NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
16 reportsClear category filterMileage unknown · Sep 5, 2023
Engine
Starting from a traffic light at Woodlands Parkway and Gosling Road in the Woodlands, TX - Vehicle accelerated normally during shifting from 1st to 2nd gear. When shifting from 2nd to 3rd - Engine RPM went to ZERO and vehicle suddenly lost all power and died. There was a large Ford F150 behind the car. Thankfully, I was watchin…
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Starting from a traffic light at Woodlands Parkway and Gosling Road in the Woodlands, TX - Vehicle accelerated normally during shifting from 1st to 2nd gear. When shifting from 2nd to 3rd - Engine RPM went to ZERO and vehicle suddenly lost all power and died. There was a large Ford F150 behind the car. Thankfully, I was watching the tachometer and coasted to the shoulder before attempting to shift back to 2 and try a rolling start at which point vehicle came to an abrupt and sudden stop. Car was towed to an approved mechanic and was diagnosed as "another seized S65" engine. OPINION of Expert engine builders and bearing manufacturers is that the original BMW S65 bearing dimensions result in inadequate journal clearance and has been thoroughly documented. This, coupled with any potential "tolerance stacking" (- clearance) can result in a final bearing clearance which is significantly tighter than ideal and is the reason why we have seen engines fail after only a few thousand miles. This was half a second or less from being a fatal accident.
NHTSA ODI #11542797
52,000 miles · Jan 29, 2021
Electrical SystemEnginePower Train
I WAS DRIVING ON THE FREEWAY ACCELERATING WHEN I HIT APPROXIMATELY 75 MPH MY CAR WAS MAKING A LOUD REVVING SOUND AND METAL CLANKING SOUND IN MIDDLE AND SMOKE WAS COMING FROM THE FRONT AND BACK OF THE VEHICLE VERY THICK WHITE SMOKE ALL OF A SUDDEN MY CAR SLOWED DOWN AND ALL THE LIGHTS WERE BLINKING ON THE DASH ALMOST GOT INTO ACC…
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I WAS DRIVING ON THE FREEWAY ACCELERATING WHEN I HIT APPROXIMATELY 75 MPH MY CAR WAS MAKING A LOUD REVVING SOUND AND METAL CLANKING SOUND IN MIDDLE AND SMOKE WAS COMING FROM THE FRONT AND BACK OF THE VEHICLE VERY THICK WHITE SMOKE ALL OF A SUDDEN MY CAR SLOWED DOWN AND ALL THE LIGHTS WERE BLINKING ON THE DASH ALMOST GOT INTO ACCIDENTS WHILE CARS AVOID HITTING! MY CAR WASN'T GOING OVER 5 10 MPH THERE WAS SO MUCH SMOKE WAS GETTING WORRIED,SOME HOW I MANAGED TO EXIT THE FREEWAY AND PARKED I WAS TOLD MY ENGLISH WAS BLOWN! MAINTENANCE WAS UP-TO-DATE ONLY DROVE IT ON THE WEEKENDS ONLY HAD 52,000 MILES NIGHTMARE 2011 BMW M3
NHTSA ODI #11390611
73,800 miles · Apr 29, 2020
EngineService BrakesSteering
