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2016 Dodge Charger

Owner reports · Recalls · Investigations

Limited comparison data

There is not enough comparable history to draw a useful model-year comparison.

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When problems were reported

Mileage at the reported incident

107 reports with mileage · 75 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.

  • Structure. Review the 53 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 25 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 25 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

7 crash reports2 fire reports8 injury reports

Structure complaints

53 reports
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34,000 miles · Jun 18, 2020
Structure

TL* THE CONTACT OWNS A 2016 DODGE CHARGER. THE CONTACT STATED THAT THE INNER AND OUTER DOOR PANELS WERE DETACHED FROM THE DOOR FRAME. THE CONTACT STATED THAT THE FAILURE CAUSED THE MIS ALIGNMENT OF THE DOOR LOCK WHICH MADE IT DIFFICULT TO ACCESS THE DOOR LOCK/UNLOCK BUTTON WHILE ATTEMPTING TO UNLOCK THE DOOR. RUSSELL WESTBROOK C…

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TL* THE CONTACT OWNS A 2016 DODGE CHARGER. THE CONTACT STATED THAT THE INNER AND OUTER DOOR PANELS WERE DETACHED FROM THE DOOR FRAME. THE CONTACT STATED THAT THE FAILURE CAUSED THE MIS ALIGNMENT OF THE DOOR LOCK WHICH MADE IT DIFFICULT TO ACCESS THE DOOR LOCK/UNLOCK BUTTON WHILE ATTEMPTING TO UNLOCK THE DOOR. RUSSELL WESTBROOK CHRYSLER DODGE JEEP RAM OF VAN NUYS (6110 VAN NUYS BLVD, VAN NUYS, CA 91401, 818-646-2364) WAS CONTACTED AND INFORMED OF THE FAILURE. THE CONTACT WAS REFERRED TO THE MANUFACTURER FOR ASSISTANCE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE CONTACT WAS REFERRED TO THE DEALER TO HAVE THE VEHICLE INSPECTED HOWEVER, THE DEALER DECLINED TO SCHEDULE AN APPOINTMENT TO HAVE THE VEHICLE INSPECTED. THE APPROXIMATE FAILURE MILEAGE WAS 34,000.

NHTSA ODI #11329611

50,000 miles · May 28, 2020
Structure

TL* THE CONTACT OWNS A 2016 DODGE CHARGER. THE CONTACT STATED THAT THAT THE DOOR PANELS ON BOTH THE DRIVER AND PASSENGER SIDE DOORS WERE WARPED, LEAVING A SPACE BETWEEN THE DOOR FRAME AND THE DOOR PANEL. NAPLETON'S NORTHLAKE CHRYSLER DODGE JEEP RAM (3701 NORTHLAKE BLVD, LAKE PARK, FL 33403) WAS CONTACTED AND NOTIFIED OF THE FAIL…

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TL* THE CONTACT OWNS A 2016 DODGE CHARGER. THE CONTACT STATED THAT THAT THE DOOR PANELS ON BOTH THE DRIVER AND PASSENGER SIDE DOORS WERE WARPED, LEAVING A SPACE BETWEEN THE DOOR FRAME AND THE DOOR PANEL. NAPLETON'S NORTHLAKE CHRYSLER DODGE JEEP RAM (3701 NORTHLAKE BLVD, LAKE PARK, FL 33403) WAS CONTACTED AND NOTIFIED OF THE FAILURE. THE CONTACT WAS REFERRED TO THE MANUFACTURER FOR ASSISTANCE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 50,000.

NHTSA ODI #11326412

6,000 miles · May 11, 2020
Structure

TL* THE CONTACT OWNS A 2016 DODGE CHARGER. THE CONTACT STATED THAT THE DRIVER'S DOOR AND PASSENGER'S SIDE FRONT DOOR PANELS DETACHED FROM THE DOORS FRAME. THE VEHICLE WAS NOT TAKEN TO THE DEALER TO HAVE THE DOORS INSPECTED. THE MANUFACTURER WAS CONTACTED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 6,000.

