IllustrationOIL COOLER LEAK REPLACED O RING 5 TIMES REPLACED NOT FIXED YET.
2003 Nissan Maxima
Owner reports · Recalls · Investigations
More warning signs than most Maxima years
Owner complaints for the 2003 Nissan Maxima are substantially higher than the model-year median of 99.
About this comparison →How this year compares
Owner complaints by model year
Compare all Maxima 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
280–25K
1925–50K
1850–75K
2375–100K
33100–150K
26150K+
147 reports with mileage · 59 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.
- Engine And Engine Cooling. Review the 54 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine. Review the 43 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 35 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
13 crash reports2 fire reports10 injury reports
Engine complaints
43 reportsVEHICLE STALLS AT RANDOM, ROUGH/NO START, LOSS OF POWER, ENGINE LIGHT/CODE SHAFT SENSOR. SAME SYMPTOMS AS RECALL FOR THIS YEAR OUR VIN WASN'T INCLUDED IN THE LIST OF RECALLED VEHICLES.
THIS IS REFERENCE TO TWO SITUATION CONCERNING NISSAN RECALLS. IN 2014 I TOOK MY CAR TO SANSONE NISSAN DEALER ON RT 1, NJ TO TAKE CARE OF THE AIRBAG RECALL ISSUE NHTSA REF#15V287000. MY AIRBAG LIGHT WAS NOT ON WHEN I TOOK IT TO THE DEALER, AFTER I CAME HOME A WEEK LATER THE AIRBAG LIGHT CAME ON. I DON'T THINK THE DEALER TOOK CAR…
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THIS IS REFERENCE TO TWO SITUATION CONCERNING NISSAN RECALLS. IN 2014 I TOOK MY CAR TO SANSONE NISSAN DEALER ON RT 1, NJ TO TAKE CARE OF THE AIRBAG RECALL ISSUE NHTSA REF#15V287000. MY AIRBAG LIGHT WAS NOT ON WHEN I TOOK IT TO THE DEALER, AFTER I CAME HOME A WEEK LATER THE AIRBAG LIGHT CAME ON. I DON'T THINK THE DEALER TOOK CARE OF THE RECALL ISSUE, IF THEY DID MY AIRBAG LIGHT WOULD NOT BE ON. I WOULD LIKE NISSAN TO GIVE AUTHORIZATION TO THE DEALER TO CORRECT THIS PROBLEM. MY SECOND ISSUE WAS ON JAN 2016, I WAS DRIVING TO WORK, ALL OF A SUDDEN THE CAR SHUT OFF ON ME, THE BRAKE LOCK UP AND ALL I COULD DO WAS STAIR TO THE SIDE OF THE ROAD..I WAS LUCKY THAT THERE WASN'T ANY ONCOMING TRAFFIC. I HAD TO CALL THE TOW TRUCK TO HAVE MY CAR TOWED BUT BEFORE THE TOW TRUCK CAME I TRIED STARTING THE CAR AGAIN AND IT STARTED. I WAS A FEW MINUTES FROM HOME, SO I DROVE BACK HOME AND I HAD MY LOCAL MECHANIC PICKED IT UP AND DID A DIAGNOSIS ON IT. HE SAID IT WAS THE CRANK POSITION SENSOR, I PURCHASED IT AND HE INSTALLED IT. THE CAR STARTED WORKING A LITTLE BETTER BUT MY SERVICE ENGINE SOON WARNING LIGHT IS STILL ON. I DID A LITTLE INVESTIGATION AND FOUND OUT THAT THERE WAS A RECALL FOR ENGINE AND ENGINE COOLING RECALL #03V455000. I READ IT AND FOUND THAT THE CONSEQUENCE ON THE RECALL IS THE EXACT SAME THING THAT HAPPEN TO ME. AGAIN SANSONE DEALER ON RT. 1 IN NJ IS CLAIMING THAT THEY TOOK CARE OF THIS ISSUE BUT I WAS NEVER TOLD THAT THIS WAS A RECALL BY NISSAN. I WANTED NISSAN TO CORRECT THIS PROBLEM BASED ON THE FIX UNDER NHTSA REF# 03V455000. I'VE BEEN TAKING CAR OF ALL THE MAINTENANCE ON MY CAR SINCE I PURCHASED IT FROM NISSAN BUT I FEEL THAT NISSAN IS RESPONSIBLE FOR THESE TWO ISSUE, SINCE IT WAS DEFECT IN DESIGN ON THEIR END.
TL* THE CONTACT OWNS A 2003 NISSAN MAXIMA. WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE STALLED AND THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS RESTARTED; HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT INCLUDED IN NHTS…
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TL* THE CONTACT OWNS A 2003 NISSAN MAXIMA. WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE STALLED AND THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS RESTARTED; HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 03V455000 (ENGINE AND ENGINE COOLING). THE FAILURE MILEAGE WAS 147,000.
