Electrical System. Review the 103 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Air Bags. Review the 35 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Engine. Review the 23 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

5 crash reports8 fire reports4 injury reports

Engine complaints

23 reports

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87,000 miles · May 6, 2017

Air BagsElectronic Stability Control (esc)Engine

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SMART GLASS OP IS BAD IN MY CAR AND MY BATTERY HAD TO BE REPLACE AFTER CHRYSLER JEEP IN MODESTO CALF FIXED MY ALTERNATOR RECALL IT TOOK TWO DAYSFOR REPAIR THE AIR BAG RECALL THEY FIXED LIGHT IS STILL ON SMART GLASS ACTING UP AFTER EVERY RECALL REPAIR ATTEMPTED ...THIS WHOLE CALL SHOULD BE REPLACED BIG HEAD ACE I WAS LIED TO BY THE DEALERSHIP I WAS TOLD A LIFETIME OF WARRANTY NOT TRUE LOTS OF PROBLEM STRESS MY WINDOW GOES UP/DOWN BY ITSELFWILL NOT STOP PLEASE RECALL THIS CAR IN TOTAL I PAYED OVER 39000 FOR HEAD ACE WINDOW WILL NOT STOP NO SECURTY DRAING MY BATTERY PAYED 212.00 FOR A NEW ONE WINDOW WILL NOT STOP

NHTSA ODI #10983802

76,000 miles · Feb 14, 2017

Engine

I WAS AT THE STORE AND TRIED TO START MY CAR. MY WARNING LIGHTS CAME ON AND CAR WOULD NOT START. THOUGHT IT WAS A DEAD BATTERY, BUT AS IT TURNED OUT IT WAS A BAD ALTERNATOR. DODGE HAS HAD ALTERNATOR RECALLS ON OTHER SIMILAR VEHICLES FROM THE SAME YEAR AND BROWSING THE INTERNET I SEE MANY COMPLAINTS ABOUT BAD ALTERNATORS WITH OWN…

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NHTSA ODI #10954481

90,000 miles · Aug 3, 2015

Electrical SystemEngine

WHILE DRIVING MY CAR IT WOULD LOSE POWER. I COULD NOT ACCELERATE. I CAN NOT ALWAYS RESTART IT RIGHT AWAY. IT GOT TO THE POINT I WAS UNABLE TO RESTART IT AND IT HAD TO BE TOWED

NHTSA ODI #10745976

21,400 miles · Jun 17, 2015

Engine

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TL* THE CONTACT OWNS A 2011 DODGE CHALLENGER. WHILE DRIVING 40 MPH AND ATTEMPTING TO ROLL DOWN THE WINDOW, IT ROLLED DOWN SLOWER THAN NORMAL. SEVERAL MOMENTS LATER, THE LIGHTING ON THE INSTRUMENT PANEL DIMMED AND THE VEHICLE STALLED. THE VEHICLE WAS TOWED TO THE DEALER. THE TECHNICIAN STATED THAT THE ALTERNATOR FAILED. THE CONTACT WAS MADE AWARE THAT THE VEHICLE WAS NOT COVERED UNDER NHTSA CAMPAIGN NUMBER: 14V634000 (ELECTRICAL SYSTEM) SINCE THE VEHICLE WAS EQUIPPED WITH A 5.7L ENGINE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 21,400.

NHTSA ODI #10725841

21,400 miles · Jun 16, 2015

EngineService BrakesFire

TL* THE CONTACT OWNS A 2011 DODGE CHALLENGER. WHILE DRIVING APPROXIMATELY 5-10 MPH, THE CONTACT NOTICED A BURNING ODOR AND THE ABS AND OIL WARNING LIGHTS ILLUMINATED. THE VEHICLE STALLED AND WAS NOT ABLE TO RESTART. THE VEHICLE WAS TOWED TO THE DEALER, BUT WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 21,4…