NHTSA ODI #11324179

Mileage unknown · May 8, 2020
Structure

TL* THE CONTACT OWNS A 2016 DODGE CHARGER. THE CONTACT STATED THE FRONT DRIVER AND PASSENGER INTERIOR WINDOWS PANEL PLASTIC SHRUNK AND DETACHED FROM THE FRAME. THE VEHICLE WAS TAKEN TO CENTRAL FLORIDA CHRYSLER DODGE JEEP RAM LOCATED AT 8675 COMMODITY CIR, ORLANDO, FL 32819, 321-445-8017, BUT WAS NOT DIAGNOSED NOR REPAIRED. THE …

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TL* THE CONTACT OWNS A 2016 DODGE CHARGER. THE CONTACT STATED THE FRONT DRIVER AND PASSENGER INTERIOR WINDOWS PANEL PLASTIC SHRUNK AND DETACHED FROM THE FRAME. THE VEHICLE WAS TAKEN TO CENTRAL FLORIDA CHRYSLER DODGE JEEP RAM LOCATED AT 8675 COMMODITY CIR, ORLANDO, FL 32819, 321-445-8017, BUT WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS CONTACTED AND REFERRED THE CONTACT TO THE LOCAL DEALER. THE FAILURE MILEAGE WAS UNKNOWN. INVALID VIN. *BF

NHTSA ODI #11323879

Mileage unknown · Apr 28, 2020
Structure

IN A COUPLE YEAR SPAN OF DODGE CHARGERS, THE PANELS ON THE DOORS SEPARATE FROM THE PLASTIC UNDERNEATH CAUSING IT TO LIFT UP WHERE THE WINDOW GOES INTO THE DOOR. ON MINE SPECIFICALLY IT'S THE DRIVERS SIDE PANEL AND THE FRONT PASSENGER SIDE PANEL. I HAVE SEEN PICTURES ON FORUMS FOR DODGE CHARGERS WHERE IT'S ALL OF THE DOORS WITH T…

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IN A COUPLE YEAR SPAN OF DODGE CHARGERS, THE PANELS ON THE DOORS SEPARATE FROM THE PLASTIC UNDERNEATH CAUSING IT TO LIFT UP WHERE THE WINDOW GOES INTO THE DOOR. ON MINE SPECIFICALLY IT'S THE DRIVERS SIDE PANEL AND THE FRONT PASSENGER SIDE PANEL. I HAVE SEEN PICTURES ON FORUMS FOR DODGE CHARGERS WHERE IT'S ALL OF THE DOORS WITH THIS ISSUE. THIS IS CAUSED BY NO FAULT OF THE OWNER BUT CLEARLY SOMEWHERE IN THE MANUFACTURING OF THE VEHICLE EITHER PARTS OR MATERIALS WEREN'T MADE PROPERLY. THE COST TO FIX THIS ON MY OWN IS AROUND $700 PER DOOR PANEL, SO $1,400 FOR BOTH.

NHTSA ODI #11322484

70,000 miles · Mar 20, 2020
EngineStructureUnknown Or Other

I WAS HEADED TO WORK YESTERDAY MORNING AND BEFORE I GOT TO WORK I HEARD A LOUD NOICE UNDER THE HOOD AND SMOKE STARTING ROLLING OUT OF UNDER THE HOOD. I PULLED OVER TO THE CLOSEST INTERSECTION TO GET OFF HIGHWAY AND DISCOVERED OIL ALL OVER THE CAR AND ALL UNDER THE CAR. I CONTACTED MY DEALERSHIP THAT I JUST BOUGHT THE CAR THROUGH…

