Service Brakes, Hydraulic. Review the 184 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Suspension. Review the 118 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Engine And Engine Cooling. Review the 86 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

11 crash reports13 fire reports8 injury reports

Steering complaints

76 reports

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59,000 miles · Dec 21, 2004

Steering

CONSUMER STATED TIE ROD WORE OUT PREMATURELY. A RECALL WAS ISSUED, HOWEVER THIS VEHICLE WAS NOT INCLUDED IN THE RECALL DUE TO VIN. *AK THE VEHICLE WAS LATER TAKEN TO AN INDEPENDENT DEALER WHO INDICATED THAT THERE WAS NOTHING WRONG WITH THE VEHICLE. *NM

NHTSA ODI #10101966

Mileage unknown · Sep 14, 2004

Steering

WHILE DRIVING AT ANY SPEED THE VEHICLE VIBRATED . THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION. THE MECHANIC INFORMED THE DRIVER THAT THE TIE RODS NEEDED TO BE REPLACED. PLEASE PROVIDE FURTHER DETAILS. *JB THE CONSUMER WANTS THE DEALER TO FIX THE PROBLEMS WITH THE VEHICLE *TC

NHTSA ODI #10073414

80,000 miles · Jul 21, 2004

SteeringSuspension

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AS A RESULT OF A PERSISTENT RATTLING IN THE FRONT RIGHT END OF MY 4 CYL. 1999 VW PASSAT, I TOOK MY CAR IN FOR INVESTIGATION. I HAVE BEEN ADVISED BY TWO INDEPENDENT REPAIR SHOPS THAT BOTH UPPER CONTROL ARMS ON BOTH SIDES OF THE CAR AS WELL AS THE TIE ROD ENDS MUST BE REPLACED TO THE TUNE OF $1200. IF THEY ARE NOT REPLACED, I HAVE BEEN ADVISED THAT ONE COULD BREAK AND I WOULD HAVE NO STEERING. OBVIOUSLY AT A HIGH RATE OF SPEED THIS COULD BE DANGEROUS OR DEADLY. I HAVE SPOKEN WITH VW AND EVEN THOUGH THEY ACKNOWLEDGE ISSUING A TSB ON THIS DEFECT, THEY REFUSE TO COVER ITS REPAIR. THIS IS A SAFETY ISSUE THAT MUST BE ADDRESSED SOONER RATHER THAN LATER. THANK YOU FOR ANY HELP YOU CAN PROVIDE IN THIS AREA.

NHTSA ODI #10082358

55,000 miles · Jul 6, 2004

Steering

VEHICLE HAS SAME PROBLEM WITH THE TIE ROD AS THOSE INCLUDED IN THE RECALL, HOWEVER, THE CONSUMER'S VEHICLE IDENTIFICATION NUMBER WAS NOT INCLUDED IN THE RECALL. *AK *SC *JB