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NHTSA ODI #10725646

47,074 miles · Jan 5, 2015

Electrical SystemEngine

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DRIVING AT APPROXIMATELY 60MPH, THE ABS AND TRACTION LIGHTS CAME ON AT FIRST. ATTEMPTING TO GET HOME WITH THE VEHICLE WHEN ALL THE SUDDEN EVERYTHING STARTED SHUTTING DOWN; FIRST THE RADIO THEN THE DIFFERENT SYSTEMS ALL THE LIGHTS IN THE DASH BEGAN TO BLINK AND THEN WENT OUT. THE VEHICLE THEN COMPLETELY DIED; WHEN I NOTICED THE ISSUES I SWITCHED THE TRANSMISSION INTO NEUTRAL SO I COULD GET TO THE SIDE OF THE ROAD. I THEN HAD TO HAVE THE VEHICLE TOWED TO THE NEAREST DEALERSHIP. THE DEALER SHIP THEN TOOK 5 DAYS TO REPAIR SAID VEHICLE AS THE ALTERNATOR NEEDED WAS ON "BACKORDER". DUE TO THE FACT IT IS "A 3 HOUR REPAIR" PER THE WARRANTY A RENTAL CAR WAS NOT COVERED AND I WAS WITHOUT A VEHICLE FOR 5 DAYS. AND THOUGH THE VEHICLE HAD LESS THAN 50,000 MILES ON IT, IT WAS NOT COVERED BY THE MANUFACTURER WARRANTY; THANK GOD I PURCHASED THE EXTENDED WARRANTY. *TR

NHTSA ODI #10670188

49,000 miles · Dec 31, 2014

Electronic Stability Control (esc)EngineSteering

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I NEARLY WAS KILLED TODAY GETTING OFF HIGHWAY I-10 WHEN MY ENTIRE CAR SHUT DOWN. THE ENTIRE ELECTRICAL SYSTEM FAILED ABS, ESP, BAS, TRACTION LIGHTING ALL CAME ON - POWER STEERING DID NOT WORK- COMPLETELY SHUT DOWN WITH NO RECOURSE FINALLY COASTED TO PARK IN THE GARAGE CLOSE BY ON A DOWNHILL EXIT. I WAS FORTUNATE ENOUGH TO FIND AN EXIT TO THE PARKING LOT AND LITERALLY COASTED IN WITHOUT POWER STEERING OR ANY ELECTRICAL AND WAS AFRAID THE BRAKES WOULD NOT WORK TO EVEN STOP THE CAR. FORTUNATELY, IT COASTED AND STOPPED. PREVIOUSLY RECEIVED AN ALTERNATOR RECALL NOTICE FROM DODGE, BUT WAS TOLD THEY DID NOT HAVE ANY PARTS AVAILABLE TO FIX THIS VEHICLE. I HAD NO IDEA THAT MEANT MY ENTIRE CAR WOULD DIE ON THE HIGHWAY WITHOUT THE ABILITY TO EVEN STEER. *JS

NHTSA ODI #10669323

65,000 miles · Oct 21, 2014

Electrical SystemEngineExterior Lighting

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I OWN A 2011 DODGE CHALLENGER THAT WAS PURCHASED BRAND NEW OFF THE SHOW ROOM FLOOR IN THE LATTER PART OF 2011. I WAS LEAVING WORK ON THIS SUNDAY AND PULLED OUT OF THE PARKING LOT TO MERGE INTO TRAFFIC. WITHIN FIVE OR TEN MINUTES OF HAVING PULLED OFF MY CAR BEGAN A COMPLETE SHUT DOWN. THE WINDOWS WOULDN'T GO UP OR DOWN. THE POWER STEERING WENT OUT. THE RADIO AND LIGHTS ALL WENT BLACK. ALSO THE CAR CUT OFF COMPLETELY WHILE I WAS DRIVING!!!! I NEARLY CAUSED A MAJOR ACCIDENT IN THE MIDDLE OF A BUSY INTERSECTION. LUCKILY THE SURROUNDING DRIVERS WERE PAYING ATTENTION AND DID NOT HIT ME. IM MORTIFIED WITH THIS EXPERIENCE. MY CAR IS ONLY THREE YEARS OLD AND I'M CURRENTLY PAYING A NEARLY $600 NOTE ON IT. IT'S SO UNACCEPTABLE AND TO MAKE MATTERS WORSE, WHEN I CONTACTED DODGE, THE ONLY RECOURSE THEY ADVISED WAS TO CONTACT THE DEALER AND HAVE THE REPAIRS DONE AND APPLY FOR REIMBURSEMENT WHENEVER THE RECALL IS ANNOUNCED. WHEN I ASKED IF THEY WOULD BE WILLING TO HAVE A DEALER COME PICK UP THE CAR AS IT IS CURRENTLY INOPERABLE, THEY SAID THAT THE TOWING FEES WOULD BE MY RESPONSIBILITY AS WELL & PROBABLY WOULD NOT BE REIMBURSED. THE CUSTOMER SERVICE REPS BOTH TIMES I CALLED WERE OF LITTLE OR NO HELP AT ALL AND SEEMED GENUINELY UNCONCERNED THAT MY VEHICLE CUT OFF WHILE I WAS DRIVING!!! MY CALL TO THE DEALERSHIP WAS THE SAME. I HAVE HAD ALL MAINTENANCE FOR MY VEHICLE PERFORMED AT THE DODGE DEALERSHIP FROM OIL CHANGES TO TIRE REPLACEMENT. I'VE BEEN A LOYAL CUSTOMER & EVEN DONE REFERRALS FOR THE DEALERSHIP. THIS IS BY FAR THE WORST EXPERIENCE I'VE HAD WITH ANY CAR COMPANY AND I AM SO DISAPPOINTED. I WILL NEVER PURCHASE ANYTHING ELSE FROM THE CHRYSLER BRAND. I NOTICED THE RECALL EVEN INCLUDES THE CARS THEY ARE CURRENTLY SELLING ON THE LOTS (2014 MODELS) SO PLEASE BEWARE AND WARN ANYONE YOU KNOW TO STAY AWAY FROM CHRYSLER & ITS PRODUCTS. THEY DON'T CARE ABOUT YOU OR YOUR SAFETY. *TR