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I WAS HEADED TO WORK YESTERDAY MORNING AND BEFORE I GOT TO WORK I HEARD A LOUD NOICE UNDER THE HOOD AND SMOKE STARTING ROLLING OUT OF UNDER THE HOOD. I PULLED OVER TO THE CLOSEST INTERSECTION TO GET OFF HIGHWAY AND DISCOVERED OIL ALL OVER THE CAR AND ALL UNDER THE CAR. I CONTACTED MY DEALERSHIP THAT I JUST BOUGHT THE CAR THROUGH (HAVEN'T EVEN MADE THE FIRST PAYMENT) AND THEY TOWED IT BACK TO THE DEALERSHIP. FURTHER INSPECTION THEY SAID THE DESIGN OF THE CAR HOW IT PULLS AIR THROUGH THE FENDER IT SUCKED WATER UP FROM DRIVING DOWN THE HIGHWAY AND HYDRO LOCKED THE MOTOR. I DO ZERO FIRST ROADS ON MY VEHICLES SO IT'S DEFINITELY NOT RIGHT FOR THIS TO HAPPEN DRIVING DOWN A HIGHWAY AND THROW A ROD THROUGH THE MOTOR. MY EXTENDED WARRANTY WON'T COVER IT NOR WILL MY INSURANCE. IT'S A BRAND NEW CAR. I NEED HELP!!

NHTSA ODI #11318777

40,000 miles · Feb 24, 2020
StructureUnknown Or Other

THE VEHICLE WAS KEPT PARKED IN A 2 CAR RESIDENTIAL GARAGE. THE DRIVER'S SIDE INTERIOR DOOR PANEL BEGAN TO PEEL UP. THE PANEL IS BREAKING AWAY FROM THE DOOR MAKING WINDOW USE, THEFT SAFETY AND CLOSING THE DOOR HAZARDOUS.

NHTSA ODI #11311028

55,000 miles · Jan 30, 2020
Structure

TL* THE CONTACT OWNS A 2016 DODGE CHARGER. THE CONTACT STATED THAT THE FRONT DRIVER SIDE AND FRONT PASSENGER SIDE INTERIOR DOOR PANELS WARPED AND WAS NOT SECURED TO THE DOOR FRAME. THE VEHICLE WAS TAKEN TO THE LOCAL DEALER SUMTER DODGE (2662 BROAD ST. SUMTER SC) WHO INDICATED THAT THE INTERIOR DOOR PANELS NEEDED TO BE REPLACED. …

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TL* THE CONTACT OWNS A 2016 DODGE CHARGER. THE CONTACT STATED THAT THE FRONT DRIVER SIDE AND FRONT PASSENGER SIDE INTERIOR DOOR PANELS WARPED AND WAS NOT SECURED TO THE DOOR FRAME. THE VEHICLE WAS TAKEN TO THE LOCAL DEALER SUMTER DODGE (2662 BROAD ST. SUMTER SC) WHO INDICATED THAT THE INTERIOR DOOR PANELS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 55,000. THE VIN WAS NOT AVAILABLE.

NHTSA ODI #11302991

46,000 miles · Jan 8, 2020
Structure

TL* THE CONTACT OWNS A 2016 DODGE CHARGER. THE CONTACT STATED THAT THE DRIVER AND PASSENGER'S SIDE DOOR PANELS SEPARATED FROM THE INNER DOOR FRAME. LAKELAND CHRYSLER DODGE JEEP LOCATED AT 2875 MALL HILL DR, LAKELAND, FL 33810, (888)687-2501, WAS CONTACTED BY PHONE AND INFORMED OF THE FAILURE. THE CONTACT WAS INFORMED BY THE SERV…

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TL* THE CONTACT OWNS A 2016 DODGE CHARGER. THE CONTACT STATED THAT THE DRIVER AND PASSENGER'S SIDE DOOR PANELS SEPARATED FROM THE INNER DOOR FRAME. LAKELAND CHRYSLER DODGE JEEP LOCATED AT 2875 MALL HILL DR, LAKELAND, FL 33810, (888)687-2501, WAS CONTACTED BY PHONE AND INFORMED OF THE FAILURE. THE CONTACT WAS INFORMED BY THE SERVICE MANAGER THAT THE VEHICLE WAS NOT SUBJECTED TO A RECALL. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 46,000.

