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2009 GMC Sierra 1500

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2009 GMC Sierra 1500 do not stand out strongly from the model-year median of 181.

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When problems were reported

Mileage at the reported incident

117 reports with mileage · 117 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 122 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 20 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Structure. Review the 20 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

4 crash reports4 fire reports3 injury reports

Engine complaints

13 reports
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56,000 miles · Aug 18, 2025
Engine

The contact owns a 2009 GMC Sierra 1500. The contact stated that while driving at highway speeds, the vehicle hesitated while depressing the accelerator pedal. The traction control and check engine warning lights were illuminated. The contact used a code reader and discovered a misfire in cylinder #4, and performed a compression…

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The contact owns a 2009 GMC Sierra 1500. The contact stated that while driving at highway speeds, the vehicle hesitated while depressing the accelerator pedal. The traction control and check engine warning lights were illuminated. The contact used a code reader and discovered a misfire in cylinder #4, and performed a compression test, which verified that cylinder #4 was failing to maintain compression. The vehicle was taken to a dealer where it was discovered that there was a failure with the lifter in cylinder #4. The vehicle was not repaired and remained with the dealer for additional diagnostic tests. The manufacturer was notified of the failure but offered no assistance. The contact was referred to the NHTSA Hotline to report the failure. The failure mileage was approximately 56,000.

NHTSA ODI #11681424

Mileage unknown · Jun 18, 2025
Engine

To Whom It May Concern, I am submitting this report regarding repeated engine and valve lifter failures in my 2009 GMC Sierra 1500 with a 5.3L V8 engine, VIN: [XXX] . 1. Component/System Malfunctioned: Both the original engine and a replacement engine—professionally installed by a Chevrolet dealership—experienced valve lifter …

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To Whom It May Concern, I am submitting this report regarding repeated engine and valve lifter failures in my 2009 GMC Sierra 1500 with a 5.3L V8 engine, VIN: [XXX] . 1. Component/System Malfunctioned: Both the original engine and a replacement engine—professionally installed by a Chevrolet dealership—experienced valve lifter failure related to the Active Fuel Management (AFM) system. The most recent failure was sudden and unexpected. The engine may be available for inspection upon request. 2. Safety Risk: Engine failure puts driver and passenger safety at serious risk, particularly if the vehicle loses power unexpectedly while in motion. In both instances, the failure created unsafe driving conditions. 3. Reproduction/Confirmation: The issue was confirmed by a Chevrolet dealership during the initial engine failure and again more recently on the current engine, which is now exhibiting the same failure. 4. Inspection Status: The vehicle has been inspected by the same dealership that performed the original engine replacement. To my knowledge, it has not been inspected by GM corporate, police, or insurance representatives. 5. Warning Signs: There were no warning lamps, messages, or clear symptoms prior to the failure. The problem occurred without advance notice and did not provide an opportunity to address it before damage occurred. This is the second engine failure my truck has suffered from the same issue, even after dealership installation of a new motor. I urge the NHTSA to investigate whether this represents a broader defect in GM 5.3L AFM-equipped engines. It is unacceptable that repeated critical failures can occur in these engines with no warning and no resolution, even after following proper replacement procedures. Thank you for your attention. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI #11667844

103,000 miles · Apr 8, 2019
Electrical SystemEngineFuel/propulsion System

TL* THE CONTACT OWNS A 2009 GMC SIERRA 1500. THE CONTACT STATED THAT THE VEHICLE HESITATED AND STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO SERRA CHEVROLET CADILLAC BUICK GMC (189 STONEBRIDGE BLVD, JACKSON, TN 38305, (888) 380-6149) WHERE THEY REPLACED THE FUEL PUMP MODULE, CLEANED THE THROTTLE BODY, REPLACED THE FUEL PUMP …

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TL* THE CONTACT OWNS A 2009 GMC SIERRA 1500. THE CONTACT STATED THAT THE VEHICLE HESITATED AND STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO SERRA CHEVROLET CADILLAC BUICK GMC (189 STONEBRIDGE BLVD, JACKSON, TN 38305, (888) 380-6149) WHERE THEY REPLACED THE FUEL PUMP MODULE, CLEANED THE THROTTLE BODY, REPLACED THE FUEL PUMP SENDING UNIT, AND REPROGRAMMED THE MODULE. THE CONTACT STATED THAT THE ENGINE POWER WAS REDUCED DUE TO LACK OF COMMUNICATION WITH THE FUEL PUMP MODULE. SHORTLY AFTER THE REPAIR, ALL OF THE WARNING INDICATORS FLASHED, WHICH HAD NOT OCCURRED PRIOR TO THE REPAIR. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 103,000.

