NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
5 reportsClear category filter55,000 miles · Mar 11, 2021
EngineFuel/propulsion SystemSuspension
VEHICLE STALLS WHEN ACCELERATING FROM A STOPPED POSITION. SEVERAL TIME, WHILE STOPPED AT AN INTERSECTION WITH CROSSING TRAFFIC, I ATTEMPTED TO DRIVE THROUGH THE INTERSECTION BUT THE CAR FAILED TO ACCELERATE. I TRIED SHIFTING FROM AUTO TO MANUAL BUT THE CAR STILL FAILED TO ACCELERATE FOR AT LEAST 5 SECONDS AT WHICH TIME IT JO…
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VEHICLE STALLS WHEN ACCELERATING FROM A STOPPED POSITION. SEVERAL TIME, WHILE STOPPED AT AN INTERSECTION WITH CROSSING TRAFFIC, I ATTEMPTED TO DRIVE THROUGH THE INTERSECTION BUT THE CAR FAILED TO ACCELERATE. I TRIED SHIFTING FROM AUTO TO MANUAL BUT THE CAR STILL FAILED TO ACCELERATE FOR AT LEAST 5 SECONDS AT WHICH TIME IT JOLTED FORWARD. THE ISSUE STARTED AT AROUND THE 50K MILE MARK 3 YEARS AGO AND CONTINUES STILL TODAY (~90K MILES). I AM NOT SEEING MY VEHICLE LISTED UNDER RECALLS RELATED TO LOSS OF ELECTRICAL POWER/STALLING FROM 2/7/2013 AND HAVE NOT HAD ANY RECALL NOTIFICATIONS RELATED TO MY CAR SINCE 2017. I HAVE BEEN ATTEMPTING TO RESOLVE A CONSTANT PROBLEM WITH CRACKING SOUNDS FROM FRONT SUSPENSION WHEN TURNING. TO DATE, I HAVE HAD THE ENTIRE FRONT SUSPENSION REBUILT INCLUDING; CONTROL ARM ASSY, SWAY BAR ASSY, BEARING, STRUTS, AND U-JOINTS. I AM STILL EXPERIENCING THIS PROBLEM, ESPECIALLY DURING COLDER WEATHER DAYS. NOW I AM LEARNING THAT THERE IS A RECALL FROM 8/1/2020 RELATED TO MY CAR MODEL BUT MY VIN IS NOT INCLUDED. NHTSA ID NUMBER: 10179812 MANUFACTURER COMMUNICATION NUMBER: B310112. SUMMARY CRACKING NOISES FROM THE FRONTAXLE AREA WHILE TURNING THE WHEELS, WHEN STATION: CRACKING NOISES ARE HEARD FROM THE FRONT AXLE AREA WHILE MANEUVERING AT LOW SPEEDS (E.G., PARKING LOT MANEUVERS) OR WHEN TURNING THE STEERING WHEEL WHILE STATIONARY.
NHTSA ODI #11402494
65,000 miles · Dec 19, 2019
Fuel/propulsion System
VEHICLE STALLS WHEN MORE THAN 1/8 THROTTLE IS APPLIED, VEHICLE HAS DIFFICULTY STARTING. CHECK ENGINE LIGHT COMES ON WHEN APPLYING SMALL THROTTLE INPUTS. THE 4 PREVIOUS YEARS OF THIS VEHICLE MAKE AND MODEL, THE HIGH PRESSURE FUEL PUMP HAS HAD A KNOWN PROBLEM WHICH RESULTED IN A CLASS ACTION LAWSUIT THAT ADJUSTED THE WARRANTY PERI…
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VEHICLE STALLS WHEN MORE THAN 1/8 THROTTLE IS APPLIED, VEHICLE HAS DIFFICULTY STARTING. CHECK ENGINE LIGHT COMES ON WHEN APPLYING SMALL THROTTLE INPUTS. THE 4 PREVIOUS YEARS OF THIS VEHICLE MAKE AND MODEL, THE HIGH PRESSURE FUEL PUMP HAS HAD A KNOWN PROBLEM WHICH RESULTED IN A CLASS ACTION LAWSUIT THAT ADJUSTED THE WARRANTY PERIOD FOR THE FOUR PREVIOUS MODEL YEARS UP TO 120K MILES. BMW MADE SLIGHT CHANGES TO THE ENGINE FOR THE NEXT MODEL YEARS, BUT LEFT THE EXACT SAME PART THAT RESULTED IN THE ORIGINAL LAWSUIT SETTLEMENT. THAT PART IS THE POINT THAT FAILED ON MY VEHICLE. SHOULD THE WARRANTY EXTENSION THEY AGREED TO IN THE SETTLEMENT APPLY TO ALL MAKES AND MODELS BMW MADE WITH THE SAME DEFECTIVE PART? THIS PROBLEM CAUSED MY WIFE TO BE STRANDED IN THE MIDDLE OF THE FREEWAY AND HAD TO BE TOWED OUT OF THE LANES OF TRAFFIC.
