IllustrationMileage unknown · Jan 12, 2025
Air Bags
Unknown
NHTSA ODI #11635537
2009 Chevrolet Suburban
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2009 Chevrolet Suburban do not stand out strongly from the model-year median of 118.
About this comparison →How this year compares
Owner complaints by model year
Compare all Suburban years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
30–25K
1525–50K
950–75K
1475–100K
10100–150K
16150K+
67 reports with mileage · 39 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.
- Air Bags. Review the 38 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 16 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Structure. Review the 11 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
1 crash reports0 fire reports2 injury reports
What owners actually said
106 reportsUnknown
Fuel pump modulator, which has a recall for other vehicles for same part, malfunctioned which caused the vehicle to cut off while my son was driving on the highway without notice, where he had to avoid being hit while trying to make it to the shoulder for safety. The fuel pump module was tested by a service mechanic and was foun…
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Fuel pump modulator, which has a recall for other vehicles for same part, malfunctioned which caused the vehicle to cut off while my son was driving on the highway without notice, where he had to avoid being hit while trying to make it to the shoulder for safety. The fuel pump module was tested by a service mechanic and was found to have corroded due to moisture. Prior to vehicle cutting off, there were no warning signals/signs, it just cut the vehicle off while driving on the highway.
Cooper Discoverer 275-55r20 had a stranger point out a very large bulge on the inner sidewall of my passenger side rear tire. This is the 3rd tire from a set of 4 that has developed the same issue within 3 months. Cooper Tires is not wanting to help resolve this issue. They want the tire dissected and returned before doing anyth…
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Cooper Discoverer 275-55r20 had a stranger point out a very large bulge on the inner sidewall of my passenger side rear tire. This is the 3rd tire from a set of 4 that has developed the same issue within 3 months. Cooper Tires is not wanting to help resolve this issue. They want the tire dissected and returned before doing anything.
On 05/19/2023 driver's side front wheel removed for brake replacement. Noticed large bulge on inner sidewall of Cooper Discoverer 275-55r20 tire. This was the 2nd tire of a set of 4 that has developed the same issue. Now a third has a bulge. I will submit a 3rd report for it.
Cooper Discoverer 275-55r20 developed bulge in inner sidewall. I was unaware of issue until a stranger pointed it out. That was on 03/08/2023. Since then, 2 more tires have developed the same issue!! The last 2 have been looked at by tire installation professionals and determined to be manufacturer defects.
The contact owns a 2009 Chevrolet Suburban. The contact stated that the vehicle intermittently failed to start after multiple attempts without warning. The contact replaced the ignition switch and the fuel pump; however, the failure persisted. The contact then used a code reader that determined that the Engine Control Module (EC…
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The contact owns a 2009 Chevrolet Suburban. The contact stated that the vehicle intermittently failed to start after multiple attempts without warning. The contact replaced the ignition switch and the fuel pump; however, the failure persisted. The contact then used a code reader that determined that the Engine Control Module (ECM) was not giving a signal to the fuel pump. The contact made additional repairs to the vehicle, but the failure persisted. The vehicle was taken to the dealer, and he was given an estimate for the repair. Upon investigation, the contact linked the failure to NHTSA Campaign Number: 09V154000 (Fuel System, Gasoline). The manufacturer was notified of the failure and informed him that his vehicle was not included in the recall. The vehicle was not repaired. The failure mileage was approximately 200,000.
The contact owns a 2009 Chevrolet Suburban. The contact stated that while her son was seated in the driver's side front seat with the door opened, the key was not in the ignition, the doors inadvertently locked and unlocked. The contact's son noticed that there was smoke coming from the dash and exited the vehicle. Upon inspecti…
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The contact owns a 2009 Chevrolet Suburban. The contact stated that while her son was seated in the driver's side front seat with the door opened, the key was not in the ignition, the doors inadvertently locked and unlocked. The contact's son noticed that there was smoke coming from the dash and exited the vehicle. Upon inspection, the contact and her son detected a burning odor and noticed that there was smoke coming from underneath the hood; however, there were no flames. The contact's son opened the hood and disconnected the battery. The fire department arrived and inspected the vehicle. The fireman informed the contact that the alternator and battery connectors were extremely hot. The fire department assisted in moving the vehicle away from the residence. A fire department report was filed. The vehicle was towed to the dealer; however, the vehicle was diagnosed but still hasn't been repaired. The contact related the failure to a faulty electrical system. The vehicle was not yet deemed totaled by the insurance company. The manufacturer was made aware of the failure. The failure mileage was approximately 133,000.
Dashboard cracked around the corner of the passenger side air bag and manufacturer did not recall. It appears there are many vehicles with this problem and could be a potential safety issue if the airbag malfunctioned and caused parts of dash to break and rupture air bag or fly into passengers of vehicle in the event of a crash.