WHILE DRIVING MY VEHICLE, THE ENGINE SUDDENLY SHUT OFF, AND THE TRANSMISSION WENT INTO NEUTRAL. I IMMEDIATELY TURNED THE CAR BACK ON, AND PULLED TO A STOP SIGN. I GAVE MY CAR A FEW REVS JUST TO MAKE SURE EVERYTHING WAS FINE. EVERYTHING SEEMED TO CHECK OUT, SO I CONTINUE DRIVING. WHILE DRIVING ABOUT 40MPH AND STRAIGHT, THE CAR SH…
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WHILE DRIVING MY VEHICLE, THE ENGINE SUDDENLY SHUT OFF, AND THE TRANSMISSION WENT INTO NEUTRAL. I IMMEDIATELY TURNED THE CAR BACK ON, AND PULLED TO A STOP SIGN. I GAVE MY CAR A FEW REVS JUST TO MAKE SURE EVERYTHING WAS FINE. EVERYTHING SEEMED TO CHECK OUT, SO I CONTINUE DRIVING. WHILE DRIVING ABOUT 40MPH AND STRAIGHT, THE CAR SHUTS OFF AGAIN, AND THIS TIME I HAVE A COMPLETE LOSS OF STEERING AND BRAKES. THANKFULLY I MANAGE TO AVOID HITTING THE CAR IN FRONT OF ME BY USING MY EMERGENCY BRAKE SLOWLY. THIS TIME THE VEHICLE DID NOT TURN BACK ON. AFTER RESEARCHING THIS ISSUE IT'S BECOME APPARENT THIS VEHICLE IS ACTUALLY KNOWN TO DO THIS. ROD BEARINGS AND MAIN BEARINGS HAVE CAUSED THESE MOTORS TO SEIZE WHILE DRIVING, AND BMW REFUSES TO ACKNOWLEDGE THIS ISSUE. I COULD HAVE KILLED SOMEONE FROM THIS ISSUE, BUT IT'S SAD ALL THEY CARE ABOUT IS DOLLARS AND CENTS.
NHTSA ODI #11322610
107,000 miles · Oct 20, 2019
Engine
I WAS DRIVING CASUALLY WHEN THE MOTOR SUDDENLY SHUT OFF. NO NOISE INDICATING ENGINE FAILURE EVER HAPPENED. I COASTED OFF THE ROAD AND TRIED TO RESTART. NOTHING BUT A CLICK. EVENTUALLY TRIED REPLACING STARTER MOTOR BUT THAT DIDN'T WORK. NO ENGINE LIGHTS OR CODES EVER POPPED UP. TURNS OUT ENGINE SEIZED DUE TO FAILED ROD BEAR…
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I WAS DRIVING CASUALLY WHEN THE MOTOR SUDDENLY SHUT OFF. NO NOISE INDICATING ENGINE FAILURE EVER HAPPENED. I COASTED OFF THE ROAD AND TRIED TO RESTART. NOTHING BUT A CLICK. EVENTUALLY TRIED REPLACING STARTER MOTOR BUT THAT DIDN'T WORK. NO ENGINE LIGHTS OR CODES EVER POPPED UP. TURNS OUT ENGINE SEIZED DUE TO FAILED ROD BEARINGS.
NHTSA ODI #11269732
80,000 miles · Jul 26, 2019
Engine
TWO WEEKS AGO, WHEN THE CAR WAS DRIVING NORMALLY, IT SUDDENLY SHUT DOWN AND COULD NO LONGER START. WHEN AUTOMOTIVE ENGINEERS TOOK THE ENGINE APART, THEY FOUND THAT THE CRANKSHAFT AND ROD BEARING BUSH WERE OVER-WORN AND BURNT OUT. THE ENGINEER TOLD ME THAT THE OIL I USED WAS TOO STICKY TO LUBRICATE THE ROD BEARING. I CHANGED THE …
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TWO WEEKS AGO, WHEN THE CAR WAS DRIVING NORMALLY, IT SUDDENLY SHUT DOWN AND COULD NO LONGER START. WHEN AUTOMOTIVE ENGINEERS TOOK THE ENGINE APART, THEY FOUND THAT THE CRANKSHAFT AND ROD BEARING BUSH WERE OVER-WORN AND BURNT OUT. THE ENGINEER TOLD ME THAT THE OIL I USED WAS TOO STICKY TO LUBRICATE THE ROD BEARING. I CHANGED THE ENGINE OIL 8,000 MILES AGO, USING THE 10W-60 OIL SUPPLIED BY BMW.
NHTSA ODI #11235191
43,300 miles · Jun 8, 2019
Engine
WHILE SHIFTING INTO 3RD GEAR, MY ENGINE THREW A ROD THROUGH THE BLOCK, CAR HAS NOT BEEN MODIFIED, HAS 43,300 ORIGINAL MILES, ORIGINAL OWNER.
