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2013 Mitsubishi Outlander

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2013 Mitsubishi Outlander do not stand out strongly from the model-year median of 47.

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How this year compares

Owner complaints by model year

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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

20 reports with mileage · 6 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.

  • Visibility/wiper. Review the 6 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 5 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

3 crash reports0 fire reports2 injury reports

What owners actually said

26 reports
99,000 miles · Mar 16, 2018
EngineUnknown Or Other

TL* THE CONTACT OWNS A 2013 MITSUBISHI OUTLANDER. WHILE DRIVING 30 MPH, THERE WAS AN ABNORMAL GRINDING NOISE AND THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE LOCAL DEALER WAS NOT CONTACTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILE…

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TL* THE CONTACT OWNS A 2013 MITSUBISHI OUTLANDER. WHILE DRIVING 30 MPH, THERE WAS AN ABNORMAL GRINDING NOISE AND THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE LOCAL DEALER WAS NOT CONTACTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 99,000.

NHTSA ODI #11079779

38,000 miles · Dec 23, 2017
Unknown Or Other

WITHOUT WARNING THE RPM WILL DROP TO ZERO. AT FIRST IT WOULD START RIGHT BACK UP WITHOUT HAVING TO RESTART IT. NOW WITHOUT WARNING IT WILL JUST DIE AND RPM GOES TO ZERO AND I HAVE TO RESTART IT. CHECK ENGINE LIGHT WILL COME ON BUT NO DIAGNOSTIC CODES ARE STORED AS TO WHAT THE PROBLEM IS. IT HAS HAPPENED WHILE STOPPED AS WELL AS …

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WITHOUT WARNING THE RPM WILL DROP TO ZERO. AT FIRST IT WOULD START RIGHT BACK UP WITHOUT HAVING TO RESTART IT. NOW WITHOUT WARNING IT WILL JUST DIE AND RPM GOES TO ZERO AND I HAVE TO RESTART IT. CHECK ENGINE LIGHT WILL COME ON BUT NO DIAGNOSTIC CODES ARE STORED AS TO WHAT THE PROBLEM IS. IT HAS HAPPENED WHILE STOPPED AS WELL AS DRIVING DON THE ROAD AT 50 MPH.

NHTSA ODI #11056195

65,000 miles · Dec 18, 2017
VisibilityVisibility/wiper

TL* THE CONTACT OWNS A 2013 MITSUBISHI OUTLANDER. WHILE DRIVING IN RAINY CONDITIONS AT APPROXIMATELY 65 MPH, THE WINDSHIELD WIPERS STOPPED WITHOUT WARNING. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE CONTACT PULLED THE VEHICLE OVER TO WAIT FOR THE RAIN TO STOP. THE VEHICLE WAS TAKEN TO THE DEALER (RAY BRANDT CHEVROLET, WES…

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TL* THE CONTACT OWNS A 2013 MITSUBISHI OUTLANDER. WHILE DRIVING IN RAINY CONDITIONS AT APPROXIMATELY 65 MPH, THE WINDSHIELD WIPERS STOPPED WITHOUT WARNING. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE CONTACT PULLED THE VEHICLE OVER TO WAIT FOR THE RAIN TO STOP. THE VEHICLE WAS TAKEN TO THE DEALER (RAY BRANDT CHEVROLET, WESTBANK EXPY, HARVEY, LA 70058 (504)-229-6013). THE DEALER DIAGNOSED THAT THE WIPER MOTOR WAS FAULTY. THE VEHICLE WAS NOT REPAIRED. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 16V792000 (VISIBILITY) AS A POSSIBLE SOLUTION; HOWEVER, THE VIN WAS NOT INCLUDED IN A RECALL. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 65,000.

NHTSA ODI #11055317

Mileage unknown · Aug 23, 2017
Visibility/wiper

TL* THE CONTACT OWNS A 2013 MITSUBISHI OUTLANDER. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V792000 (VISIBILITY) HOWEVER, THE PARTS TO DO THE REPAIR WERE UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. DON WILLIAMSON NISSAN LOCATED AT 310 WESTE…

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TL* THE CONTACT OWNS A 2013 MITSUBISHI OUTLANDER. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V792000 (VISIBILITY) HOWEVER, THE PARTS TO DO THE REPAIR WERE UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. DON WILLIAMSON NISSAN LOCATED AT 310 WESTERN BLVD, JACKSONVILLE, NC 28546 WAS CONTACTED AND REFUSED TO DO THE RECALL REMEDY. THE MANUFACTURER WAS NOT MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.