I am STILL waiting for this recall to be fixed. Why is this taking so long? Every time I drive this vehicle, it is a danger for my passenger due to the defective airbag. It almost seems to me that maybe this is a stall tactic so there will be less of a cost for the repairs due to the less vehicles still on the road. Just m…
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I am STILL waiting for this recall to be fixed. Why is this taking so long? Every time I drive this vehicle, it is a danger for my passenger due to the defective airbag. It almost seems to me that maybe this is a stall tactic so there will be less of a cost for the repairs due to the less vehicles still on the road. Just my opinion. I would like to know what is taking so long to fix. It is already late 2021 and this vehicle is a 2009. Wow. I guess the safety of the customers is second to the cost of repairs.
TL* THE CONTACT OWNS A 2009 CHEVROLET SUBURBAN. THE CONTACT STATED WHILE DRIVING 45 MPH, THE VEHICLE STARTED TO SPUTTER AND SHAKE WITH A LOUD KNOCKING SOUND COMING FROM THE ENGINE. THE CHECK ENGINE WARNING LIGHT WAS ILLUMINATED AND THE VEHICLE SHIFTED INTO LIMP MODE AND DECELERATED. THE VEHICLE WAS DRIVEN BACK TO THE CONTACT'S R…
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TL* THE CONTACT OWNS A 2009 CHEVROLET SUBURBAN. THE CONTACT STATED WHILE DRIVING 45 MPH, THE VEHICLE STARTED TO SPUTTER AND SHAKE WITH A LOUD KNOCKING SOUND COMING FROM THE ENGINE. THE CHECK ENGINE WARNING LIGHT WAS ILLUMINATED AND THE VEHICLE SHIFTED INTO LIMP MODE AND DECELERATED. THE VEHICLE WAS DRIVEN BACK TO THE CONTACT'S RESIDENCE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE ENGINE WAS LOW ON OIL. ADDITIONALLY, THE NUMBER 6 LIFTER NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED HOWEVER, THE FAILURE PERSISTED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 167,000.*DT
Official recalls
521V050000 · Air Bags:frontal:passenger Side:inflator Module
Feb 5, 2021
General Motors, LLC (GM) is recalling certain 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, GMC Sierra 1500, Yukon, Yukon XL, and 2009-2011 Chevrolet Silverado 2500, Silverado 3500, GMC Sierra 2500 and Sierra 3500 vehicles originally sold, or ever registered, in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A." Additionally, GM is recalling certain 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT, Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, GMC Sierra 1500, Yukon, Yukon XL vehicles originally sold, or ever registered, in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B." These vehicles are equipped with non-desiccated passenger frontal inflators containing phase-stabilized ammonium nitrate (PSAN) propellant. 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: GM will notify owners, and dealers will replace the front passenger air bag inflator with an alternate one, free of charge. Interim letters notifying owners of the safety risk were mailed on February 22, 2021. Second notification letters will be mailed once the remedy is available. Owner notification letters were mailed on March 1, 2021. Owners may contact Chevrolet customer service at 1-800-222-1020; Cadillac customer service at 1-800-458-8006; and GMC customer service at 1-800-462-8782. GM's number for this recall is N212328760.
21V052000 · Air Bags:frontal:passenger Side:inflator Module
Feb 5, 2021
General Motors, LLC (GM) is recalling certain 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, Chevrolet Avalanche, Silverado 1500, Silverado 2500, Silverado 3500, Suburban, Tahoe, GMC Sierra 1500, Sierra 2500, Sierra 3500, Yukon, and Yukon XL vehicles originally sold, or ever registered, in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B." Additionally, GM is recalling certain 2007-2008 Cadillac Escalade, Escalade ESV, and Escalade EXT, Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, GMC Sierra 1500, Yukon, and Yukon XL vehicles originally sold, or ever registered, in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin, and Wyoming or "Zone C." These vehicles are equipped with non-desiccated passenger frontal inflators containing phase-stabilized ammonium nitrate (PSAN) propellant. 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: GM will notify owners, and dealers will replace the front passenger air bag inflator with an alternate one, free of charge. Interim letters notifying owners of the safety risk were mailed on February 23, 2021. Second notification letters will be mailed once the remedy is available. Owner notification letters were mailed on September 20, 2021. Owners may contact Chevrolet customer service at 1-800-222-1020, Cadillac customer service at 1-800-458-8006, and GMC customer service at 1-800-462-8782. GM's number for this recall is N212328780.
21V053000 · Air Bags:frontal:passenger Side:inflator Module
Feb 5, 2021
General Motors, LLC (GM) is recalling certain 2013 Cadillac Escalade, Escalade ESV, and Escalade EXT, Chevrolet Avalanche, Silverado 1500, Silverado 2500/3500, Suburban, Tahoe, GMC Sierra 1500, Sierra 2500/3500, Yukon, and Yukon XL vehicles originally sold, or ever registered, in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A." Additionally, GM is recalling certain 2010 Cadillac Escalade, Escalade ESV, and Escalade EXT, Chevrolet Avalanche, Silverado 1500, Silverado 2500/3500, Suburban, Tahoe, GMC Sierra 1500, Sierra 2500/3500, Yukon, and Yukon XL vehicles originally sold, or ever registered in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B." Additionally, GM is recalling certain 2009 Cadillac Escalade, Escalade ESV, and Escalade EXT, Chevrolet Avalanche, Silverado 1500, Silverado 2500/3500, Suburban, Tahoe, GMC Sierra 1500, Sierra 2500/3500, Yukon, and Yukon XL vehicles originally sold, or ever registered, in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin, and Wyoming or "Zone C."