NHTSA ODI #10649079

100,000 miles · Oct 3, 2014

Electrical SystemEngine

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2011 DODGE CHALLENGER - I WAS DRIVING AND THEN ALL THESE DIFFRENT LIGHTS STARTED TO FLAH ABS, ESP, AND BRAKE ASSIST. THEN THE EMERGENCY BRAKE AND SEAT BELT LIGHTS STARTED FLASHING. MY LOCKED UP I WASNT EVEN ABALE TO TURN THE WHEEL!! THEN THE CAR JUST SHUT DONE, I HAD THE CAR TOWED TO MY HOUSE .(MORE MONEY SPENT) THIS WAS TWO DAYS AGO, THE SAME THING HAPPEND 03/2013 I HAD THE ALTERNATOR FIXED $800.00 THIS SHOULD NOT GO OUT AFTER 1 YEAR IN A 2011! THIS HAS TO BE A DEFFECT! I WILL NEVER PURCHASE ANOTHER DODGE! I SHOULD NOT HAVE TO REPAY TO GET THIS ALTERNATOR FIXED AGAIN THIS WILL BE THE 3RD ALTERNATOR IN 3 YEARS.. VERY UNHAPPY WITH DODGE> SO THEN I TOWED MY CARE 25MILES TO THE DEALER SHIP( $160.00) TO ADVISED ME ITS MY ALTERNATOR AND MY WARRANTY EXPIRED 03/2014 VERY UPSET AT THIS POINT AND $200 TO TELL WHAT I ALREADY NEW!!! I CALLED DODGE CUSTOMER SERVICE WAS NOT OFFER ANY ASSISTANT'S WITH PAYING FOR THIS I WAS ADVISED TO WAIT FOR A RECALL! WHAT THE HELL VERY POOR CUSTOMER SERVICE!! I WILL NOW WRITE TO THERE CORPORATE OFFICE AT CHRYSLER GROUP CUSTOMER CARE PO. BOX 21-8004 AUBURN MICHIGAN 48321-8004! THIS TYPE OF BUSINESS PRACTICE IS UNACCEPTABLE. *TR