NHTSA ODI #11218617
60,000 miles · Jun 6, 2018
Engine
O2 SENSORS CONSTANTLY GO OUT REPLACED 3 TIMES, THROTTLE BODY ACUTATORS CONSTANTLY GO BAD PUTTING CAR IN LIMP MODE VERY DANGEROUS MY CAR CUT OFF AT 65MPH ON THE FREEWAY. I WAS WITH MY FAMILY!!! SOMETHING BAD COULD OF HAPPENED. PLEASE LOOK INTO THIS BMW M3 2008-2013 PLEASE LOOK INTO THIS. ROD BEARINGS GO BAD ASWELL
NHTSA ODI #11100142
42,000 miles · Feb 8, 2018
Engine
WHILE DRIVING MY LOW MILAGE 2011 BMW M3 (42K MILES) ON THE HIGHWAY, OUT OF NO WHERE, I NOTICED THE CAR DRIVING A LITTLE DIFFERENTLY AND SLIGHTLY SHAKING. THIS HAPPENED MOMENTS BEFORE I REACHED MY EXIT. I PULLED OVER AT A GAS STATION RIGHT OFF THE EXIT AND OPENED THE HOOD, THE ENGINE WAS MAKING A TINGING/SCRAPING NOISE WITH EACH …
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WHILE DRIVING MY LOW MILAGE 2011 BMW M3 (42K MILES) ON THE HIGHWAY, OUT OF NO WHERE, I NOTICED THE CAR DRIVING A LITTLE DIFFERENTLY AND SLIGHTLY SHAKING. THIS HAPPENED MOMENTS BEFORE I REACHED MY EXIT. I PULLED OVER AT A GAS STATION RIGHT OFF THE EXIT AND OPENED THE HOOD, THE ENGINE WAS MAKING A TINGING/SCRAPING NOISE WITH EACH REVOLUTION. I CLOSED IT UP, AND DROVE TO MY HOME WHICH WAS A COUPLE MINUTES AWAY. WHILE DRIVING, THE NOISE WAS HAPPENING MORE IN LOWER GEARS. WHEN I GOT HOME, I LOOKED UNDER THE CAR AND SAW IT WAS LEAKING OIL, AND STILL MAKING THE NOISE. AFTER SOME INVESTIGATION, I LEARNED THE ROD BEARINGS IN THE ENGINE HAD FAILED, RESULTING IN COMPLETE ENGINE FAILURE. I PURCHASED THE CAR FROM AN AUTHORIZED BMW STORE AT 38K MILES IN MAY OF 2017, I ALWAYS SERVICED IT AT MY LOCAL BMW STORE - THIS OCCURRED FEBRUARY 3RD, 2018. AFTER READING UP, I AM LEARNING THAT THIS IS AN ISSUE WITH THE S65 ENGINES THAT ARE IN THIS MODEL OF M3'S. BMW HAS YET TO MAKE A RECALL, BUT THEY ARE AWARE OF THE ISSUE. NO ACTION HAS BEEN TAKEN, BUT SOMETHING NEEDS TO BE DONE. I CAN'T AFFORD A NEW ENGINE (IT COSTS 30 SOMETHING THOUSAND DOLLARS, WHICH IS ALMOST AS MUCH AS I PAID FOR THE CAR), AND THE ENGINE CANNOT BE REPAIRED. I FEEL WRONGED BY BMW, AND ADVISE THE NHTSA TO URGE BMW TO RECALL THIS ENGINE TO SAVE FUTURE CUSTOMERS FROM CATASTROPHIC ENGINE FAILURE.
NHTSA ODI #11071817
63,850 miles · Nov 21, 2017
Engine
AT 63,860 MILE THE S65 ENGINE IN MY 2011 BMW M3 FAILED. DEALER DIAGNOSED ENGINE BEARING FAILURE. FAILURE OCCURRED WHILE DRIVING.
