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2004 Volkswagen Touareg

Owner reports · Recalls · Investigations

More warning signs than most Touareg years

Owner complaints for the 2004 Volkswagen Touareg are substantially higher than the model-year median of 27.5.

About this comparison →

When problems were reported

Mileage at the reported incident

165 reports with mileage · 66 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.

  • Power Train. Review the 50 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 49 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Tires. Review the 36 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

9 crash reports5 fire reports6 injury reports

Air Bags complaints

27 reports
Clear category filter
90,000 miles · Jun 28, 2021
Air Bags

The contact owns a 2004 Volkswagen Touareg. The contact stated while driving approximately 75 mph, the driver’s side curtain air bag deployed inadvertently. Due to the inadvertent air bag deployment, the vehicle failed to restart. The contact had not taken the vehicle to a dealer. The vehicle had not been repaired. The manufactu…

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The contact owns a 2004 Volkswagen Touareg. The contact stated while driving approximately 75 mph, the driver’s side curtain air bag deployed inadvertently. Due to the inadvertent air bag deployment, the vehicle failed to restart. The contact had not taken the vehicle to a dealer. The vehicle had not been repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 90,000.

NHTSA ODI #11422591

1,180,000 miles · Mar 10, 2019
Air Bags

HIT A VERY MASSIVE POTHOLE AND IT CAUSED THE AIRBAG FAULTY STATEMENT TO APPEAR ON THE DASHBOARD. IT APPEARS THE AIRBAG ATTEMPTED TO DISCHARGE UPON HITTING A POTHOLE AND DID NOT DISCHARGE AND THUS THE AIRBAG MECHANISM WAS CONSIDERED FAULTY. A POTHOLE/RUMBLE STRIP SHOULD NOT CAUSE A AIRBAG FAULT TO APPEAR AS THIS COULD BE D…

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HIT A VERY MASSIVE POTHOLE AND IT CAUSED THE AIRBAG FAULTY STATEMENT TO APPEAR ON THE DASHBOARD. IT APPEARS THE AIRBAG ATTEMPTED TO DISCHARGE UPON HITTING A POTHOLE AND DID NOT DISCHARGE AND THUS THE AIRBAG MECHANISM WAS CONSIDERED FAULTY. A POTHOLE/RUMBLE STRIP SHOULD NOT CAUSE A AIRBAG FAULT TO APPEAR AS THIS COULD BE DANGEROUS.

NHTSA ODI #11185712

Mileage unknown · Dec 26, 2017
Air BagsEngineFuel/propulsion System

DRIVE IT SHORT DISTANCE AND IT WON'T START AGAIN FOR HOURS! HAVE TAKEN IT TO VW TO PUT ON BRAKES AND ASKED THEM TO CHECK IT OUT, FOUND NOTHING! THEY HAVE KNOWN ABOUT THIS RECALL SINCE APRIL 2017 SHOWS AIR BAG LIGHT ON ALL THE TIME !

NHTSA ODI #11056565

49,850 miles · Jun 10, 2016
Air BagsEngine

AIRBAG WARNING LIGHT COMES ON AFTER CHANGING BATTERY. LOCAL MECHANICS CAN'T TURN IT OFF. DEALER WANTS LARGE AMOUNT TO "DIAGNOSE" THE PROBLEM. SEVERAL OTHER OWNERS HAVE THE SAME ISSUE WITH THE SEATBAG WARNING SYSTEM COMING ON RANDOMLY...VERY DANGEROUS...AND VW KNOWS ABOUT THE PROBLEM. HAS BEEN HAPPENING FOR YEARS. THE OTHE…