NHTSA ODI #11290149
56,000 miles · Jun 26, 2019
EngineFuel/propulsion System
VEHICLE ALMOST STALLS WHEN ACCELERATING FROM A STOP. VEHICLE WILL ALSO SURGE FORWARD WHEN VEHICLE COMES TO A STOP. BOTH ISSUES ARE WORSENED WHEN THE TEMPERATURE IS WARM OUTSIDE AND THE AIR CONDITIONING IS ON. HAVE TAKEN VEHICLE TO THE BMW DEALER SEVERAL TIMES TO CORRECT, BUT THEY NEVER FIND ANYTHING WRONG.
NHTSA ODI #11222668
44,000 miles · Aug 23, 2018
Fuel/propulsion System
I WAS STOPPED AT A TRAFFIC LIGHT SO WHEN THE LIGHT TURNED GREEN FOR THE LEFT TURN I TURNED ONTO THE MIDDLE LANE OF A 6 LANE HIGHWAY AND STARTED TO ACCELERATE WHEN SUDDENLY THERE WAS A VIBRATION AND THE SUSPENSION LIGHT CAME ON SO I SLOWED DOWN AND MOVED TO THE FAR RIGHT LANE WHERE I NOTICED I HAD NO ACCELERATION. I LIMPED INTO …
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I WAS STOPPED AT A TRAFFIC LIGHT SO WHEN THE LIGHT TURNED GREEN FOR THE LEFT TURN I TURNED ONTO THE MIDDLE LANE OF A 6 LANE HIGHWAY AND STARTED TO ACCELERATE WHEN SUDDENLY THERE WAS A VIBRATION AND THE SUSPENSION LIGHT CAME ON SO I SLOWED DOWN AND MOVED TO THE FAR RIGHT LANE WHERE I NOTICED I HAD NO ACCELERATION. I LIMPED INTO A PARKING LOT AND THE CAR SEEMED TO BE VIBRATING AND RUNNING ROUGH SO I SHUT IT DOWN AND WALKED HOME. AFTER TOWING IT TO BMW OF DAYTONA I GOT THE NEWS THAT I BLEW A CHARGE PIPE. THEY SAID THE CHARGE PIPE IS MADE OF PLASTIC AND GOT BRITTLE OVER TIME AND BLEW OFF THE THROTTLE BODY. I FOUND NUMEROUS REMARKS OF OTHERS THAT HAD THAT PROBLEM WHEN I GOOGLED IT. MANY OF THEM STATED THEY HAD IT REPLACED WITH AN ALUMINUM CHARGE PIPE SO I CALLED BMW BACK AND ASK THEM WHAT THEY WERE REPLACING IT WITH PLASTIC OR ALUMINUM. THEY STATED THAT IT WAS THE SAME PLASTIC PART I HAD ON THE CAR IN THE FIRST PLACE. SO I SAID GREAT THEN WE CAN EXPECT IT TO HAPPEN AGAIN. MANY COMMENTS ONLINE SUGGESTED THIS SHOULD BE A RECALL ITEM. ONE CAN IMAGINE PULLING OUT IN FRONT OF A TRUCK AND SUDDENLY LOOSING ACCELERATION. THE REAL KICKER IS BMW REPLACING IT WITH A KNOWN FAULTY PART.