NHTSA ODI #10073567

40,000 miles · Jun 6, 2004

SteeringSuspension

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CONTROL ARM'S OF '1998-'2000 PASSATS ARE FAILURE PRONE MUCH EARLIER THEN THE NORM FOR PASSANEGER AUTOMOBILES. (A FACT THEY RECOGNIZED BY A REDESIGN OF THE CONTROL ARMS ON '2001 AND UP PASSAT'S. I PURCHASED MY CAR IN 7/99. I DRIVE 70 MILES A DAY, MOSTLY FREEWAY, WHICH AS ALL KNOW IS ACTUALLY VERY EASY ON AN AUTOMOBILE. YET WITH-IN 2 YEARS (40K) MY FRONT SUSPENSION WAS SHOWING SIGNS OF PREMATURE WEAR. I GET MANY "CREAKS" AND "CLUNKS" THAT ARE EASY TO HEAR AT LOW SPEEDS. AFTER RESEARCHING IN POPULAR INTERNET FORUMS FOR THE CAR,(WWW.CLUBB5.COM , WWW.VWVORTEX.COM) I FOUND OUT THIS FAILURE IS VERY COMMON FOR THIS AUTOMOBILE. VMOA (VOLKSWAGEN OF AMERICA) HAS NOT ISSUED A RECALL YET (EVEN THOUGH THEY HAVE RECEIVED THOUSANDS OF COMPLAINTS) AS OF THIS LATE DATE. (6/04) THE RESPONSE FROM VWOA AND YOUR DEALER NETWORK HAS BEEN INCONSISTENT, TO SAY THE LEAST. SOME DEALERS WILL NOT EVEN LOOK AT THE CAR, SOME WILL LOOK AT IT AND SAY NOTHING IS WRONG, AND SOME WILL SAY THAT IT IS THE CONTROL ARMS, BUT WILL NOT HELP OUT THE OWNER WHEN THE TIME COMES TO CONTACT THE CUSTOMER CARE CENTER AT VWOA . VWOA IS NOT MUCH MORE HELP, PROMISING TO GET ON THE PROBLEM AND TELLING YOU THEY WILL CALLBACK, ONLY THEY DONT. OR IF THEY DO ,IT IS, SORRY WE CANNOT HELP YOU.. SO WHAT HAPPENS IS THAT MANY OF THE OWNERS THAT ARE OUT OF WARRANTY, MUST PAY FOR A COSTLY REPAIR OUT OF POCKET. A REPAIR THAT SHOULD HAVE NEVER HAPPENED. (I HAVE NEVER HAD CONTROL ARM BUSHING FAILURE IN MY PREVIOUS 13 AUTOMOBILES!) REPAIR COSTS RUN OVER $700 FOR PARTS, AND THE SAME AMOUNT IN LABOR. I AM PURCHASING MY CAR FROM THE BANK SOON. OVERALL IT IS A GREAT CAR. I MUST REPLACE THE CONTROL ARMS VERY SOON. I DONT LOOK FORWARD TO THAT AND THE HIGH COST IT WILL RUN ME. I WISH FOR VMOA TO TREAT ITS CUSTOMERS LIKE A MODERN CUSTOMER FOCUSED COMPANY. BAD DESIGNS HAPPEN. THEY OWE IT TO THEIR CUSTOMERS TO MAKE IT RIGHT. THANK YOU. JOHN E. TAMI. *AK

NHTSA ODI #10074888

78,000 miles · May 18, 2004

Steering

ONCE THE STEERING WHEEL WAS TURNED, A TAPPING/RATTLING SOUND COULD BE HEARD. THE NOISE WAS CAUSED BY THE PROBLEM DESCRIBED IN THE TIE ROD RECALL 00V414000, BUT THE VEHICLE IDENTIFICATION NUMBER WAS NOT INCLUDED IN THE RECALL. *JB

NHTSA ODI #10073823

39,998 miles · May 17, 2004

SteeringUnknown Or Other

MY CAR BEGAN TO SHAKE AND THE CHECK ENGINE LIGHT STARTED FLASHING. I DROVE DIRECTLY TO THE VW DEALER SERVICE DEPT. I FOUND THAT MY POWER OUTPUT STAGE HAS FAILED AND TIE ROD ENDS ARE BLOWN OUT ON 1999 VW PASSAT AT 39,990 MILES. NOT TO MENTION THAT MY POLLEN FILTER HOUSING IS LEAKING. *AK

NHTSA ODI #10072730

95,000 miles · May 3, 2004

Steering

THIS VEHICLE EXPERIENCED THE SAME FAILURE AS DESCRIBED IN TIE ROD RECALL 00V414000. HOWEVER, THIS VEHICLE WAS NOT INCLUDED IN THE RECALL DUE TO VIN. *AK