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AIRBAG WARNING LIGHT COMES ON AFTER CHANGING BATTERY. LOCAL MECHANICS CAN'T TURN IT OFF. DEALER WANTS LARGE AMOUNT TO "DIAGNOSE" THE PROBLEM. SEVERAL OTHER OWNERS HAVE THE SAME ISSUE WITH THE SEATBAG WARNING SYSTEM COMING ON RANDOMLY...VERY DANGEROUS...AND VW KNOWS ABOUT THE PROBLEM. HAS BEEN HAPPENING FOR YEARS. THE OTHER ISSUE IS WITH THE ENGINE...THE 2004 TOUAREG ENGINE BLEW AT LESS THAN 50K...DEALER SAID WE MUST HAVE DRIVEN THE CAR WHEN IT WAS HOT. JUST NONSENSE. SEVERAL OTHERS HAVE HAD MAJOR PROBLEMS WITH THE TOUAREGS.. ENGINE PROBLEMS AND THE TRANSMISSIONS/ENGINES SURGE ON SLOWING DOWN OR EVEN SPEEDING UP. TONS OF PROBLEMS WITH THE VEHICLE LINE AND VW AMERICA AND GERMANY WILL NOT DO ANYTHING ABOUT. THE ENGINE BLEW WHEN IT WAS ABOUT 100 DEGREES OUTSIDE.. WE ALWAYS SERVICE OUR VEHICLES REGULARLY.

NHTSA ODI #10873624

57,000 miles · Jan 14, 2016
Air Bags

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE DRIVING AT 50 MPH, THE AIR BAG WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE FRONT DRIVER SIDE SEAT AIR BAGS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE W…

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TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE DRIVING AT 50 MPH, THE AIR BAG WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE FRONT DRIVER SIDE SEAT AIR BAGS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 57,000.

NHTSA ODI #10820182

54,496 miles · Feb 4, 2015
Air BagsPower TrainVisibility/wiper

AIRBAG MODULE DEFECTIVE WITH ONLY 54,496 MILES AND A $1200 COST TO FIX. THIS IS A SAFETY ISSUE! DASH LIGHTING HAS WENT ON AND OFF FOR AIRBAG. A WASHER PUMP DEFECTIVE, POWER TRAIN TRANSMISSION JUMPS AND HAS BEEN AN ONGOING PROBLEM AND KNOWN PROBLEM BY VOLKSWAGEN BUT NOBODY WANTS TO ADMIT THE DEFECT PROBLEM. *TR

NHTSA ODI #10681122

101,202 miles · Sep 9, 2014
Air Bags

BOTH RIGHT AND LEFT SIDE FRONT AIRBAG WIRING HARNESSES REQUIRED REPAIR WITHIN 600 MILES OF FIRST INCIDENT TO CORRECT PRIOR REPAIRS TO REPLACE HARNESS CONNECTORS WITH SPLICED WIRE UNDER VOLUNTARY SERVICE PACK "RECALL". BOTH REPAIRS WERE TRIGGERED BY AIRBAG FAULT LIGHT ON DASH. YOU HAD DONE AN INVESTIGATION IN 2006 ON THIS. VW WOU…

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BOTH RIGHT AND LEFT SIDE FRONT AIRBAG WIRING HARNESSES REQUIRED REPAIR WITHIN 600 MILES OF FIRST INCIDENT TO CORRECT PRIOR REPAIRS TO REPLACE HARNESS CONNECTORS WITH SPLICED WIRE UNDER VOLUNTARY SERVICE PACK "RECALL". BOTH REPAIRS WERE TRIGGERED BY AIRBAG FAULT LIGHT ON DASH. YOU HAD DONE AN INVESTIGATION IN 2006 ON THIS. VW WOULD NOT COVER THE REPAIRS BECAUSE I WAS "OUT OF WARRANTY". IT COST ME $600 TO FIX THE PROBLEM AND I HAVE NO ASSURANCE FROM THE DEALER IT WON'T OCCUR AGAIN OR THAT I WILL NEED NEW HARNESSES OR AIRBAG MODULES. *TR

NHTSA ODI #10631849

40,000 miles · Jan 18, 2011
Air Bags

2004 VW TOUREG FAULT WITH AIRBAGS. ELECTRICAL SYSTEM HAS FAILED WHICH HAS RESULTED IN ALL OF THE AIRBAGS TO BE DEACTIVATED. THE WIRING IS ROUTED AROUND THE HORN WHICH HAS RESULTED IN ONE SIDE OF THE HORN TO NOT WORK. UNSAFE AND NEEDS TO BE RECALLED. *TR