NHTSA ODI #11019084

47,000 miles · Jul 15, 2017
Air BagsCrashInjury

STRUCK IN RIGHT FRONT QUARTER PANEL BY PICKUP TRUCK GOING 70MPH WHICH TOTALLED MY VEHICLE AND CAUSED INJURIES TO MYSELF AND GRANDSON BUT NO AIRBAGS DEPLOYED. DEPLOYMENT WOULD HAVE REDUCED OUR INJURIES.

NHTSA ODI #11005483

57,800 miles · Jun 23, 2017
Visibility/wiper

TL* THE CONTACT OWNS A 2013 MITSUBISHI OUTLANDER. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V791000 (VISIBILITY/WIPER). THE PARTS TO DO THE REPAIR WERE UNAVAILABLE. IN ADDITION, THE WIPERS FAILED TO WORK INTERMITTENTLY. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE REC…

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TL* THE CONTACT OWNS A 2013 MITSUBISHI OUTLANDER. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V791000 (VISIBILITY/WIPER). THE PARTS TO DO THE REPAIR WERE UNAVAILABLE. IN ADDITION, THE WIPERS FAILED TO WORK INTERMITTENTLY. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE CONTACT CALLED A LOCAL DEALER (MOTOR WORLD GROUP AT 150 MOTORWORLD DR, WILKES-BARRE, PA, 18705) AND WAS INFORMED THAT THE PARTS WERE ON BACKORDER AND THE CONTACT WOULD BE NOTIFIED WHEN THEY BECOME AVAILABLE. THE FAILURE MILEAGE WAS 57,800. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.

NHTSA ODI #11000800

84,000 miles · Mar 31, 2017
Visibility/wiper

TL* THE CONTACT OWNS A 2013 MITSUBISHI OUTLANDER. THE CONTACT STATED THAT WHILE THE VEHICLE WAS PARKED, THE WINDSHIELD WIPERS FAILED WITHOUT WARNING. THE VEHICLE WAS LATER TAKEN TO A DEALER TO BE REPAIRED UNDER NHTSA CAMPAIGN NUMBER 16V792000 (VISIBILITY) HOWEVER IT WAS DIAGNOSED THAT THE WIPER LINKAGES WERE FRACTURED AND THE RE…

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TL* THE CONTACT OWNS A 2013 MITSUBISHI OUTLANDER. THE CONTACT STATED THAT WHILE THE VEHICLE WAS PARKED, THE WINDSHIELD WIPERS FAILED WITHOUT WARNING. THE VEHICLE WAS LATER TAKEN TO A DEALER TO BE REPAIRED UNDER NHTSA CAMPAIGN NUMBER 16V792000 (VISIBILITY) HOWEVER IT WAS DIAGNOSED THAT THE WIPER LINKAGES WERE FRACTURED AND THE RECALL REMEDY WOULD NOT RECTIFY THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 84,000.

NHTSA ODI #10969739

Mileage unknown · Mar 22, 2017
Visibility/wiper

TL* THE CONTACT OWNS A 2013 MITSUBISHI OUTLANDER. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V791000 (VISIBILITY). THE PARTS TO DO THE REPAIR WERE UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE CO…

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TL* THE CONTACT OWNS A 2013 MITSUBISHI OUTLANDER. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V791000 (VISIBILITY). THE PARTS TO DO THE REPAIR WERE UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. VIN TOOL CONFIRMS PARTS NOT AVAILABLE. ..UPDATED 05/23/17 *BF *AS