NHTSA ODI #10071965

80,000 miles · May 3, 2004

Steering

Read full complaint

I AM CONCERN WITH THE FRONT SUSPENSION OF MY CAR. I TOOK IN THE CAR FOR AN 80,000 MILE VOLKSWAGEN RECOMMENDED CHECK UP. I EXPLAINED TO SERVICE TECHNICIAN THAT THERE IS A NOISE IN THE FROT SUSPENSION. THAT NOISE HAD BEEN THERE SINCE I GOT THE CAR AT AROUND 65,000 MILES. I EXPLAINED TO THE TECHNICIAN THAT I HAD CALLED VOLKSWAGEN OF AMERICA BECAUSE THROUGH CARFAX I FOUND OUT THAT THERE WAS AN ISSUE WITH THE FRON SUSPENSION OF THE 1999 VOLKSWAGEN PASSAN 1.8 TURBO GLS. VOLKSWAGEN OF AMERICA TOLD ME THAT THEY HAD NOT ISSUED A RECALL YET. SO I TOLD THE TECHNICIAN TO CHECK FOR ME AGAIN TO SEE IF THERE WAS A RECALL ISSUED TO THE FRON SUSPENSION. HE SAID NO AND HE MENTIONED THAT TO FIX THE SUSPENSION PROBLEM I WILL HAVE TO REPLACE THE SUSPENSION STEERING LINKAGES AND OTHER COMPONENTS. HE GAVE ME AN ESTIMATE FOR THE FIX AT AROUND $1200.00 DOLLARS. 2 WEEKENDS AGO I WENTO TO A VOLKSWAGEN SWAP MEET AND FOUND OUT THAT A FEW OTHER PASSAT DRIVERS WERE HAVING THE SAME ISSUE WITH THEIR SUSPENSIONS. I HAVE BEEN A VOLKSWAGEN DRIVER FOR 17 YEARS. I HAVE NEVER HAD ANY SUSPENSION PROBLEMS OF THIS KIND WITH ANY OF THE VOLKSWAGEN CARS I OWNED. I TRUELY BELIVE VW HAS RELEASED CARS WITH MALFUNCTIONING COMPONENTS AND THEY WANT THE CONSUMER TO PAY FOR AN EXPENSIVE REPAIR. I APPRECIATE YOU GUYS TAKING THE TIME TO READ MY EAMIL AND LOOKING IN TO THIS MATTER FOR THE SAFETY OF VW DRIVERS AND PEDESTRIANS A LIKE.*AK

NHTSA ODI #10068203

90,000 miles · Mar 17, 2004

Steering

TIE ROD ENDS WORE OUT PREMATURELY DUE TO FAULTY LUBRICANT BOOTS RESULTING IN ERRATIC CONTROL OF THE VEHICLE. MODELS SIMILAR TO MINE WERE RECALLED BY VW, BUT NOT MINE. MY MECHANIC SAYS THE PARTS ARE IDENTICAL. *NM

NHTSA ODI #10062406

Official recalls

08V156000 · Fuel System, Gasoline:delivery

Apr 7, 2008

VOLKSWAGEN IS RECALLING 412,000 MY 1999-2005 PASSAT (5TH GENERATION) VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS AND PRODUCED AFTER JUNE 14, 1999. THESE VEHICLES MAY HAVE AN UNDERBODY HEAT SHIELD THAT CAN BECOME DAMAGED. IN ADDITION, AFFECTED VEHICLES WITH AUTOMATIC OR MANUAL TRANSMISSIONS MAY HAVE A FUEL LINE (1.8T ENGINES ONLY) OR FUEL TANK VENTILATION VALVE (4MOTION/ALL WHEEL DRIVE ONLY) THAT CAN LEAK DUE TO FRACTURE.

Consequence & remedy

Consequence: A HEAT SHIELD THAT MAY CONTACT THE EXHAUST SYSTEM CAN RESULT IN A VEHICLE FIRE. IN ADDITION, A FUEL LEAK FROM A FUEL LINE OR FUEL TANK VENTILATION VALVE, IN THE PRESENCE OF AN IGNITION SOURCE, CAN LEAD TO A VEHICLE FIRE.