NHTSA ODI #10641272

44,000 miles · Aug 23, 2014

Electrical SystemEngineSteering

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I WAS DRIVING MY CAR ON 7/19/2014 AS NORMAL AND I NOTICED SEVERAL DRIVERS FROM OTHER CARS POINTING AT MY HOOD. THERE WERE NO DASH INDICATOR LIGHTS ON . I PULLED OVER AND THE CAR POWERED DOWN AND SMOKE STARTED BILLOWING THROUGH THE VENTS AND FROM UNDER THE HOOD. I RELEASED THE HOOD AND NOTICED THE ALTERNATOR SMOKING HEAVILY AND MELTING, I THOUGHT IT WAS ABOUT TO CATCH FIRE. I HAD THE CAR TOWED TO THE DEALERSHIP AND WAS TOLD 4 DAYS LATER THE ALTERNATOR HAD TO BE REPLACED, NOT COVERED UNDER WARRANTY; DUE TO IT BEING CONSIDERED AN ACCESSORY; WOULD COST 723.00 TO REPAIR. BEING THAT THE CAR ONLY HAS 44,000 MILES ON IT, I WAS VERY DISTURBED. MY CAR WAS READY IN ABOUT 4 DAYS WHICH I WENT AHEAD AND PAID FOR REPAIRS AS I NEED THE CAR FOR TRANSPORTATION AND EVEN AFTER I SAW THE COUNTLESS REPORTS OF SIMILAR INCIDENTS ON THE INTERNET AND WAS APPALLED THIS PART HAD NOT BEEN RECALLED. I FIGURED MOST CARS HAVE TO HAVE AT LEAST ONE MAJOR REPAIR SO I'M GOOD FOR AWHILE. WRONG! THE SAME WEEK THE CAR GOT OUT OF THE SHOP, I STARTED HEARING A CLICKING UNDER THE GEAR SHIFT AND THE ABS, ESP AND TRACTION CAME ON THE DASH. I CONTACTED THE DEALERSHIP TO MAKE AN APPOINTMENT TO BRING IT IN BUT IT ISN'T UNTIL A WEEK LATER. I WAS TOLD AS LONG AS THE LIGHT DOESN'T STEADILY REMAIN ON, I SHOULD BE FINE UNTIL MY APPOINTMENT DRIVING IT. TODAY I WAS RIDING ALONG ON A HIGHWAY AND THE CAR BEGIN TO LOSE POWER NOT ALLOWING ME TO ACCELERATE OR STEER, NOW THE MALFUNCTION LIGHT IS ON. DODGE REALLY NEEDS TO CONSIDER RECALLING THIS MODEL AS PROBLEMS START TO OCCUR AT 40,000 MILES FROM WHAT I HAVE READ AND CAN CAUSE SERIOUS SAFETY ISSUES BECAUSE IT STALLS WITH THE INDICATOR LIGHTS FOLLOWING LEAVING CONSUMERS WITH THE INABILITY TO STEER OR GET OUT OF THE DANGERS OF INCOMING TRAFFIC. *TR

NHTSA ODI #10627710

Official recalls

19V018000 · Air Bags:frontal:passenger Side:inflator Module

Jan 15, 2019

Chrysler (FCA US LLC) is recalling certain 2010 Dodge Ram 3500, Ram 4500/5500, 2010-2011 Dodge Dakota, 2010-2014 Dodge Challenger, 2010-2015 Dodge Challenger, Chrysler 300, and 2010-2016 Jeep Wrangler vehicles. Upon deployment of the driver's frontal air bag, excessive internal pressure may cause the inflator to explode.

Consequence & remedy

Consequence: In the event of a crash necessitating deployment of the passenger's frontal air bag, the inflator could explode with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.

Remedy: Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. The recall began February 4, 2019. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is V01.

18V021000 · Air Bags:frontal:passenger Side:inflator Module

Jan 9, 2018

Chrysler (FCA US LLC) is recalling certain 2009-2013 Jeep Wrangler, Chrysler 300, Dodge Challenger and Dodge Charger vehicles, and 2009-2011 Dodge Dakota vehicles 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, Chrysler is recalling certain 2009-2010 RAM 4500 Cab Chassis, RAM 5500 Cab Chassis, RAM 3500 Cab Chassis, Jeep Wrangler, Chrysler 300, Dodge Dakota, Dodge Challenger, and Dodge Charger vehicles 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." Chrysler is also recalling certain 2009 RAM 3500, RAM 2500, RAM 4500 Cab Chassis, RAM 5500 Cab Chassis, Dodge Durango, Chrysler Aspen, RAM 3500 Cab Chassis, Jeep Wrangler, Chrysler 300, Dodge Dakota, Dodge Challenger, and Dodge Charger vehicles 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. In the event of a crash necessitating deployment of the passenger frontal air bag, these passenger air bag inflator may explode due to propellant degradation occurring after long-term exposure to absolute humidity and 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: Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. The recall began February 28, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is U03.

17V435000 · Electrical System:alternator/generator/regulator

Jul 10, 2017

Chrysler (FCA US LLC) is recalling certain model year 2011-2014 Dodge Challenger, Dodge Charger, Chrysler 300, Dodge Durango, and 2012-2014 Jeep Grand Cherokee vehicles. The affected vehicles have electro-hydraulic power steering (EHPS) and are equipped with a 5.7L or a 3.6L engine and a 160, 180 or 220 amp alternator. In the affected vehicles, the alternator may suddenly fail.

Consequence & remedy

Consequence: If the alternator fails, the vehicle may stall without warning, increasing the risk of a crash. There is also the possibility that the alternator may short circuit, increasing the risk of a fire.

Remedy: Chrysler will notify owners, and dealers will inspect the alternator and depending on the part number, will replace the alternator, if necessary, free of charge. The recall began February 12, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is T36.