NHTSA ODI #10377017

91,000 miles · Dec 30, 2010
Air BagsCrash

I WAS TRAVELING APPROXIMATELY 40 MILES PER HOUR WHEN I REAR ENDED A VEHICLE. MY AIRBAG DEPLOYED, BUT NOT AS MUCH AS I THOUGHT IT WOULD. THE AIRBAG BARELY HIT MY UPPER BODY AND THEN IT SEEMED 3/4 DEFLATED ALMOST IMMEDIATELY. I DON'T THINK THE AIRBAG WAS WORKING PROPERLY BECAUSE I WOULD THINK FROM WHAT I'VE SEEN THAT THE AIRBAG…

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I WAS TRAVELING APPROXIMATELY 40 MILES PER HOUR WHEN I REAR ENDED A VEHICLE. MY AIRBAG DEPLOYED, BUT NOT AS MUCH AS I THOUGHT IT WOULD. THE AIRBAG BARELY HIT MY UPPER BODY AND THEN IT SEEMED 3/4 DEFLATED ALMOST IMMEDIATELY. I DON'T THINK THE AIRBAG WAS WORKING PROPERLY BECAUSE I WOULD THINK FROM WHAT I'VE SEEN THAT THE AIRBAG WOULD HAVE BEEN ALOT FULLER AND WOULD HAVE ME PINNED UP AGAINST MY DRIVER SEAT, BUT IT DID NOT. I WAS ABLE TO EXIT MY CAR WITHOUT A STRUGGLE AND DON'T REMEMBER EVEN TOUCHING THE AIRBAG WHEN I EXITED THE VEHICLE. NONE OF THE OTHER AIRBAGS DEPLOYED, ARE THEY SUPPOSED TO WHEN YOU GET INTO AN ACCIDENT. I GUESS I'M LUCKY THAT WHEN I HIT THE VEHICLE IN FRONT OF ME THAT THE IMPACT WAS NOT HARDER, BECAUSE I DON'T BELIEVE THE AIRBAG WOULD HAVE KEPT ME FROM HITTING THE STEERING WHEEL WITH GREAT FORCE OR EVEN SAVING MY LIFE. I PLAN TO CONTACT VOLKSWAGEN DIRECTLY ABOUT MY COMPLAINT AS WELL. *TR

NHTSA ODI #10373515

95,000 miles · Jun 4, 2010
Air BagsElectrical SystemLatches/locks/linkages

2004 VW TOUAREG V-8 MANY PROBLEMS BUT 3 WORTH REPORTING: FOR NO APPARENT REASON PASSENGER DOOR COULD NOT BE OPENED OR UNLATCHED BY USING ANY KNOWN MEANS INCLUDING THE INSIDE DOOR HANDLE OR OUTSIDE DOOR HANDLE, ELECTRIC LOCK ACTUATOR CLICKS AS IF THE DOOR IS UNLOCKED BUT THE DOOR CAN NOT BE OPENED OR UNLATCHED. VEHICLE HAD TO…

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2004 VW TOUAREG V-8 MANY PROBLEMS BUT 3 WORTH REPORTING: FOR NO APPARENT REASON PASSENGER DOOR COULD NOT BE OPENED OR UNLATCHED BY USING ANY KNOWN MEANS INCLUDING THE INSIDE DOOR HANDLE OR OUTSIDE DOOR HANDLE, ELECTRIC LOCK ACTUATOR CLICKS AS IF THE DOOR IS UNLOCKED BUT THE DOOR CAN NOT BE OPENED OR UNLATCHED. VEHICLE HAD TO BE BROUGHT TO VW DEALERSHIP AND WORKED ON BY DESTROYING THE DOOR HANDLE TO OPEN THE DOOR AND PERHAPS CUTTING A WHOLE IN THE BODY PANNEL AT THE COST OF 2 HOURS OF DIAGNOSTICS, 8 HOURS OF LABOR TO OPEN DOOR AND PROBABLY 2 OR 3 ADDITIONAL HOURS OF REPLACING DOOR HANDLE IF BODY OF DOOR IS NOT BENT, PLUS PARTS VEHICLE HAS MANY ELECTRICAL GLITCHES INCLUDING BUT NOT LIMITED TO INTERMITTENT MALFUNCTION OF AIR BAG IGNITERS....ONCE AGAIN HAVING THE POTENTIAL TO CAUSE SERIOUS HARM OCCUPANTS GIVEN THE RIGHT CIRCUMSTANCES THIS IS A POTENTIAL DANGEROUS SITUATION AND HAS MADE ME LOSE ALL FAIH IN THIS MANUFACTURER. VEHICLE LUNGES FORWARD WHEN STOPPED AT TRAFIC LIGHTS AND BEGINNING TO PROCCEED ON A GREEN. *TR