Remedy: DEALERS WILL INSTALL ADDITIONAL UNDERBODY HEAT SHIELDS ON VEHICLES WITH AUTOMATIC TRANSMISSIONS TO COVER THE POSSIBLY DAMAGED AREAS AND FLASH ALL 1.8T ENGINES WITH A PRECAUTIONARY SOFTWARE UPDATE. DEALERS WILL ALSO INSPECT AND ADJUST THE FUEL LINE ROUTING ON 1.8T VEHICLES AND THE FUEL TANK VENTILATION VALVE ON 4MOTION/ALL WHEEL DRIVE VEHICLES, AND REPLACE COMPONENTS IF NECESSARY FREE OF CHARGE. THE RECALL BEGAN ON JUNE 13, 2008. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.

02V026000 · Fuel System, Gasoline:storage:tank Assembly:filler Pipe And Cap

Jan 25, 2002

ON SOME PASSENGER VEHICLES, THE FUEL TANK FILLER NECK CAN SUFFER ABRASION DAMAGE IF THE REAR TIRE GOES FLAT AND THE VEHICLE IS DRIVEN UNTIL THE TIRE DISINTEGRATES.

Consequence & remedy

Consequence: FUEL LEAKAGE CAN OCCUR INCREASING THE RISK OF A FIRE.

Remedy: DEALERS WILL FIT PASSAT VEHICLES WITH A NEW WHEEL HOUSE LINER THAT WILL BETTER PROTECT THE CAR'S FILLER NECK. JETTA VEHICLES WILL BE FITTED WITH A DIFFERENT METAL SHIELD DESIGNED TO ENHANCE ABRASION PROTECTION IN THE EVENT OF TIRE DISINTEGRATION. OWNER NOTIFICATION BEGAN JUNE 13, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.

00V414000 · Steering:linkages:rod:relay:connecting

Dec 6, 2000

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE TIE RODS OF THE STEERING ASSEMBLY ARE PROTECTED ON EACH SIDE BY A SEAL TO PREVENT MOISTURE AND DUST PARTICLES FROM ENTERING THE SWIVEL BEARING MECHANISM. IT IS POSSIBLE THAT SOME TIE ROD SEALS MAY NOT SEAL PROPERLY.

Consequence & remedy

Consequence: IF MOISTURE AND/OR DUST PARTICLES ENTER THE SWIVEL BEARING MECHANISM, THE SWIVEL BEARING COULD WEAR OVER TIME DIMINISHING THE STEERING CONTROL OF THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE TIE RODS.

99V248000 · Steering:linkages:rod:relay:connecting

Sep 13, 1999

Consequence & remedy

Consequence: IF MOISTURE AND/OR DUST PARTICLES ENTER THE SWIVEL BEARING MECHANISM, THE SWIVEL BEARING COULD WEAR OVER TIME DIMINISHING THE STEERING CONTROL OF THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE TIE RODS.

99V131001 · Service Brakes, Hydraulic:power Assist:vacuum:hoses, Lines/piping, And Fittings

May 21, 1999

VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS. A CONTROL VALVE IN THE VACUUM HOSE CONNECTING THE BRAKE BOOSTER TO THE INTAKE MANIFOLD MAY NOT OPEN OR CLOSE FULLY AT TEMPERATURES BELOW -4 F UNDER CERTAIN DRIVING CONDITIONS.

Consequence & remedy

Consequence: THIS CONDITION COULD CAUSE INSUFFICIENT VACUUM TO BE PROVIDED TO THE BRAKE BOOSTER.

Remedy: DEALERS WILL INSTALL A VACUUM BY-PASS SYSTEM INTO VEHICLES OPERATED IN THESE STATES WHICH IS DESIGNED TO PROVIDE SUFFICIENT VACUUM FOR FULL BRAKE ASSIST UNDER ALL WEATHER CONDITIONS.

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

EA07014 · Passenger Engine Compartment Fires

Opened Sep 28, 2007 · Closed Jul 7, 2008

Status: closed (inferred from source dates) · Electrical System:ignition; Engine And Engine Cooling:exhaust System

THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.

