IllustrationHAVE NEVER BEEN CONTACTED WHEN THE PARTS WERE AVAILBLE OR WHEN THE VEHICLE COOULD BE BROUGHT IN FOR THE RECALL CORRECTIONS
2008 GMC Yukon Xl
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2008 GMC Yukon Xl do not stand out strongly from the model-year median of 68.
About this comparison →How this year compares
Owner complaints by model year
Compare all Yukon Xl 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
40–25K
825–50K
250–75K
375–100K
5100–150K
13150K+
35 reports with mileage · 34 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 42 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 11 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Structure. Review the 8 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
2 crash reports1 fire reports5 injury reports
What owners actually said
69 reportsCRACKS IN THE DASHBOARD AROUND AIRBAG AND ENTIRE DASH HAS CRACKED.
INTERIOR DOOR HANDLES - CHROME PLATING IS PEELING AWAY FROM PLASTIC UNDERNEATH ON THE FRONT PASSENGER HANDLE. THIS PEELING CHROME CUTS FLESH. IT HAS BEEN RECALLED ON 'SOME' 2007 MODELS, HOWEVER, SINCE THIS IS CAUSING INJURY I BELIEVE IT SHOULD BE RECALLED/REPLACED ON ALL MODELS WITH CHROME PLATED HANDLES THAT INCUR THIS PROBLEM.…
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INTERIOR DOOR HANDLES - CHROME PLATING IS PEELING AWAY FROM PLASTIC UNDERNEATH ON THE FRONT PASSENGER HANDLE. THIS PEELING CHROME CUTS FLESH. IT HAS BEEN RECALLED ON 'SOME' 2007 MODELS, HOWEVER, SINCE THIS IS CAUSING INJURY I BELIEVE IT SHOULD BE RECALLED/REPLACED ON ALL MODELS WITH CHROME PLATED HANDLES THAT INCUR THIS PROBLEM. IT SHOULD NOT MATTER THE YEAR/MAKE/MODEL OF THE VEHICLE. THIS IS A DEFECT ACROSS THE BOARD. *TR
NOVEMBER 13, I WENT OUT TO START MY 2008 YUKON AND THE LIGHTS, DOOR LOCKS, AND CD PLAYER BEGAN TO FLICKER AND THEN SHUT OFF. THE GAUGES ALSO BEGAN TO FLICKER ERRATICALLY, THEN THE CAR WOULD NOT START. LATER IN THE AFTERNOON, MY HUSBAND AND I PUSHED THE CAR OUT OF THE GARAGE AND WHEN THE YUKON WENT OVER THE LIP OF THE GARAGE I…
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NOVEMBER 13, I WENT OUT TO START MY 2008 YUKON AND THE LIGHTS, DOOR LOCKS, AND CD PLAYER BEGAN TO FLICKER AND THEN SHUT OFF. THE GAUGES ALSO BEGAN TO FLICKER ERRATICALLY, THEN THE CAR WOULD NOT START. LATER IN THE AFTERNOON, MY HUSBAND AND I PUSHED THE CAR OUT OF THE GARAGE AND WHEN THE YUKON WENT OVER THE LIP OF THE GARAGE INTO THE DRIVEWAY, THE BUMP CAUSED ALL THE LIGHTS, RADIO, AND BACK DLOOR LATCH TO COME ON OR BEGIN WORKING. THIS OCCURRED SEVERAL OTHER TIMES OVER SEVERAL WEEKS AND INCLUDED THE REAR DOOR NOT WORKING OR THE POWERLOCKS NOT WORKING WITH THE REMOTE. WE TOOK IT TO DRIVER'S AUTOMOTIVE IN THE WOODLANDS, TEXAS, AND HAD THEM RUN A DIAGNOSTIC ON THE VEHICLE. THE AUTO REPAIRMAN CHECKED THE BATTERY AND CABLES AND SAID NOTHING SHOWS UP IN THE DIAGNOSTIC BUT EVENTUALLY THEY DID REPLACE THE CBM. WE PAID $ 718.00 TO REPLACE THE CBM, TRUSTING THAT WAS THE PROBLEM. THE VEHICLE STARTED UP FINE FOR SEVERAL WEEKS AFTER THAT BUT SINCE DECEMBER 21, THE YUKON HAS DUPLICATED THE ERRATIC LIGHT FLICKERING, RADIO AND IGNITION NOT WORKING, THE REAR DOOR NOT OPENING (USING THE CAR REMOTE AS WELL AS THE POWER BUTTON ON FRONT CONSOLE INSIDE VEHICLE). IN ADDITION, THE DOORS WON'T LOCK AND THE GAUGES FLICKER UNCONTROLLABLY AND THE VEHICLE WON'T START. WE ARE VERY CONCERNED. A DIAGNOSTIC SAYS NOTHING IS WRONG BUT WITH THE ELECTRICAL ISSUES, I AM FEARFUL OF WHAT COULD HAPPEN. *TR