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: GM will notify owners, and dealers will replace the front passenger air bag inflator with an alternate one, free of charge. Interim letters notifying owners of the safety risk were mailed on February 24, 2021. Second notification letters will be mailed once the remedy is available. Owner notification letters were mailed on May 11, 2021. Owners may contact Cadillac customer service at 1-800-458-8006; Chevrolet customer service at 1-800-222-1020; and GMC customer service at 1-800-462-8782. GM's number for this recall is N212328790.
10V240000 · Electrical System
Jun 4, 2010
GM IS RECALLING CERTAIN MODEL YEAR 2006-2009 BUICK, LUCERNE; CADILLAC DTS; HUMMER H2; MODEL YEAR 2008-2009 BUICK ENCLAVE; CADILLAC CTS; MODEL YEAR 2007-2009 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT; CHEVROLET AVALANCHE, SILVERADO, SUBURBAN, TAHOE; GMC ACADIA, SIERRA, YUKON, YUKON XL; SATURN OUTLOOK; AND MODEL YEAR 2009 CHEVROLET TRAVERSE VEHICLES EQUIPPED WITH A HEATED WASHER FLUID SYSTEM (HWFS). A RECALL WAS IMPLEMENTED IN 2008 TO ADD A FUSE TO THE CONTROL CIRCUIT HARNESS TO ADDRESS THE POTENTIAL CONSEQUENCES OF A PRINTED CIRCUIT BOARD (PCB) ELECTRICAL SHORT. HOWEVER, THERE HAVE BEEN NEW REPORTS OF THERMAL INCIDENTS ON HWFS MODULES AFTER THIS IMPROVEMENT WAS INSTALLED. THESE INCIDENTS RESULTED FROM A NEW FAILURE MODE ATTRIBUTED TO THE DEVICE'S THERMAL PROTECTION FEATURE. THE SIGNIFICANCE VARIES FROM MINOR DISTORTION TO CONSIDERABLE MELTING OF THE PLASTIC AROUND THE HWFS FLUID CHAMBER.
Consequence & remedy
Consequence: IT IS POSSIBLE FOR THE HEATED WASHER MODULE TO IGNITE AND A FIRE MAY OCCUR.
Remedy: DEALERS WILL PERMANENTLY DISABLE AND REMOVE THE HEATED WASHER FLUID MODULE. AN UPDATED PAGE FOR THE OWNER MANUAL WILL BE PROVIDED AND INSERTED IN THE OWNER MANUAL TO DOCUMENT THAT THE FEATURE HAS BEEN PERMANENTLY DISABLED AND REMOVED FROM THE VEHICLE. THE SAFETY RECALL BEGAN ON JUNE 11, 2010. OWNERS MAY CONTACT BUICK AT 1-866-608-8080, CADILLAC AT 1-866-982-2339, CHEVROLET AT 1-800-630-2438, SATURN AT 1-800-972-8876, GMC AT 1-866-996-9463 AND HUMMER AT 1-800-732-5493 OR AT THE OWNER CENTER AT WWW.GMOWNERCENTER.COM.
09V154000 · Fuel System, Gasoline
May 6, 2009
GM IS RECALLING 27,188 MY 2009 CADILLAC ESCALADE, ESCALADE HYBRID, ESCALADE ESV, AND ESCALADE EXT; CHEVROLET AVALANCHE, SUBURBAN, TAHOE, TAHOE HYBRID, AND COLORADO; AND GMC YUKON, YUKON HYBRID, YUKON XL, AND CANYON VEHICLES. THE FUEL SYSTEM CONTROL MODULES MAY HAVE A CONDITION IN WHICH AN ADHESIVE SEPARATION OF THE ROOM TEMPERATURE VULCANIZING (RTV) SEAL BETWEEN THE SEAL AND THE HOUSING MAY ALLOW WATER TO SEEP INTO THE MODULE.
Consequence & remedy
Consequence: WATER IN THE MODULE COULD CAUSE A SHORT OR OPEN CIRCUIT, ILLUMINATION OF THE SERVICE ENGINE SOON LAMP, SETTING OF DIAGNOSTIC TROUBLE CODES OR THE ENGINE MAY BE HARD TO START, MAY NOT START OR MAY STALL INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSTALL A NEW FUEL SYSTEM CONTROL MODULE FREE OF CHARGE. THE RECALL BEGAN ON MAY 18, 2009. OWNERS MAY CONTACT CADILLAC AT 1-866-982-2339, CHEVROLET AT 1-800-630-2438 AND GMC AT 1-866-996-9463 OR AT WWW.GMOWNERCENTER.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.