Additional source detail variants (2)

Electrical System:ignition

Engine And Engine Cooling:exhaust System

DP05003 · Alleged Premature Tie Rod Failure

Opened Aug 8, 2005 · Closed Dec 9, 2005

Status: closed (inferred from source dates) · Steering:linkages:tie Rod Assembly

ON AUGUST 2, 2005, ODI RECEIVED A PETITION SUBMITTED BY MS. MIRIAM SCHNEIDER OF OLNEY, MD, REQUESTING AN INVESTIGATION OF ALLEGEDLY DEFECTIVE TIE RODS IN CERTAIN MODEL YEAR (MY) 1999 VOLKSWAGEN PASSAT VEHICLES NOT INCLUDED IN TWO PREVIOUS SAFETY RECALL CAMPAIGNS (IDENTIFIED HENCEFORTH AS THE SUBJECT VEHICLES).IN A SEPTEMBER 1999 LETTER, VOLKSWAGEN OF AMERICA, INC. (VW) NOTIFIED THE AGENCY THAT AN UNDETERMINED PERCENTAGE OF MY 1998-1999 VOLKSWAGEN PASSAT AND AUDI A4, A6, AND A8 VEHICLES CONTAINED A SAFETY-RELATED DEFECT AFFECTING ALUMINUM TIE ROD ENDS IN THE STEERING SYSTEM.VW INDICATED THAT IT WAS POSSIBLE THAT SOME TIE RODS WOULD NOT SEAL PROPERLY WHICH COULD ALLOW MOISTURE AND DUST PARTICLES TO ENTER THE SWIVEL BEARING MECHANISM, RESULTING IN PREMATURE WEAR.THE APPROXIMATELY 22,200 VOLKSWAGEN AND 29,700 AUDI VEHICLES AFFECTED BY THIS RECALL (IDENTIFIED BY NHTSA RECALL NO. 99V-248) WERE BUILT FROM JANUARY 1998 THROUGH JULY 1998 AND FELL WITHIN A SPECIFIC VEHICLE IDENTIFICATION NUMBER (VIN) RANGE.IN NOVEMBER 2000, VW CHOSE TO EXPAND THE SCOPE OF THE RECALL (IDENTIFIED BY NHTSA RECALL NO. 00V-414) AFTER IT DETERMINED THAT SOME POTENTIALLY DEFECTIVE ALUMINUM TIE ROD ENDS MAY HAVE BEEN INSTALLED IN AN ADDITIONAL 44,000 VOLKSWAGEN AND 39,000 AUDI VEHICLES BUILT FROM AUGUST 1998 THROUGH APRIL 1999.THESE SUBJECT RECALL ACTIONS WERE NOT INFLUENCED BY ODI.INSTEAD, VW MADE AN INDEPENDENT DETERMINATION TO CONDUCT A RECALL AFTER GERMAN VEHICLE INSPECTION AUTHORITIES NOTIFIED IT OF ?WORN? TIE RODS AND FACTORY INSPECTION OF SOME ?WORN? TIE RODS REVEALED IMPROPER SEALING.ACCORDING TO A DECEMBER 2004 REPORT, THE PETITIONER BROUGHT HER MY 1999 PASSAT TO AN AUTHORIZED VOLKSWAGEN DEALER FOR AN UNRELATED RECALL REPAIR WHERE SHE WAS NOTIFIED BY SERVICE PERSONNEL THAT, AFTER 59,000 MILES TRAVELED, THE TIE RODS ?HAVE TOO MUCH PLAY,? AND THE RECOMMENDED REPAIRS WOULD NOT BE COVERED FREE OF CHARGE BECAUSE HER VIN (WVWNA63B1XE499116) WAS OUTSIDE THE RECALL RANGE.IN JUNE 2005, AFTER 65,400 MILES TRAVELED, THE PETITIONER PAID $588.59 TO REPLACE WORN INNER AND OUTER TIE ROD ENDS ON BOTH SIDES OF THE VEHICLE.THE PETITION LETTER SPECIFICALLY REQUESTS THAT THE SCOPE OF VW?S RECALL BE EXPANDED TO INCLUDE THE PETITIONER?S VEHICLE AND THAT SHE BE REIMBURSED FOR THE COST OF THE REPAIRS.THERE ARE A TOTAL OF 191 NON-DUPLICATIVE COMPLAINTS TO ODI AND VW THAT ALLEGE PREMATURE WEAR OF EITHER ONE OR BOTH OUTER TIE ROD ENDS IN THE SUBJECT VEHICLES.AS OF NOVEMBER 18, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS OF TIE ROD SEPARATIONS RESULTING IN A LOSS OF VEHICLE CONTROL, CRASH OR INJURY IN THE SUBJECT VEHICLES.THE PETITIONER?S VEHICLE WAS MANUFACTURED ON JUNE 8, 1999 USING REVISED STEEL TIE ROD ENDS AND THEREFORE WAS ALREADY EQUIPPED WITH THE TIE ROD ENDS USED TO REMEDY DEFECTIVE VEHICLES IN THE SUBJECT RECALLS.ANALYSIS INDICATES THAT THERE DOES NOT APPEAR TO BE A SAFETY-RELATED DEFECT TREND WITH RESPECT TO THE STEEL TIE ROD ENDS USED IN THE SUBJECT VEHICLES.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AS DEFINED BY THE PETITIONER AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.