MY 2008 YUKON XL IS GIVING SEVERAL ERROR MESSAGES. TRACTION CONTROL OFF, SERVICE STABILITRAC, CHECK ENGINE LIGHT REMAINS ON EVEN AFTER I'VE REPLACED THE THROTTLE POSITION SENSOR, COIL PACK, FULL TUNE UP NOTHING SEEMS TO FIX THE ISSUE AND I SEE THAT I'M NOT THE ONLY ONE EXPERIENCING THIS ISSUE. ANY INSIGHT ON RESOLVING THIS PROB…
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MY 2008 YUKON XL IS GIVING SEVERAL ERROR MESSAGES. TRACTION CONTROL OFF, SERVICE STABILITRAC, CHECK ENGINE LIGHT REMAINS ON EVEN AFTER I'VE REPLACED THE THROTTLE POSITION SENSOR, COIL PACK, FULL TUNE UP NOTHING SEEMS TO FIX THE ISSUE AND I SEE THAT I'M NOT THE ONLY ONE EXPERIENCING THIS ISSUE. ANY INSIGHT ON RESOLVING THIS PROBLEM WOULD BE GLADLY APPRECIATED IT IS ALSO USING MORE OIL THAN USUAL. *TR
I HAVE AN ISSUE WITH MY YUKON 2008 DASHBOARD, IT IS CRACKED ON THE PASSENGER SIDE WHERE THE AIRBAG IS LOCATED AS WELL AS TODAY A BIG CRACK APPEARED OVER THE DRIVER SIDE WHERE THE INSTRUMENT PANEL HUMP IS LOCATED ON THE LEFT SIDE. I AM WORRIED THAT THE SAFETY DURING A COLLISION OR AIRBAG DEPLOYMENT FROM SHARP PLASTIC EXPOSED DUE …
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I HAVE AN ISSUE WITH MY YUKON 2008 DASHBOARD, IT IS CRACKED ON THE PASSENGER SIDE WHERE THE AIRBAG IS LOCATED AS WELL AS TODAY A BIG CRACK APPEARED OVER THE DRIVER SIDE WHERE THE INSTRUMENT PANEL HUMP IS LOCATED ON THE LEFT SIDE. I AM WORRIED THAT THE SAFETY DURING A COLLISION OR AIRBAG DEPLOYMENT FROM SHARP PLASTIC EXPOSED DUE TO THE CRACKS IN THE DASH CUTTING THE AIRBAG OR SHARDS OF PLASTIC BECOMING PROJECTILES POTENTIALLY CAUSING INJURY TO OCCUPANTS. I KEEP MY YUKON VERY CLEAN AND WELL MAINTAINED AND IT IS ALWAYS STORED IN MY GARAGE AND KEPT IN METICULOUS CONDITION AND LOOKS AND SMELLS NEW AND USE RIGOROUSLY A WINDSHIELD SUN GUARD TO PROTECT MY STEERING WHEEL AND DASHBOARD . I PURCHASED THIS VEHICLE BACK IN 2008 AND BELIEVE IT WAS USED BY THE DEALERSHIP BECAUSE IT HAD MILES ON IT. I HAVE SEEN SEVERAL POSTS REGARDING THIS MANUFACTURING ISSUE AND MANY PEOPLE ARE COMPLAINING OF THE POOR MANUFACTURING MATERIALS USED ON THE DASHBOARD THAT MAKES THEM ALL CRACK ON THE SAME EXACT AREA I AM SPEAKING AS TO HAVE HAPPENED ON MINE. THE COST TO REPLACE IS APPROXIMATELY 800.00 WHICH INCLUDES PARTS AND LABOR. THIS SHOULDN'T BE THE RESPONSIBILITY OF THE CUSTOMER BUT OF THE MANUFACTURER AS THIS IS A DEFECTIVE PART. THIS IS RIDICULOUS TO HAVE PAID SO MUCH FOR A SUPPOSED QUALITY VEHICLE AND I WAS NEVER EXPECTING THIS HAPPENING AND THINK THIS IS UNACCEPTABLE; AND SEEING BY SO MANY COMMENTS ON THE SAME ISSUE THAT IT SHOULD BE A RECALL ITEM BECAUSE IT HAPPENS SO OFTEN IN THE SAME EXACT AREAS DUE TO THE SAFETY DURING A COLLISION CAUSING THE AIRBAG DEPLOYMENT FROM SHARP PLASTIC EXPOSED DUE TO THE CRACKS CAUSING THE PLASTIC TO PROJECT CAUSING POSSIBLE INJURY TO THE OCCUPANTS. *JS