NHTSA ODI #10334661

Official recalls

4

17V583000 · Fuel System, Gasoline:delivery:fuel Pump

Sep 20, 2017

Volkswagen Group of America, Inc. (Volkswagen) is recalling certain 2004-2007 Touareg vehicles. These gasoline-powered vehicles have a fuel filter flange that may crack, allowing fuel to leak.

Consequence & remedy

Consequence: A fuel leak in the presence of an ignition source increases the risk of a fire.

Remedy: Volkswagen will notify owners, and dealers will inspect the fuel filter flange for cracks, replacing the flange if cracks are found. If no cracks are found, a protective cover will be installed onto the filter flange. These repairs will be performed free of charge. The recall began March 9, 2018. Owners may contact Volkswagen customer service at 1-800-893-5298. Volkswagen's number for this recall is 20Ai.

04V592000 · Seat Belts

Dec 15, 2004

CERTAIN PASSENGER CARS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, "OCCUPANT CRASH PROTECTION." ALL THREE REAR SEAT POSITIONS AND THE FRONT PASSENGER POSITION ARE EQUIPPED WITH SEAT BELT RETRACTORS THAT HAVE A LOCKING FEATURE WHICH CONVERTS THE RETRACTOR FROM AN EMERGENCY LOCKING RETRACTOR (ELR) MODE TO AN AUTOMATIC LOCKING RETRACTOR (ALR) MODE FOR THE PURPOSES OF CHILD RESTRAINT INSTALLATION. THE BELT MAY DEACTIVATE THE ALR MODE WITH CERTAIN CHILD RESTRAINTS.

Consequence & remedy

Consequence: WHEN INVOLVED IN A CRASH, THE CHILD RESTRAINTS MAY NOT BE PROPERLY SECURED, INCREASING THE RISK OF INJURIES OR DEATH.

Remedy: DEALERS WILL PERMANENTLY INSTALL A 'CLIP' IN EACH OF THE TWO REAR OUTBOARD SEAT BELTS. THE CLIPS WILL PREVENT UNWANTED DEACTIVATION OF THE ALR MODE WITH CHILD SEAT INSTALLATIONS. THE RECALL BEGAN ON APRIL 11, 2005. OWNERS SHOULD CONTACT VW AT 1-800-822-8987.

04V233000 · Seat Belts:rear/other

May 19, 2004

ON CERTAIN SPORT UTILITY VEHICLES, THE REAR SEAT BELT LATCH ATTACHMENT BOLT MAY HAVE BEEN INSUFFICIENTLY RIVETED.

Consequence & remedy

Consequence: IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE BELT BUCKLE. OWNER NOTIFICATION BEGAN ON JUNE 21, 2004. OWNERS SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.

03V266000 · Electrical System:wiring

Jul 25, 2003

ON CERTAIN SPORT UTILITY VEHICLES, THE TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING HARNESS MAY HAVE BEEN IMPROPERLY ROUTED DURING ASSEMBLY. AN IMPROPERLY ROUTED TPMS WIRING HARNESS MAY CONTACT THE PARKING BRAKE CABLE SPRING.

Consequence & remedy

Consequence: IF THIS HAPPENS, THE TPMS WIRING CIRCUIT COULD BE INTERRUPTED, RESULTING IN AN INOPERATIVE TPMS, AND CAUSING A SHORT-TO-GROUND CONDITION THAT COULD POTENTIALLY RESULT IN A FIRE.