NHTSA ODI #11298013

8,000 miles · Jan 6, 2020
Structure

THERE IS A POPPING OR CRACKING STRUCTURAL DEFECT SOUND THAT IS COMING FROM THE DRIVER'S SIDE DOOR OR PILLAR BETWEEN FRONT AND REAR DOOR. THIS IS WHILE DRIVING NORMALLY NOT REALLY ON BUMPS BUT WHEN YOU ARE ON JUST A REGULAR ROAD. MORE WHEN THE ROAD IS UNEVEN OR WHEN THE BODY HAS SOME TWIST FROM UNEVEN PAVEMENT. THE FIRST RIDE WAS…

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THERE IS A POPPING OR CRACKING STRUCTURAL DEFECT SOUND THAT IS COMING FROM THE DRIVER'S SIDE DOOR OR PILLAR BETWEEN FRONT AND REAR DOOR. THIS IS WHILE DRIVING NORMALLY NOT REALLY ON BUMPS BUT WHEN YOU ARE ON JUST A REGULAR ROAD. MORE WHEN THE ROAD IS UNEVEN OR WHEN THE BODY HAS SOME TWIST FROM UNEVEN PAVEMENT. THE FIRST RIDE WAS WITH WITH CHRISTIAN THE SERVICE ADVISOR AT LUMS DRIVING THE VEHICLE AND HEARD THE SOUND. HE MADE THE FIRST APPOINTMENT TO LOOK AT IT. 7/8/19 VEHICLE STILL UNDER FULL WARRANTY. LUMS AUTO CENTER IN WARRENTON OR, TRIED TO DO A BLIND REPAIR BY REPLACING THE SEATBELT TENSIONER. IT DID SEEM TO CALM IT DOWN BUT DID NOT WORK AND WE HAVE TAKEN IT BACK, A SECOND TIME AND THEY HAVE STATED THEY COULD NOT DUPLICATE THE SOUND. BUT THEY DID OPEN THE DOOR AND CHECKED IT. 11/1/19 AND YET AGAIN WE ARE GOING TO TAKE IT BACK AGAIN AFTER CHRISTIAN THE SAME SERVICE ADVISOR THAT WE HAVE BEEN WORKING WITH DROVE WITH ME AND HEARD THE SOUND AGAIN. 01/3/20 NOW THE FULL WARRANTY IS OVER. THE PROBLEM COMES AND GOES AND HE STATES THAT IT WILL BE HARD TO FIND?? WE DO NOT BELIEVE THAT THEY ARE CAPABLE OF FIXING WHAT REALLY SEEMS TO BE A STRUCTURAL PROBLEM...

NHTSA ODI #11297497

Official recalls

5

18V332000 · Electrical System:software; Electrical System:wiring; Vehicle Speed Control:cruise Control

May 17, 2018

Chrysler (FCA US LLC) is recalling certain 2014-2018 Dodge Journey, Charger and Durango, RAM 2500, 3500, 3500 Cab Chassis (more than 10,000lb), 4500 Cab Chassis and 5500 Cab Chassis, Jeep Cherokee and Grand Cherokee and Chrysler 300, 2014-2019 RAM 1500, 2015-2018 Dodge Challenger, 2015-2017 Chrysler 200, 2016-2018 RAM 3500 Cab Chassis (less than 10,000 lb), 2017-2018 Chrysler Pacifica and 2018 Jeep Wrangler vehicles. These vehicles are being recalled to address a defect that could prevent the cruise control system from disengaging. If, when using cruise control, there is a short circuit within the vehicle's wiring, the driver may not be able to shut off the cruise control either by depressing the brake pedal or manually turning the system off once it has been engaged, resulting in either the vehicle maintaining its current speed or possibly accelerating.

Consequence & remedy

Consequence: If the vehicle maintains its speed or accelerates despite attempts to deactivate the cruise control, there would be an increased risk of a crash.