EA04017 · STUCK-OPEN Throttle

Opened Jun 30, 2004 · Closed Feb 10, 2005

Status: closed (inferred from source dates) · Fuel System, Gasoline:fuel Injection System

VWOA HAS RECALLED APPROXIMATELY 28,300 MY 1998-99 A6 VEHICLES IN COLD WEATHER STATES THAT EXPERIENCED THE HIGHEST RATE OF THROTTLE ICING INCIDENTS IN THE SUBJECT VEHICLES (04V-495).THE FAILURE RATE IN THE A4 AND PASSAT VEHICLES IS MUCH LOWER THAN IN THE RECALLED VEHICLES.ODI WILL CONTINUE TO MONITOR THE EXPERIENCE IN THE A4 AND PASSAT VEHICLES.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS FOR THE AUDI A4 OR VW PASSAT VEHICLES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY A CHANGE IN CIRCUMSTANCES. FOR FURTHER DETAILS SEE THE ATTACHED CLOSING REPORT.

EA03020 · Passenger Air Bag Lid Failure

Opened Oct 7, 2003 · Closed Apr 23, 2004

Status: closed (inferred from source dates) · Air Bags; Air Bags:frontal

THIS INVESTIGATION INVOLVES THE VOLKSWAGEN (VW) PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) LID UTILIZED IN MY 1998-2002 VW PASSAT.THE PSIR LID MAY DETACH FROM THE INSTRUMENT PANEL DURING AIR BAG DEPLOYMENT.THE OFFICE OF DEFECTS INVESTIGATION (ODI) OF THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) OPENED THE PRELIMINARY EVALUATION ON MAY 23, 2003 TO DETERMINE WHETHER ALLEGED PSIR LID DETACHMENT PRESENTS AN UNREASONABLE SAFETY RISK TO PASSENGERS IN THE VEHICLE.ODI?S INVESTIGATION REVEALS THAT DETACHMENT OF THE PSIR LID DURING AIR BAG DEPLOYMENT MAY OCCUR FOR TWO REASONS: 1) THE SHAPE OF THE PSIR LID, AND THE LENGTH OF THE ATTACHING TETHER, MAY SNAG THE AIR BAG DURING DEPLOYMENT APPLYING ADDITIONAL PRESSURE ON BOLTS THAT FASTEN THE LID TO THE INSTRUMENT PANEL (IP); AND/OR 2) THE ORIGINAL PSIR LID DESIGN (SUBJECT VEHICLES) UTILIZED SIX GRADE 4.8 MM CARBON STEEL TACK WELD BOLTS WHICH MAY NOT BE AS STRONG AS THE NEW DESIGN PSIR LID CONSISTING OF SIX GRADE 8.8 MM CARBON STEEL PRESS BOLTS THAT ARE HEAT TREATED.ODI CONCLUDES THAT DETACHMENT OF THE PSIR LID IS A DEFECT BECAUSE THE LID SHOULD REMAIN ATTACHED TO THE IP AFTER DEPLOYMENT OF THE AIRBAG.HOWEVER, AFTER ANALYZING VW?S RESPONSES, AND TEST DATA COLLECTED BY VW AND FAURECIA, THE PSIR LID SUPPLIER, ODI BELIEVES THAT FURTHER INVESTIGATION WOULD NOT LIKELY IDENTIFY A SAFETY-RELATED DEFECT TREND BECAUSE A DETACHED PSIR LID AND PARTS DO NOT PROJECT TOWARDS A PASSENGER DURING DEPLOYMENT OF THE AIRBAG.THE TEST DATA SHOWS THAT THE AIRBAG PUSHES A DETACHED PSIR LID UPWARDS INTO THE WINDSHIELD DURING DEPLOYMENT, AND AWAY FROM THE PASSENGER COMPARTMENT.IT IS HIGHLY UNLIKELY THAT A PASSENGER WOULD CONTACT THE PSIR LID OR ASSOCIATED PARTS DURING AIR BAG DEPLOYMENT.THEREFORE THIS ENGINEERING ANALYSIS (EA 03-020) IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. FOR A DETAILED DISCUSSION OF THE PSIR LID AND TESTING, SEE THE ATTACHED REPORT.