NHTSA ODI #11121857
33,000 miles · Jun 13, 2014
EngineFuel/propulsion System
I HAVE BROUGHT MY CAR INTO SCHOMP BMW TWICE FOR THIS ISSUE, THE LATEST BEING LAST WEEK TELLING THEM I BELIEVE THERE IS A RECALL FOR MY VEHICLE AND IT FEELS AS IF IT WILL STALL AS I AM TURNING A CORNER OR STOPPED AND BEGIN ACCELERATING. THEY SHOWED NO RECALL AND HOOKED MY CAR UP TO COMPUTER AND NO CODES CAME BACK WITH ANY ISSUES…
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I HAVE BROUGHT MY CAR INTO SCHOMP BMW TWICE FOR THIS ISSUE, THE LATEST BEING LAST WEEK TELLING THEM I BELIEVE THERE IS A RECALL FOR MY VEHICLE AND IT FEELS AS IF IT WILL STALL AS I AM TURNING A CORNER OR STOPPED AND BEGIN ACCELERATING. THEY SHOWED NO RECALL AND HOOKED MY CAR UP TO COMPUTER AND NO CODES CAME BACK WITH ANY ISSUES. I AM REALLY SCARED THAT MY CAR WILL STALL IN THE MIDDLE OF TURNING IN FRONT OF TRAFFIC. IT HAS HESITATED TO WHERE I HAVE HAD TO PRESS THE ACCELERATOR TO THE FLOOR TO GET THE CAR TO MOVE. I AM AFRAID FOR MY SAFETY AND FOR THE SAFETY OF OTHERS. I RECEIVED THE OFFICIAL RECALL NOTICE IN THE MAIL WEDNESDAY AND CALLED SCHOMP AND TOLD THEM I WANT IT REPAIRED IMMEDIATELY IF THAT IS THE ISSUE. THEY TOLD ME THEY DON'T HAVE PARTS AND THAT I WILL RECEIVE ANOTHER NOTICE AND THAT I HAVE TO WAIT. I AM NERVOUS THAT SOMETHING WILL HAPPEN AND SOMEONE WILL BE INJURED. WHAT CAN I DO FOR NOW? *JS
NHTSA ODI #10598161
Official recalls
6Jan 15, 2020
BMW of North America, LLC (BMW) is recalling certain 2008-2013 128i and 135i Convertibles, 128i, 135i, and M Coupes, 2007-2010 X3 30si and X3 xDrive30i, 2013-2015 X1 sDrive28i, X1 xDrive28i and X1 xDrive35i, 2007-2013 328i, 328i xDrive, 335i, 335is, 335i xDrive and M3 Coupes, 2006-2011 328i, 328xi, 328i xDrive, 325i, 325xi, 330i, 330xi, 335i, 335xi, 335i xDrive and M3, 2009-2011 335D, 2006-2012 325xi, 328i, 328xi and 328i xDrive, 2010-2011 X6 ActiveHybrid, 2007-2013 328i, 335i, 335is, M3 Coupes, X5 30si, X5 xDrive30i, X5 xDrive35i, X5 48i, X5 xDrive48i, X5 xDrive50i and X5 M, 2009-2013 X5 xDrive35d and 2008-2014 X6 xDrive35i, X6 xDrive50i and X6M vehicles equipped with non-desiccated driver frontal air bag inflators containing phase stabilized ammonium nitrate (PSAN) that were used as interim remedy parts for previous Takata recalls. These inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
Consequence & remedy
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: BMW will notify owners, and dealers will replace the driver air bag. On X5 and X6 vehicles, only the inflator will be replaced. All repairs will be performed free of charge. The recall began March 11, 2020. Owners may contact BMW customer service at 1-800-525-7417.
Aug 6, 2019
BMW of North America, LLC (BMW) is recalling certain 2008-2012 BMW 128i, 135i, 135is Coupes and 128i, 135i Convertible vehicles. The wiring and electrical connectors in the blower-regulator wiring harness may overheat.
Consequence & remedy
Consequence: Wiring that overheats could cause the electrical connectors to melt, and increase the risk of a fire, even when the vehicle is unattended.
Remedy: BMW will notify owners, and dealers will inspect the blower-regulator wiring harness, and replace it with a new part, free of charge. The recall began October 4, 2019. Owners may contact BMW customer service at 1-800-525-7417. Note: This recall is an expansion of an earlier recall number 17V-676.
Feb 2, 2017
BMW of North America, LLC (BMW) is recalling certain 2011-2012 135i Coupe, 1 Series M Coupe and 135i Convertible vehicles, 2011 Z4 sDrive 35i, 335i, 335d, 335i Coupe, 335is Coupe, 335i Convertible, 335is Convertible, 535i, 535i xDrive, 535i Gran Turismo and 550i xDrive Gran Turismo vehicles and 2012 740i and 740Li vehicles. The rear driveshaft constant velocity (CV) joint on the affected vehicles may fatigue and break.
