and chrome plated lug nuts. The coating on the lug nuts may give, causing the lug nuts to loosen or the wheel studs to fracture.
Consequence & remedy
Consequence: If the lug nuts loosen, or the wheel studs fracture, the wheel may separate from the vehicle, increasing the risk of a crash.
Remedy: GST will notify owners, and dealers will replace 20 lug nuts and torque them to specification, free of charge. The recall began in August 2014. Owners may contact GST customer service at 1-800-444-1074.
13V123000 · Equipment:other:labels
Apr 9, 2013
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.
13V014000 · Air Bags:frontal:sensor/control MODULE-INACTIVE ; Seats
Jan 16, 2013
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.
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
1EA19001 · 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.
Illustration