Additional source detail variants (2)

Air Bags:frontal

Air Bags

PE03021 · Passenger Sir Door Mounting Stud Failure

Opened May 23, 2003 · Closed Oct 7, 2003

Status: closed (inferred from source dates) · Air Bags:frontal

ODI OPENED A PRELIMINARY EVALUATION (PE03-021) BASED ON TWO REPORTS OF FAILED BOLT STUDS THAT ATTACH THE PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) DOOR COVER TO THE INSTRUMENT PANEL (IP) ON THE VOLKSWAGEN (VW) PASSAT (MODEL YEARS 2000, 2002).VW HAS INDICATED TO ODI THAT IT HAS NO ADDITIONAL REPORTS.VW IMPLEMENTED A PROCESS CHANGE ON MARCH 1, 2002.THIS PROCESS CHANGE CONSISTED OF CHANGING THE BOLT APPLICATION THAT FASTENS THE PSIR DOOR TO THE IP FROM A WELD ON APPLICATION TO A PRESS ON APPLICATION.VW ALSO CHANGED THE MATERIAL OF THE BOLT.VW STATED THAT THE CHANGES WERE MADE TO EASE PRODUCTION BY ELIMINATING A WELDING PROCESS.ODI HAS UPGRADED ITS INVESTIGATION TO ENGINEERING ANALYSIS (EA03-020).

EA00028 · Fuel Tank Puncture

Opened Dec 28, 2000 · Closed Jan 29, 2002

Status: closed (inferred from source dates) · Vehicle Speed Control:linkages

No summary supplied.

PE00033 · Fuel Tank Puncture

Opened Aug 10, 2000 · Closed Dec 28, 2000

Status: closed (inferred from source dates) · Vehicle Speed Control:linkages

THE OFFICE OF DEFECTS INVESTIGATION OPENED THIS INVESTIGATION ON AUGUST 10, 2000 BASED ON 9 REPORTS REGARDING PUNCTURED FUEL TANKS INVOLVING THE JETTA, PASSAT, AND CABRIO MODELS.THE REPORTS INDICATE ADDITIONAL REPORTS IN ITS RESPONSE TO THE PRELIMINARY EVALUATION.THIS INVESTIGATION HAS BEEN UPGRADED FOR FURTHER STUDY.

RQ99008 · Power Brake Booster Vacuum BY-PASS

Opened Jun 1, 1999 · Closed Nov 14, 2000

Status: closed (inferred from source dates) · Service Brakes, Hydraulic

There is no summary currently available