16V352000 · Air Bags:frontal:passenger Side:inflator Module

May 24, 2016

Chrysler (FCA US LLC) expanded the affected population to include 73,712 2005-2009 RAM 2500 trucks produced at the St. Louis North Assembly Plant. With this change, Chrysler is recalling certain model year 2004-2008 RAM 1500, 2005-2009 RAM 2500, 2006-2009 RAM 3500, 2007-2010 RAM 3500 Cab Chassis, 2008-2010 RAM 4500 and 5500 Cab Chassis, 2004-2009 Dodge Durango, 2007-2009 Chrysler Aspen, 2007-2012 Jeep Wrangler, 2008-2012 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2012 Chrysler 300, 2006-2012 Dodge Charger, 2005-2011 Dodge Dakota, and 2006-2009 Mitsubishi Raider vehicles originally sold, or ever registered, in AL, CA, FL, GA, HI, LA, MS, SC, TX, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Chrysler is also recalling 2004-2008 RAM 1500, 2005-2009 RAM 2500, 2006-2009 RAM 3500, 2007-2009 RAM 3500 Cab Chassis, 2008-2009 RAM 4500 and 5500 Cab Chassis, 2004-2009 Dodge Durango, 2007-2009 Chrysler Aspen, 2007-2009 Jeep Wrangler, 2008-2009 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2009 Chrysler 300, 2006-2009 Dodge Charger, 2005-2009 Dodge Dakota and 2006-2009 Mitsubishi Raider vehicles originally sold, or ever registered, in AZ, AR, DE, Washington D.C., IL, IN, KS, KY, MD, MO, NE, NV, NJ, NM, NC, OH, OK, PA, TN, VA, and WV, or "Zone B." Lastly, unless included in "Zone A" or "Zone B" above, Chrysler is recalling certain 2005-2008 RAM 2500, 2006-2008 RAM 3500, 2007-2008 RAM 3500 Cab Chassis, 2008 RAM 4500 and 5500 Cab Chassis, 2004-2008 Dodge Durango, 2007-2008 Chrysler Aspen, 2007-2008 Jeep Wrangler, 2008 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2008 Chrysler 300, 2006-2008 Dodge Charger, 2005-2008 Dodge Dakota, and 2006-2008 Mitsubishi Raider vehicles originally sold, or registered, in AK, CO, CT, ID, IA, ME, MA, MI, MN, MT, NH, NY, ND, OR, RI, SD, UT, VT, WA, WI, and WY.

Consequence & remedy

Consequence: These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. These inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling. An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.

Remedy: Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler will notify the Chrysler, Dodge, Jeep and RAM owners. Mitsubishi owners will be notified by their company. Dealers will replace the passenger frontal air bag inflator, free of charge. The recall began on March 27, 2017. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is S43. Note: This recall supersedes recall 14V-7700.

14V634000 · Electrical System:alternator/generator/regulator

Oct 8, 2014

Chrysler Group LLC (Chrysler) is recalling certain model year 2011-2014 Chrysler 300, Dodge Charger, Challenger, and Durango; and 2012-2014 Jeep Grand Cherokee vehicles manufactured April 22, 2010, to January 2, 2014, and equipped with a 3.6L engine and a 160 amp alternator. In the affected vehicles, the alternator may suddenly fail.

Consequence & remedy

Consequence: If the alternator fails, the vehicle may stall without warning, increasing the risk of a crash.

Remedy: Chrysler has notified owners, and dealers will replace the alternator, free of charge. The recall began on February 27, 2015. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is P60.

13V118000 · Air Bags

Apr 3, 2013

Chrysler Group LLC (Chrysler) is recalling certain model year 2011-2012 Chrysler 300, Dodge Challenger, and Dodge Charger vehicles manufactured April 11, 2011, through December 14, 2011. The affected vehicles may have improperly sized terminal crimps on the seat side-airbag wiring harness which may cause the seat side-airbags to malfunction and illuminate the airbag warning light.

Consequence & remedy

Consequence: In the event of a crash necessitating airbag deployment the airbags may not operate as designed, increasing the risk of injury.

Remedy: Chrysler will notify owners, and dealers will replace both driver and passenger seat airbag wiring harnesses, free of charge. The recall began on April 22, 2013. Owners may contact Chrysler at 1-800-247-9753. Chrysler's recall campaign number is N07.

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

EA21002 · 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

Air Bags:frontal:passenger Side:inflator Module