2008 GMC YUKON XL - 5 DOOR LOCK ACTUATOR FAILURES. ALL FOUR DOOR LOCKS HAVE FAILED AND NOW THE REAR PASSENGER LOCK ACTUATOR HAS FAILED FOR THE SECOND TIME. THIS IS A SERIOUS SAFETY ISSUE AS YOU EITHER HAVE TO DRIVE WITH THE DOOR UNLOCKED OR IF LOCKED YOU RISK NOT BEING ABLE TO GET A CHILD OUT QUICKLY IF NECESSARY. I HAVE CO…
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2008 GMC YUKON XL - 5 DOOR LOCK ACTUATOR FAILURES. ALL FOUR DOOR LOCKS HAVE FAILED AND NOW THE REAR PASSENGER LOCK ACTUATOR HAS FAILED FOR THE SECOND TIME. THIS IS A SERIOUS SAFETY ISSUE AS YOU EITHER HAVE TO DRIVE WITH THE DOOR UNLOCKED OR IF LOCKED YOU RISK NOT BEING ABLE TO GET A CHILD OUT QUICKLY IF NECESSARY. I HAVE CONTACTED GM AND THEY REFERRED THE ISSUE TO MY LOCAL REP WHO HAS DENIED COVERING THE PART, ACCORDING TO MY DEALER. MANY CASES OF THIS SAME FAILURE CAN BE FOUND ONLINE AND IN MY CASE, 5 FAILURES OF THE SAME PART. I WOULD SAY THIS INDICATES A PROBLEM. WHY WON'T GM ACKNOWLEDGE THIS AND OFFER TO FIX IT? WILL IT TAKES TRAGEDY LIKE A CHILD NOT BEING ABLE TO BE REMOVED IN AN EMERGENCY? *TR
DASH BOARD CRACK AT LEFT CORNER OF AIRBAG, CAN RESULT IN SHRAPNEL OR IMPEDE AIRBAG DEPLOYMENT. ALSO A CRACK ON THE DASH BOARD AT THE LEFT CORNER OF THE INSTRUMENT PANEL HAPPENED AT THE SAME TIME. *TR
I HAVE ISSUES WITH ALL FOUR DOOR LOCKS NOT WORKING, THE POWER SEATS WORK SOMETIMES, AND MY RADIO / NV SYSTEM GOES ON AND OFF. *TR
DOOR LOCK MECHANISM MULTIPLE FAILS AND HAVE FOUND THIS IS WIDESPREAD AMONG THESE VEHICLES. FIND IT DANGEROUS AS YOU CANNOT ACCESS THE INTERIOR IN CASE OF EMERGENCY ESPECIALLY WITH CHILDREN. *TR
Official recalls
421V050000 · 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.
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.
08V441000 · Electrical System
Aug 28, 2008
GM IS RECALLING 857,735 MY 2006-2008 BUICK LUCERNE; CADILLAC DTS; HUMMER H2; MY 2007-2008 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT; CHEVROLET AVALANCHE, SILVERADO, SUBURBAN, TAHOE; GMC ACADIA, SIERRA, YUKON, YUKON XL, SATURN OUTLOOK; AND MY 2008 BUICK ENCLAVE VEHICLES EQUIPPED WITH A HEATED WIPER WASHER FLUID SYSTEM. A SHORT CIRCUIT ON THE PRINTED CIRCUIT BOARD FOR THE WASHER FLUID HEATER MAY OVERHEAT THE CONTROL-CIRCUIT GROUND WIRE.
Consequence & remedy
Consequence: THIS MAY CAUSE OTHER ELECTRICAL FEATURES TO MALFUNCTION, CREATE AN ODOR, OR CAUSE SMOKE INCREASING THE RISK OF A FIRE.
Remedy: DEALERS WILL INSTALL A WIRE HARNESS WITH AN IN-LINE FUSE FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 12, 2008. OWNERS MAY CONTACT BUICK AT 1-866-608-8080; CADILLAC AT 1-800-982-2339 OR HTTP://WWW.CADILLAC.COM; CHEVROLET AT 1-800-630-2438; SATURN AT 1-800-972-8876 OR HTTP://WWW.SATURN.COM, GMC AT 1-866-996-9436; OR HUMMER AT 1-800-732-5493; OR THROUGH THEIR WEBSITE AT <A HREF=HTTP://WWW.GMOWNERCENTER.COM>HTTP://WWW.GMOWNERCENTER.COM</A> .
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.