NHTSA ODI #10967740

68,578 miles · Jun 18, 2016
Visibility/wiper

WE PURCHASE THIS VEHICLE FROM LITTLE JOE'S MITSUBISHI AT 1601 S MILITARY HWY, CHESAPEAKE, VA 23320 ON MAY 20, 2016 AS A PRE OWNED VEHICLE. TWO WEEKS AFTER TAKING POSSESSION OF THE VEHICLE ONE DAY WHEN IT WAS RAINING, THE WIPERS WOULD STOP WITH THE WIPER BLADES STRAIGHT UP AND DOWN AND STAY THERE TILL L HIT THE WIPER HANDLE ON T…

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WE PURCHASE THIS VEHICLE FROM LITTLE JOE'S MITSUBISHI AT 1601 S MILITARY HWY, CHESAPEAKE, VA 23320 ON MAY 20, 2016 AS A PRE OWNED VEHICLE. TWO WEEKS AFTER TAKING POSSESSION OF THE VEHICLE ONE DAY WHEN IT WAS RAINING, THE WIPERS WOULD STOP WITH THE WIPER BLADES STRAIGHT UP AND DOWN AND STAY THERE TILL L HIT THE WIPER HANDLE ON THE STEERING WHEEL ON THE RIGHT SIDE, L CALLED THE DEALERSHIP AND SPOKE TO CHRIS BLAIR TJE SALES REPRESENTATIVE AND ADVISED HIM OF THIS THE SAME DAY IT HAPPENED, HE TOL ME HE WOULD TRANSFER ME TO SERVICE, SPOKE TO A MANAGER NAME WAS NICOLE IN SERVICE AND TOLD HER THE PROBLEM, SHE TOLD ME TO BRING THE VEHICLE IN, TOLD HER L WOULD WHEN L RETURNED BACK TO THE STATE AS L WAS OUT OF STATE AS THIS WIPER SITUATION HAPPENED TO ME ON THE WAY TO THE AIRPORT IN MY AREA. I SCHEDULED AN APPOINTMENT FOR FRIDAY JUNE 17,2016 AND THEY HAD A MECHANIC CHECK IT AND THIS IS WHAT THEY SAID WAS POSSIBLE WRONG, SEE ATTACHED. THEY TOLD ME L WOULD HAVE TO PAY HALF OF $632 WHICH WAS $316 AND L TOLD THEM THEY NEEDED TO REPLACE THIS AS IT WAS A SAFETY ISSUE, AND GOD FORBID IF THEY STOPPED WORKING WHILE L WAS DRIVING WHEN IT WAS RAINING OR SNOWING OR ANY WET CONDITION L COULD BE POTENTIALLY INVOLVED IN AN ACCIDENT AS L WOULD NOT BE ABLE TO SEE WHERE L AM GOING, THE SERVICE MANAGER NICOLE WHO WAS RUDE SAID IT WAS WORKING WHEN WE HAD THE VEHICLE, L TOLD HER L DID NOT BREAK IT. I TOLD HER THIS IS A SAFETY RELATED DRIVING ISSUE, SHE DID NOT WANT TO HEAR ABOUT IT. I ASKED FOR THE COPY OF THE SITUATION IN RELATION TO THE WIPER ISSUE AND TOLD HER L WOULD FILE A COMPLAINT. I AM ASKING THEY REPLACE THIS SAFETY RELATED DRIVING ISSUE AT THERE EXPENSE 100%, SINCE MAY 20, 2016 TILL JUNE 17, 2016 L HAVE ONLY PUT 1623 MILES ON THE VEHICLE SINCE L TOOK OWNERSHIP. THE FINANCE MANAGER ON MAY 20,2016 WHEN ASKED IF THE FLUIDS HAD BEEN CHANGED STATED YES, SERVICE DEPARTMENT SAYS ONLY OIL WAS.