Consequence & remedy
Consequence: If the CV joint breaks, the vehicle may have a loss of propulsion, increasing the risk of a crash.
Remedy: BMW will notify owners, and dealers will inspect the rear driveshaft CV joint and, based on its production date, will replace it, free of charge. The recall began April 21, 2017. Owners may contact BMW customer service at 1-800-525-7417.
Feb 5, 2016
BMW of North America, LLC (BMW) is recalling certain model year 2008-2013 128i and 135i coupes and convertibles and 1 Series M coupes, 2006-2011 325i, 325xi, 328i, 328xi, 328i xDrive, 330i, 330xi, 335i, 335xi, 335i xDrive Sedans, 2009-2011 335d sedans, 2006-2012 325xiT, 328i and 328xi sports wagons, 2007-2013 328i, 328xi, 328i xDrive, 335i, 335xi, 335i xDrive, 335is and M3 Coupes and Convertibles, 2013-2015 X1 sDrive28i, X1 xDrive28i and X1 xDrive35i SAVs, 2007-2010 X3 xDrive30i SAVs, 2007-2013 X5 xDrive30i, X5 xDrive35i, X5 xDrive48i, X5 xDrive50i and X5 M SAVs, 2009-2013 BMW X5 xDrive35d SAVs, 2008-2014 X6 xDrive35i, X6 xDrive50i, and X6 M SACs, 2010-2011 BMW X6 xDrive50i SACs and 2008-2011 M3 Sedan vehicles. Upon deployment of the driver's frontal air bag, excessive internal pressure may cause the inflator to rupture.
Consequence & remedy
Consequence: In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could rupture with metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: BMW will notify owners, and dealers will replace the driver's frontal air bag module or inflator depending on the vehicle model, free of charge. The recall began March 9, 2018. Owners may contact BMW customer service at 1-800-525-7417.
Apr 10, 2014
BMW of North America, LLC (BMW) is recalling certain model year 2010-2011 128i Coupe, 128i Convertible, 328i Sedan, 328i xDrive Sedan, 328i Coupe, 328i Convertible, 328i Sports Wagon and Z4 sDrive 30i, 2011-2012 135i Coupe, 135i Convertible, 335i Sedan, X5 xDrive 35i, and X6 xDrive 35i, 2011 335i xDrive Sedan, 335i Coupe, 335i Convertible, 528i Sedan, 535i Sedan, 535i xDrive Sedan, X3 xDrive 28i, and X3 xDrive 35i, 2010 X3 xDrive 30i, and X5 xDrive 30i, 2012 640i Coupe, and 640i Convertible and 2010-2012 535i Gran Turismo vehicles. In the affected vehicles, the bolts that secure the housing for the variable camshaft timing adjustment (VANOS) unit can loosen over time and may possibly break.
Consequence & remedy
Consequence: If the bolts loosen or break the engine may have reduced power or stall. An engine stall increases the risk of a crash.
Remedy: BMW will notify owners, and dealers will replace the four VANOS housing bolts for both VANOS units (intake and exhaust), free of charge. In addition, owners of approximately 170,172 model year 2010-2012 BMW vehicles equipped with inline 6 cylinder engines not covered by this recall, will receive an extended warranty to address this condition. The recall began on September 24, 2014. Owners may contact BMW at 1-800-525-7417.
Feb 7, 2013
BMW is recalling certain model year 2008-2012 1-Series coupes and convertibles manufactured December 2007 through September 2011; and 2007-2011 3-Series coupes and convertibles manufactured March 2007 through October 2011; 2007-2011 3-Series sedans manufactured March 2007 through October 2011; 2007-2011 3-Series sports wagons manufactured March 2007 through June 2011; and 2009-2011 Z4 vehicles manufactured March 2009 through June 2011. In February 2013, BMW recalled 504,545 vehicles. In July 2013, BMW informed the agency that it was adding 1-Series, 3-Series, and Z4 vehicles, representing an additional 12,094 vehicles. The total number of vehicles being recalled is now 516,791. The connector for the positive battery cable connector and the corresponding terminal on the fuse box may degrade over time. Over time, the high current flow and heat from electrical resistance may lead to a breakage of the connection, and a loss of electrical power to the vehicle.