Remedy: DEALERS WILL INSPECT THE TPMS WIRING HARNESS ROUTING AND, IF NECESSARY, CORRECT THE WIRING HARNESS ROUTING. OWNER NOTIFICATION BEGAN AUGUST 18, 2003. OWNERS SHOULD CONTACT VWOA AT 1-800-893-5298.

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

2

PE06022 · Srs Warning Light Illumination

Opened Jun 19, 2006 · Closed Oct 30, 2006

Status: closed (inferred from source dates) · Air Bags; Air Bags:side/window

MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN OCTOBER AND NOVEMBER 2003, MAY CONTAIN AN INCORRECTLY MANUFACTURED SIDE AIR BAG MODULE.THIS ALSO MAY PRODUCE ABL ILLUMINATION THAT WOULD BECOME EVIDENT SOON AFTER THE VEHICLE IS PUT INTO SERVICE.WARRANTY DATA INDICATES THAT THESE MODULES HAVE BEEN CORRECTED AND NO LONGER PRESENT A RISK.VW HAS NOT RECEIVED ANY ALLEGED SIDE AIR BAG NON-DEPLOYMENT REPORT.ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUE RAISED BY THIS INVESTIGATION.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Additional source detail variants (2)

Air Bags:side/window

MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN OCTOBER AND NOVEMBER 2003, MAY CONTAIN AN INCORRECTLY MANUFACTURED SIDE AIR BAG MODULE.THIS ALSO MAY PRODUCE ABL ILLUMINATION THAT WOULD BECOME EVIDENT SOON AFTER THE VEHICLE IS PUT INTO SERVICE.WARRANTY DATA INDICATES THAT THESE MODULES HAVE BEEN CORRECTED AND NO LONGER PRESENT A RISK.VW HAS NOT RECEIVED ANY ALLEGED SIDE AIR BAG NON-DEPLOYMENT REPORT.ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUE RAISED BY THIS INVESTIGATION.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Air Bags

MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN OCTOBER AND NOVEMBER 2003, MAY CONTAIN AN INCORRECTLY MANUFACTURED SIDE AIR BAG MODULE.THIS ALSO MAY PRODUCE ABL ILLUMINATION THAT WOULD BECOME EVIDENT SOON AFTER THE VEHICLE IS PUT INTO SERVICE.WARRANTY DATA INDICATES THAT THESE MODULES HAVE BEEN CORRECTED AND NO LONGER PRESENT A RISK.VW HAS NOT RECEIVED ANY ALLEGED SIDE AIR BAG NON-DEPLOYMENT REPORT.ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUE RAISED BY THIS INVESTIGATION.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

PE05042 · Exterior Door Handle Malfunction

Opened Aug 11, 2005 · Closed Dec 21, 2005

Status: closed (inferred from source dates) · Latches/locks/linkages:doors:latch

VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB) DATED JUNE 10, 2005, DESCRIBING A CONDITION OF EXTERIOR DOOR HANDLE STICKS IN THE OPENED POSITION AFTER THE DOOR IS OPENED.VW DESCRIBED THE CAUSE OF THE PROBLEM TO BE A POTENTIAL FOR INCREASED FRICTION BETWEEN THE DOOR HANDLE AND THE LOCK CYLINDER HOUSING . . . BECAUSE SOME GUIDE NUBS THAT WERE MOLDED INTO THE PLASTIC DOOR HANDLE . . . WERE SLIGHTLY HIGHER THAN SPECIFIED.IN ADDITION TO THE TSB, VW HAS INTRODUCED PRODUCTION CHANGES (LUBRICATION, DELETION OF THE GUIDE NUBS, INTRODUCTION OF A LOW FRICTION GUIDE SURFACE ON THE LOCK CYLINDER HOUSING) TO ADDRESS THE PROBLEM.VW REPORTS THAT THE FAILURE OCCURS PREDOMINANTLY IN THE VERY EARLY LIFE STAGE OF THE VEHICLE.ODI EXAMINATION OF VW'S WARRANTY DATA SHOWS FEWER CLAIMS AS THE VEHICLE AGES.THE ONE INJURY RESULTED WHEN THE UNLATCHED DOOR HIT THE OCCUPANT'S HAND.A SAFETY DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.ODI WILL CONTINUE TO MONITOR COMPLAINTS ANDRESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.