Remedy: Chrysler will notify owners, and dealers will inspect the software, and perform a software flash on the engine or powertrain control module, free of charge. The recall began June 4, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Note: Owners are advised to stop using cruise control until the software update has been performed. In the event that cruise control cannot be disengaged while driving, owners should firmly and steadily apply the brakes and shift the transmission to neutral, placing the vehicle in park once it has stopped.

Additional source detail variants (3)

Electrical System:software

Chrysler (FCA US LLC) is recalling certain 2014-2018 Dodge Journey, Charger and Durango, RAM 2500, 3500, 3500 Cab Chassis (more than 10,000lb), 4500 Cab Chassis and 5500 Cab Chassis, Jeep Cherokee and Grand Cherokee and Chrysler 300, 2014-2019 RAM 1500, 2015-2018 Dodge Challenger, 2015-2017 Chrysler 200, 2016-2018 RAM 3500 Cab Chassis (less than 10,000 lb), 2017-2018 Chrysler Pacifica and 2018 Jeep Wrangler vehicles. These vehicles are being recalled to address a defect that could prevent the cruise control system from disengaging. If, when using cruise control, there is a short circuit within the vehicle's wiring, the driver may not be able to shut off the cruise control either by depressing the brake pedal or manually turning the system off once it has been engaged, resulting in either the vehicle maintaining its current speed or possibly accelerating.

Consequence: If the vehicle maintains its speed or accelerates despite attempts to deactivate the cruise control, there would be an increased risk of a crash.

Remedy: Chrysler will notify owners, and dealers will inspect the software, and perform a software flash on the engine or powertrain control module, free of charge. The recall began June 4, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Note: Owners are advised to stop using cruise control until the software update has been performed. In the event that cruise control cannot be disengaged while driving, owners should firmly and steadily apply the brakes and shift the transmission to neutral, placing the vehicle in park once it has stopped.

Vehicle Speed Control:cruise Control

Chrysler (FCA US LLC) is recalling certain 2014-2018 Dodge Journey, Charger and Durango, RAM 2500, 3500, 3500 Cab Chassis (more than 10,000lb), 4500 Cab Chassis and 5500 Cab Chassis, Jeep Cherokee and Grand Cherokee and Chrysler 300, 2014-2019 RAM 1500, 2015-2018 Dodge Challenger, 2015-2017 Chrysler 200, 2016-2018 RAM 3500 Cab Chassis (less than 10,000 lb), 2017-2018 Chrysler Pacifica and 2018 Jeep Wrangler vehicles. These vehicles are being recalled to address a defect that could prevent the cruise control system from disengaging. If, when using cruise control, there is a short circuit within the vehicle's wiring, the driver may not be able to shut off the cruise control either by depressing the brake pedal or manually turning the system off once it has been engaged, resulting in either the vehicle maintaining its current speed or possibly accelerating.

Consequence: If the vehicle maintains its speed or accelerates despite attempts to deactivate the cruise control, there would be an increased risk of a crash.

Remedy: Chrysler will notify owners, and dealers will inspect the software, and perform a software flash on the engine or powertrain control module, free of charge. The recall began June 4, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Note: Owners are advised to stop using cruise control until the software update has been performed. In the event that cruise control cannot be disengaged while driving, owners should firmly and steadily apply the brakes and shift the transmission to neutral, placing the vehicle in park once it has stopped.

Electrical System:wiring

Chrysler (FCA US LLC) is recalling certain 2014-2018 Dodge Journey, Charger and Durango, RAM 2500, 3500, 3500 Cab Chassis (more than 10,000lb), 4500 Cab Chassis and 5500 Cab Chassis, Jeep Cherokee and Grand Cherokee and Chrysler 300, 2014-2019 RAM 1500, 2015-2018 Dodge Challenger, 2015-2017 Chrysler 200, 2016-2018 RAM 3500 Cab Chassis (less than 10,000 lb), 2017-2018 Chrysler Pacifica and 2018 Jeep Wrangler vehicles. These vehicles are being recalled to address a defect that could prevent the cruise control system from disengaging. If, when using cruise control, there is a short circuit within the vehicle's wiring, the driver may not be able to shut off the cruise control either by depressing the brake pedal or manually turning the system off once it has been engaged, resulting in either the vehicle maintaining its current speed or possibly accelerating.