Consequence & remedy
Consequence: If there is a loss of electrical power to the vehicle, the vehicle may unexpectedly stall, increasing the risk of a crash.
Remedy: BMW will notify owners, and dealers will replace the positive battery cable connector and secure it with an improved method, free of charge. The recall began on March 13, 2013. Owners may call BMW at 1-800-525-7417 or email BMW at CustomerRelations@bmwusa.com.
Additional source detail variants (3)
Electrical System:wiring:fuses And Circuit Breakers
BMW is recalling certain model year 2008-2012 1-Series coupes and convertibles manufactured December 2007 through September 2011; and 2007-2011 3-Series coupes and convertibles manufactured March 2007 through October 2011; 2007-2011 3-Series sedans manufactured March 2007 through October 2011; 2007-2011 3-Series sports wagons manufactured March 2007 through June 2011; and 2009-2011 Z4 vehicles manufactured March 2009 through June 2011. In February 2013, BMW recalled 504,545 vehicles. In July 2013, BMW informed the agency that it was adding 1-Series, 3-Series, and Z4 vehicles, representing an additional 12,094 vehicles. The total number of vehicles being recalled is now 516,791. The connector for the positive battery cable connector and the corresponding terminal on the fuse box may degrade over time. Over time, the high current flow and heat from electrical resistance may lead to a breakage of the connection, and a loss of electrical power to the vehicle.
Consequence: If there is a loss of electrical power to the vehicle, the vehicle may unexpectedly stall, increasing the risk of a crash.
Remedy: BMW will notify owners, and dealers will replace the positive battery cable connector and secure it with an improved method, free of charge. The recall began on March 13, 2013. Owners may call BMW at 1-800-525-7417 or email BMW at CustomerRelations@bmwusa.com.
Electrical SYSTEM:12V/24V/48V Battery:cables
BMW is recalling certain model year 2008-2012 1-Series coupes and convertibles manufactured December 2007 through September 2011; and 2007-2011 3-Series coupes and convertibles manufactured March 2007 through October 2011; 2007-2011 3-Series sedans manufactured March 2007 through October 2011; 2007-2011 3-Series sports wagons manufactured March 2007 through June 2011; and 2009-2011 Z4 vehicles manufactured March 2009 through June 2011. In February 2013, BMW recalled 504,545 vehicles. In July 2013, BMW informed the agency that it was adding 1-Series, 3-Series, and Z4 vehicles, representing an additional 12,094 vehicles. The total number of vehicles being recalled is now 516,791. The connector for the positive battery cable connector and the corresponding terminal on the fuse box may degrade over time. Over time, the high current flow and heat from electrical resistance may lead to a breakage of the connection, and a loss of electrical power to the vehicle.
Consequence: If there is a loss of electrical power to the vehicle, the vehicle may unexpectedly stall, increasing the risk of a crash.
Remedy: BMW will notify owners, and dealers will replace the positive battery cable connector and secure it with an improved method, free of charge. The recall began on March 13, 2013. Owners may call BMW at 1-800-525-7417 or email BMW at CustomerRelations@bmwusa.com.
Electrical System
BMW is recalling certain model year 2008-2012 1-Series coupes and convertibles manufactured December 2007 through September 2011; and 2007-2011 3-Series coupes and convertibles manufactured March 2007 through October 2011; 2007-2011 3-Series sedans manufactured March 2007 through October 2011; 2007-2011 3-Series sports wagons manufactured March 2007 through June 2011; and 2009-2011 Z4 vehicles manufactured March 2009 through June 2011. In February 2013, BMW recalled 504,545 vehicles. In July 2013, BMW informed the agency that it was adding 1-Series, 3-Series, and Z4 vehicles, representing an additional 12,094 vehicles. The total number of vehicles being recalled is now 516,791. The connector for the positive battery cable connector and the corresponding terminal on the fuse box may degrade over time. Over time, the high current flow and heat from electrical resistance may lead to a breakage of the connection, and a loss of electrical power to the vehicle.
Consequence: If there is a loss of electrical power to the vehicle, the vehicle may unexpectedly stall, increasing the risk of a crash.
Remedy: BMW will notify owners, and dealers will replace the positive battery cable connector and secure it with an improved method, free of charge. The recall began on March 13, 2013. Owners may call BMW at 1-800-525-7417 or email BMW at CustomerRelations@bmwusa.com.
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
1EA21002 · 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.
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