NHTSA ODI #10875010

16,000 miles · Sep 19, 2014
Electrical System

BETWEEN APRIL AND MAY 2014 THIS 2013 MITSUBISHI OUTLANDER HAS BEEN HAVING DIFFICULTY IN STARTING, AT ONE POINT IT WOULD NOT START AT ALL. SOME BELTS (I DON'T KNOW WHICH) SQUEAK EVERY SO OFTEN. ON 03 JULY 2014 THE DEALER WHERE THE VEHICLE WAS PURCHASED AND HAS SINCE BEEN RECEIVING IT'S SCHEDULED MAINTENANCE, INDICATED THAT THE…

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BETWEEN APRIL AND MAY 2014 THIS 2013 MITSUBISHI OUTLANDER HAS BEEN HAVING DIFFICULTY IN STARTING, AT ONE POINT IT WOULD NOT START AT ALL. SOME BELTS (I DON'T KNOW WHICH) SQUEAK EVERY SO OFTEN. ON 03 JULY 2014 THE DEALER WHERE THE VEHICLE WAS PURCHASED AND HAS SINCE BEEN RECEIVING IT'S SCHEDULED MAINTENANCE, INDICATED THAT THE ALTERNATOR HAS TO BE REPLACED AND THAT THEY HAD NONE IN STOCK. I WAS TOLD TO CALL BACK IN A WEEK. I HAVE CALLED EVERY WEEK SINCE THEN AND I AM ALWAYS TOLD IT IS IN BACK ORDER, THAT THERE ARE MANY OF THE SAME VEHICLES WAITING FOR THIS PART. SEEMS TO ME THAT THIS IS INDICATIVE OF A PROBLEM. IT HAS BEEN 55 DAYS SINCE THEY FINALLY DIAGNOSED THE PROBLEM AND CANNOT KEEP A ALTERNATOR FOR MY VEHICLE IN STOCK LONG ENOUGH TO REPLACE THE FAULTY ONE IN MY VEHICLE. *TR

NHTSA ODI #10637470

Official recalls

5

20V279000 · Structure:frame And Members; Suspension:front:control Arm:lower Arm

May 18, 2020

Mitsubishi Motors North America, Inc. (MMNA) is recalling certain 2008-2010 Lancer, 2009-2010 Lancer Sportback, 2008-2013 Outlander, and 2011-2016 Outlander Sport vehicles originally sold in, or ever registered in, Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin. The front lower control arms may detach due to the front cross member corroding from salt water exposure such as from road salt use.

Consequence & remedy

Consequence: A detached front control arm can result in a loss of vehicle control, increasing the risk of a crash.

Remedy: MMNA will notify owners, and dealers will inspect the front cross members. Depending on the level of existing corrosion, either a sealing/anti-corrosion agent will be applied or the front cross member will be replaced with a new one. These repairs will be performed free of charge. The recall began August 7, 2020. Owners may contact MMNA customer service at 1-888-648-7820. MMNA's number for this recall is SR-20-003.

Additional source detail variants (2)

Structure:frame And Members

Mitsubishi Motors North America, Inc. (MMNA) is recalling certain 2008-2010 Lancer, 2009-2010 Lancer Sportback, 2008-2013 Outlander, and 2011-2016 Outlander Sport vehicles originally sold in, or ever registered in, Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin. The front lower control arms may detach due to the front cross member corroding from salt water exposure such as from road salt use.

Consequence: A detached front control arm can result in a loss of vehicle control, increasing the risk of a crash.

Remedy: MMNA will notify owners, and dealers will inspect the front cross members. Depending on the level of existing corrosion, either a sealing/anti-corrosion agent will be applied or the front cross member will be replaced with a new one. These repairs will be performed free of charge. The recall began August 7, 2020. Owners may contact MMNA customer service at 1-888-648-7820. MMNA's number for this recall is SR-20-003.

Suspension:front:control Arm:lower Arm

Mitsubishi Motors North America, Inc. (MMNA) is recalling certain 2008-2010 Lancer, 2009-2010 Lancer Sportback, 2008-2013 Outlander, and 2011-2016 Outlander Sport vehicles originally sold in, or ever registered in, Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin. The front lower control arms may detach due to the front cross member corroding from salt water exposure such as from road salt use.

Consequence: A detached front control arm can result in a loss of vehicle control, increasing the risk of a crash.

Remedy: MMNA will notify owners, and dealers will inspect the front cross members. Depending on the level of existing corrosion, either a sealing/anti-corrosion agent will be applied or the front cross member will be replaced with a new one. These repairs will be performed free of charge. The recall began August 7, 2020. Owners may contact MMNA customer service at 1-888-648-7820. MMNA's number for this recall is SR-20-003.