Consequence: If the vehicle maintains its speed or accelerates despite attempts to deactivate the cruise control, there would be an increased risk of a crash.

Remedy: Chrysler will notify owners, and dealers will inspect the software, and perform a software flash on the engine or powertrain control module, free of charge. The recall began June 4, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Note: Owners are advised to stop using cruise control until the software update has been performed. In the event that cruise control cannot be disengaged while driving, owners should firmly and steadily apply the brakes and shift the transmission to neutral, placing the vehicle in park once it has stopped.

18V281000 · Power Train:driveline:driveshaft

May 1, 2018

Chrysler (FCA US LLC) is recalling certain 2015-2018 Dodge Charger pursuit police vehicles equipped with all-wheel drive and V8 engines. The front driveshaft universal joint may seize or fracture causing the shaft to detach from the vehicle.

Consequence & remedy

Consequence: If the front driveshaft detaches from the vehicle it may become a road hazard, increasing the risk of a crash.

Remedy: Chrysler will notify owners, and dealers will replace the front driveshaft, free of charge. The recall began June 27, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is U37.

17V824000 · Equipment

Dec 21, 2017

Chrysler (FCA US LLC) is recalling various Dodge, Chrysler, and RAM vehicles equipped with Kidde Plastic-Handle or Push Button 'Pindicator' Fire Extinguishers. A list of the affected trailer models is available at: https://static.nhtsa.gov/odi/rcl/2017/RMISC-17V824-0103.pdf. These extinguishers may become clogged, preventing the extinguisher from discharging as expected or requiring excessive force to activate the extinguisher. Additionally, in certain models, the nozzle may detach from the valve assembly with enough force that it could cause injury and also render the product inoperable. For a full list of the affected fire extinguisher models visit: https://static.nhtsa.gov/odi/rcl/2017/RMISC-17E062-5427.pdf

Consequence & remedy

Consequence: If the fire extinguisher does not function properly, it can increase the risk of injury in the event of a fire.

Remedy: Chrysler will notify owners instructing them to contact Kidde for a replacement fire extinguisher, free of charge. The recall began February 14, 2018. Owners may contact Chrysler customer service at 1-800-853-1403 or Kidde customer service service toll-free at 1-855-262-3540, or online at www.kidde.com and click on "Product Safety Recall" for more information. Chrysler's number for this recall is T82.

17V097000 · Power Train:axle Assembly:axle Shaft

Feb 14, 2017

Chrysler (FCA US LLC) is recalling certain 2014-2017 Dodge Charger and Chrysler 300 vehicles equipped with all-wheel drive (AWD). The front driveshaft bolts may loosen and allow the front driveshaft to disconnect, potentially causing a loss of motive power.

Consequence & remedy

Consequence: A loss of motive power can increase the risk of a crash.

Remedy: Chrysler will notify owners, and dealers will replace all eight front driveshaft bolts, free of charge. The recall began April 7, 2017. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is T03.

16V043000 · Structure

Jan 28, 2016

FCA US LLC (Chrysler) is recalling certain model year 2011-2016 Dodge Charger vehicles manufactured August 23, 2010, to January 7, 2016. When an affected vehicle is lifted using the supplied tire jack without chocking the wheels, the vehicle's body-side sill may give causing the tire jack to fail and the car to fall.

Consequence & remedy

Consequence: A car that falls unexpectedly increases the risk of injury.

Remedy: Chrysler will notify owners, and dealers will provide owners with wheel chocks and instructions for their use, free of charge. The recall began on March 21, 2016. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is S03.

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

1

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

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.