NHTSA ODI #11194576

47,540 miles · Sep 18, 2018
Electrical SystemEngine

TL* THE CONTACT OWNS A 2009 GMC SIERRA 1500. WHILE DRIVING 65 MPH, THE SPEEDOMETER AND THE TACHOMETER GAUGES FLUCTUATED UP AND DOWN, THE AIR BAG AND TRANSMISSION INDICATORS ILLUMINATED, AND THE ENGINE SEIZED. THE VEHICLE WAS NOT TAKEN TO A DEALER TO BE DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED AND INFORMED THE CONTACT…

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TL* THE CONTACT OWNS A 2009 GMC SIERRA 1500. WHILE DRIVING 65 MPH, THE SPEEDOMETER AND THE TACHOMETER GAUGES FLUCTUATED UP AND DOWN, THE AIR BAG AND TRANSMISSION INDICATORS ILLUMINATED, AND THE ENGINE SEIZED. THE VEHICLE WAS NOT TAKEN TO A DEALER TO BE DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED AND INFORMED THE CONTACT TO CALL A DEALER. THE FAILURE MILEAGE WAS APPROXIMATELY 47,540.

NHTSA ODI #11130208

129,000 miles · Oct 19, 2017
Engine

AT AROUND 100,000 MILES, THE CHECK ENGINE LIGHT WOULD COME ON AND INDICATE LOW OIL PRESSURE. CHANGING THE SENSOR OUT DID NOT EFFECT THE SITUATION. CHANGING THE OIL WOULD HELP BUT USUALLY ONLY FOR AROUND 3,500 MILES. THE ENGINE WAS LOSING OIL MORE THAN IT SHOULD. THEN AT AROUND 129,000 MILES, THE TRUCK STARTING SHAKING BECAUSE OF…

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AT AROUND 100,000 MILES, THE CHECK ENGINE LIGHT WOULD COME ON AND INDICATE LOW OIL PRESSURE. CHANGING THE SENSOR OUT DID NOT EFFECT THE SITUATION. CHANGING THE OIL WOULD HELP BUT USUALLY ONLY FOR AROUND 3,500 MILES. THE ENGINE WAS LOSING OIL MORE THAN IT SHOULD. THEN AT AROUND 129,000 MILES, THE TRUCK STARTING SHAKING BECAUSE OF THE ENGINE AND THE CHECK ENGINE LIGHT CAME ON. IT WAS DETERMINED TO BE A CYLINDER 7 MISFIRE. CHANGING THE COIL PACK, SPARK PLUG, AND SPARK PLUG WIRE DID NOTHING. IT WAS DETERMINED THAT THE ENGINE WAS IRREPARABLE AND NEEDED REPLACING. UPON RESEARCH, IT APPEARS THAT THIS IS A FAIRLY COMMON PROBLEM AMONG 2008-2012 GM ENGINES WITH THE AFM SYSTEM. GM SHOULD ABSOLUTELY ISSUE A RECALL AND REPAIR THESE DEFECTIVE ENGINES OR OTHERWISE REIMBURSE THE OWNERS FOR THE REPAIRS.

NHTSA ODI #11034520

184,000 miles · Apr 9, 2017
Engine

ACTIVE FUEL MANAGEMENT FAILURE NUMBER 4 CYLINDER. P0304 DTC. HAS A LOUD TICKING NOISE AND A MISS ON NUMBER 4 CYLINDER. THE TRUCK HAS BEEN MAINTAINED AND AS I RESEARCHED THE PROBLEM, IT APPEARS TO BE MORE LIKELY THAN NOT TO AFFECT THESE TRUCKS.

NHTSA ODI #10971531

80,000 miles · Mar 22, 2017
Engine

AT 80000 MY TRUCK IS GOING THROUGH 4 TO 6 QTS OF OIL BETWEEN OIL CHANGES. AS A MASTER TECHNICIAN THIS HAS GOT TO BE THE POOREST EXCUSE FOR ENGINEERING I HAVE EVER COME ACROSS WITH THIS AFM SYSTEM THEY HAVE. I KNOW SEVERAL PEOPLE THAT HAVE LOST AN ENGINE BY 100000 MILES. WITH TODAYS TECHNOLOGY THAT'S A BAD JOKE ON THE CONSUMER. …

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AT 80000 MY TRUCK IS GOING THROUGH 4 TO 6 QTS OF OIL BETWEEN OIL CHANGES. AS A MASTER TECHNICIAN THIS HAS GOT TO BE THE POOREST EXCUSE FOR ENGINEERING I HAVE EVER COME ACROSS WITH THIS AFM SYSTEM THEY HAVE. I KNOW SEVERAL PEOPLE THAT HAVE LOST AN ENGINE BY 100000 MILES. WITH TODAYS TECHNOLOGY THAT'S A BAD JOKE ON THE CONSUMER. WITH SHORTER INTERVALS AND SOME ADDITIVE'S I HAVE MANAGED TO GET TO 1 QT EVERY 1900 MILES AND THAT'S AS GOOD AS IT GETS.