17V461000 · Visibility:windshield Wiper/washer:motor

Jul 20, 2017

Mitsubishi Motors North America, Inc. (MMNA) is recalling certain 2007-2013 Outlander vehicles. In the affected vehicles, water may drop between the hood and the windshield and leak into the wiper motor breathing hole. The water may cause internal corrosion of the windshield wiper motor and the possible failure of the motor.

Consequence & remedy

Consequence: Failure of the wiper motor can cause a loss of visibility, increasing the risk of a crash.

Remedy: MMNA will notify owners, and dealers will replace the wiper motor, free of charge. The recall began July 28, 2017. Owners may contact MMNA customer service at 1-888-648-7820. MMNA's number for this recall is SR-17-003.

16V791000 · Visibility:windshield Wiper/washer:linkages

Oct 31, 2016

Mitsubishi Motors North America, Inc. (MMNA) is recalling certain model year 2007-2013 Outlander vehicles manufactured September 8, 2006, to March 29, 2013. In the affected vehicles, water may enter between the hood and windshield and cause the front wiper link ball joint to corrode, possibly resulting in the wiper link separating and the wipers becoming inoperative.

Consequence & remedy

Consequence: Loss of wiper function can reduce visibility and increase the risk of a crash.

Remedy: MMNA will notify owners, and dealers will replace the rubber boot on the ball joint to prevent water intrusion. Additionally, they will inspect the wiper motor crank arm for excessive play, replacing it as necessary. These repairs will be done free of charge. The recall began on July 28, 2017. Owners may contact MMNA customer service at 1-888-648-7820. MMNA's number for this recall is SR-16-009.

16V458000 · Suspension:front:control Arm:lower Arm

Jun 23, 2016

Mitsubishi Motors North America, Inc. (MMNA) is recalling certain model year 2002-2007 Lancer, 2004 Lancer Wagon, 2003-2006 Lancer Evolution, 2003-2006 Outlander and 2007-2013 Outlander V-6 vehicles originally sold in, or ever registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, Wisconsin and the District of Columbia. In the affected vehicles, the front lower control arms may detach due to the front cross member corroding from salt water exposure such as from road salt use.

Consequence & remedy

Consequence: A detached front control arm can result in the loss of control of the vehicle, increasing the risk of a crash.

Remedy: MMNA will notify owners, and dealers will inspect the front cross members. Depending on the level of existing corrosion, either a sealing/anti-corrosion agent will be applied or the front cross member will be replaced with a new one that has a sealing/anti-corrosion agent applied to it. These repairs will be performed free of charge. The recall began January 2017. Owners may contact MMNA customer service at 1-888-648-7820. MMNA's number for this recall is SR-16-003.

14V366000 · Steering:hydraulic Power Assist:hose, Piping, And Connections

Jun 25, 2014

Mitsubishi Motors North America, Inc. (Mitsubishi) is recalling certain model year 2013 Outlander vehicles equipped with a 6-speed automatic transmission. Additionally, Mitusbishi is recalling certain 2007-2012 Outlander vehicles that received replacement 6-speed automatic transmissions during servicing. The transmissions in these vehicles have insufficient clearance between the power steering pressure tube and the converter housing of the automatic transmission. As a result of the contact, the power steering pressure tube may develop a hole and leak power steering fluid.

Consequence & remedy

Consequence: A power steering fluid leak could result in a loss of steering assistance, increasing the risk of a crash.

Remedy: Mitsubishi will notify owners, and dealers will replace the power steering pressure tube and return tube, free of charge. The recall began in August 2014. Owners may contact Mitsubishi customer service at 1-888-648-7820. Mitsubishi's number for this recall is SR-14-006.

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

EA19001 · Electrical Overstress

Opened Apr 19, 2019 · Closed Sep 19, 2024

Status: closed (inferred from source dates) · Air Bags: Air Bag/restraint Control Module

The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect.  During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW.  The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications.  The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU.  In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment.  FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle.  Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW.  These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes.  An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time.   In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU.  This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners.  Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW.  The risk associated with the ASIC is equally shared among all OEMS involved in the investigation.  The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage.  There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation.  The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU.  If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC.  Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC.  All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled.  In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024.  With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.