NHTSA ODI #11047832
46,000 miles · Nov 17, 2017
Engine
ENGINE KNOCKING. CONNECTING ROD BEARING AND MAIN BEARING FAILURE RESULTING IN REQUIRED ENGINE REPLACEMENT. ENGINE NOT ABLE TO BE REBUILT DUE TO CRACKED MAIN BEARING SADDLES.
NHTSA ODI #11047061
Official recalls
4Jan 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.
Jun 19, 2019
BMW of North America, LLC (BMW) is recalling certain 2009 328i and 328xi, 2009-2011 335d, 2008-2012 M3 Coupe and M3 Convertible, and 2008-2011 M3 Sedan vehicles. The connection of the positive battery cable at the fuse box terminal may degrade, resulting in an intermittent loss of electrical power.
Consequence & remedy
Consequence: A loss of electrical power can cause the vehicle to stall, increasing the risk of a crash.
Remedy: BMW will notify owners, and dealers will replace and secure the positive battery cable connector, free of charge. The recall began August 14, 2019. Owners may contact BMW customer service at 1-800-525-7417. Note: This recall is an expansion of a previous recall, number 18V-314.
Additional source detail variants (3)
Electrical System:wiring:fuses And Circuit Breakers
BMW of North America, LLC (BMW) is recalling certain 2009 328i and 328xi, 2009-2011 335d, 2008-2012 M3 Coupe and M3 Convertible, and 2008-2011 M3 Sedan vehicles. The connection of the positive battery cable at the fuse box terminal may degrade, resulting in an intermittent loss of electrical power.
Consequence: A loss of electrical power can cause the vehicle to stall, increasing the risk of a crash.
Remedy: BMW will notify owners, and dealers will replace and secure the positive battery cable connector, free of charge. The recall began August 14, 2019. Owners may contact BMW customer service at 1-800-525-7417. Note: This recall is an expansion of a previous recall, number 18V-314.
Electrical SYSTEM:12V/24V/48V Battery:cables
BMW of North America, LLC (BMW) is recalling certain 2009 328i and 328xi, 2009-2011 335d, 2008-2012 M3 Coupe and M3 Convertible, and 2008-2011 M3 Sedan vehicles. The connection of the positive battery cable at the fuse box terminal may degrade, resulting in an intermittent loss of electrical power.
Consequence: A loss of electrical power can cause the vehicle to stall, increasing the risk of a crash.
Remedy: BMW will notify owners, and dealers will replace and secure the positive battery cable connector, free of charge. The recall began August 14, 2019. Owners may contact BMW customer service at 1-800-525-7417. Note: This recall is an expansion of a previous recall, number 18V-314.
Electrical System
BMW of North America, LLC (BMW) is recalling certain 2009 328i and 328xi, 2009-2011 335d, 2008-2012 M3 Coupe and M3 Convertible, and 2008-2011 M3 Sedan vehicles. The connection of the positive battery cable at the fuse box terminal may degrade, resulting in an intermittent loss of electrical power.
Consequence: A loss of electrical power can cause the vehicle to stall, increasing the risk of a crash.
Remedy: BMW will notify owners, and dealers will replace and secure the positive battery cable connector, free of charge. The recall began August 14, 2019. Owners may contact BMW customer service at 1-800-525-7417. Note: This recall is an expansion of a previous recall, number 18V-314.
Oct 25, 2017
BMW of North America, LLC (BMW) is recalling certain 2006-2011 323i, 325i, 325xi, 328i, 328xi, 330i, 330xi, 335i, 335xi and M3, 2007-2011 328i xDrive, 335i xDrive and 335is and 2009-2011 335d vehicles. The wiring and electrical connectors for the system that controls air flow for the heating and air conditioning system 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 replace the wiring and electrical connectors, free of charge. Interim letters were mailed on November 27, 2017. Owners will receive a second notice when the remedy becomes available. 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.
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.
Illustration