NHTSA ODI #10967667

Mileage unknown · Nov 22, 2016
Electronic Stability Control (esc)EngineService Brakes

STABILITY CONTROL. THE STABILITRACK WARNING APPEARS. ALL OF THE GAUGES GO TO ZERO, THE POWER LOCKS ENGAGE AND DISENGAGE, THE ENGINE REVS AND THE DRIVER LOSES CONTROL OF THE TRUCK. THIS IS AN EXTREMELY DANGEROUS PROBLEM. THE DEALERSHIP CAN'T FIND ANYTHING WRONG BECAUSE NO CODES ARE SHOWING. THIS NEEDS TO BE A MAJOR RECALL. …

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STABILITY CONTROL. THE STABILITRACK WARNING APPEARS. ALL OF THE GAUGES GO TO ZERO, THE POWER LOCKS ENGAGE AND DISENGAGE, THE ENGINE REVS AND THE DRIVER LOSES CONTROL OF THE TRUCK. THIS IS AN EXTREMELY DANGEROUS PROBLEM. THE DEALERSHIP CAN'T FIND ANYTHING WRONG BECAUSE NO CODES ARE SHOWING. THIS NEEDS TO BE A MAJOR RECALL. IT'S A COMMON PROBLEM, GOOGLE IT AND SEE HOW MANY PEOPLE HAVE THE SAME ISSUE WITH NO RESOLUTION. FORCE GM TO ADDRESS AND RESOLVE THIS KNOWN ISSUE.

NHTSA ODI #10927513

Mileage unknown · Jul 18, 2016
Engine

LIFTER FAILURE! EXPENSIVE REPAIR! COMMON ISSUE ON AFM 5.3 V8 ENGINES. DRIVING DOWN HWY. JUST HAD HAD LOW OIL PRESSURE ISSUES AND MADE NECESSARY REPAIRS THE VERY DAY BEFORE (CLEANED SMALL SCREEN THAT PICKS UP OIL TO SEND PRESSURE TO DASH GUAGE) CHANGED OIL AT DEALERSHIP, ONLY TO DRIVE TRUCK LESS THAN 75 MILES AND LOUD KNOCKING IN…

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LIFTER FAILURE! EXPENSIVE REPAIR! COMMON ISSUE ON AFM 5.3 V8 ENGINES. DRIVING DOWN HWY. JUST HAD HAD LOW OIL PRESSURE ISSUES AND MADE NECESSARY REPAIRS THE VERY DAY BEFORE (CLEANED SMALL SCREEN THAT PICKS UP OIL TO SEND PRESSURE TO DASH GUAGE) CHANGED OIL AT DEALERSHIP, ONLY TO DRIVE TRUCK LESS THAN 75 MILES AND LOUD KNOCKING IN ENGINE OCCURED, TRUCK WENT INTO "LIMP MODE" HAD TO BE TOWED TO DEALERSHIP FOR A FULL LIFTER REPLACEMENT. AGAIN, COMMON PROBLEM THAT SHOULD OF BEEN RECALLED/REPAIRED BEFORE DRIVERS ARE LEFT STRANDED FACING HUGE EXPENSIVE REPAIR BILLS.

NHTSA ODI #10885481

74,259 miles · May 3, 2016
EnginePower Train

EXCESSIVE OIL USAGE, HAVE HAD IT MONITORED 3 TIMES PER GM. USES OIL EVERY 2 THOUSAND MILES ,THEY ARE AWARE THAT THESE 5.3 V8 ARE DOING SO. THERE IS A SERVICE BULLETIN OUT ON THIS PROBLEM, THIS PROBLEM NEEDS TO BE INVESTIGATED BY OUR GOVERNMENT.

NHTSA ODI #10862758

Official recalls

4

21V050000 · 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.

18V267000 · Equipment

Apr 26, 2018

General Motors LLC (GM) is recalling certain 2009-2014 Chevrolet Silverado HD and GMC Sierra HD, 2009 GMC Topkick 5000, 6000, 7000 and 8000 Series and Isuzu F Series, and 2009-2018 Chevrolet Express, and GMC Savana vehicles, equipped with certain Plastic-Handle Fire Extinguishers or Push Button 'Pindicator' Fire Extinguishers. 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: In the event of a fire, if the fire extinguisher does not function properly, it can increase the risk of injury.

Remedy: GM will notify owners, instructing them to contact Kidde to get a replacement fire extinguisher, free of charge. The recall began June 11, 2018. Owners may contact Chevrolet customer service at 1-800-222-1020, GMC customer service at 1-800-462-8782, and Isuzu customer service at 1-866-441-9638. GM's number for this recall is 18146.

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

2

DP22005 · Pedestrian Alert Sounds

Opened Jan 27, 2023 · Closed Aug 7, 2023

Status: closed (inferred from source dates) · Electrical System:propulsion System

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

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.