TL* THE CONTACT OWNS A 2003 NISSAN MAXIMA. WHILE DRIVING AT VARIOUS SPEEDS, THE ENGINE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE VEHICLE'S TITLE WAS RE-WORKED; THEREFORE, THE DEALER WAS NOT OBLIGATED TO PERFORM ANY RECALL OR WARRANTY WORK ON THE VEHICLE. THE VEHICLE WAS NOT REPA…
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TL* THE CONTACT OWNS A 2003 NISSAN MAXIMA. WHILE DRIVING AT VARIOUS SPEEDS, THE ENGINE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE VEHICLE'S TITLE WAS RE-WORKED; THEREFORE, THE DEALER WAS NOT OBLIGATED TO PERFORM ANY RECALL OR WARRANTY WORK ON THE VEHICLE. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 03V455000 (ENGINE AND ENGINE COOLING). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.
THE VEHICLE STALLED WHEN IT WAS DRIVEN AT SPEED OF 20 TO 35 MPH. THE WARNING LIGHT ON AND THE CAR CAN START AGAIN AFTER THE GEAR CHANGED TO NEUTRAL. IT HAS BEEN HAPPENED TWO TIMES IN A MONTH AND THEN MILEAGES IS 114000 MILES. THE NISSAN WORKSHOP CAN'T FIGURE OUT IT DUES TO CAMSHAFT SENSOR PROBLEM.
WHILE DRIVING, CAR SUDDENLY STOPS RESPONDING, THE STEERING WHEEL LOCKS INTO POSITION, THE ENGINE LOOSES POWER, AND STOPS RUNNING. IT HAPPENED FOUR TIMES OVER THE PAST TWO YEARS. THE SPEED OF THE VEHICLE DURING THE INCIDENTS WAS BETWEEN 20 - 35 MPH.
WAS DRIVING ON 4 LANE DIVIDED ROAD AT APPROX. 50 MPH. WHEN DEPRESSED GAS PEDAL TO ACCELERATE, CAR ACTED LIKE IT WASN'T GETTING GAS. AFTER A FEW SECONDS, IT ACTED NORMAL AGAIN. CAME UPON STOP LIGHT. AS I WAS WAITING FOR LIGHT TO CHANGE, ENGINE SUDDENLY CUT OFF WITHOUT ANY WARNING, ALL DASH LIGHTS FLASHED. I IMMEDIATELY CUT T…
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WAS DRIVING ON 4 LANE DIVIDED ROAD AT APPROX. 50 MPH. WHEN DEPRESSED GAS PEDAL TO ACCELERATE, CAR ACTED LIKE IT WASN'T GETTING GAS. AFTER A FEW SECONDS, IT ACTED NORMAL AGAIN. CAME UPON STOP LIGHT. AS I WAS WAITING FOR LIGHT TO CHANGE, ENGINE SUDDENLY CUT OFF WITHOUT ANY WARNING, ALL DASH LIGHTS FLASHED. I IMMEDIATELY CUT THE A/C, RADIO AND LIGHTS THINKING IT WAS MY BATTERY GOING BAD. I PUT THE CAR IN PARK AND RESTARTED IT WITH NO PROBLEM. I IMMEDIATELY DROVE APPROX. 15 MILES TO NEAREST AAA SHOP TO GET BATTERY CHECKED. BATTERY CHECKED OUT FINE AND MECHANIC LOOKED UNDER HOOD AND COULD NOT SEE ANYTHING OBVIOUS. I GOT HOME AND FOUND OUT THAT THIS YEAR NISSAN HAD BEEN RECALLED FOR CAMSHAFT PROBLEMS. THE DESCRIPTION OF CAMSHAFT PROBLEMS (ENGINE SUDDENLY TURNING OFF) MADE ME SUSPICIOUS ESPECIALLY SINCE IT HAD BEEN RECALLED. TOOK TO NISSAN DEALERSHIP NEXT MORNING AND THEY CONFIRMED THAT THE CAMSHAFT WAS WEAK SO THEY REPLACED ($552.00 EXPENSE). DON'T UNDERSTAND WHY ALL THE NISSAN 2003 MAXIMAS WERE NOT RECALLED FOR THIS PROBLEM. I AM ASKING THAT NISSAN CONSIDERING RECALLING ALL THE 2003 MAXIMAS FOR THIS PROBLEM. I WAS VERY FRIGHTENED WHEN ENGINE CUT OUT AND COULD HAVE BE STUCK IN THE MIDDLE OF THE ROAD AND REAR-ENDED. I AM GRATEFUL I WAS STOPPED WHEN IT HAPPENED AND NOT TRAVELING AT A HIGH SPEED.
TL* THE CONTACT OWNS A 2003 NISSAN MAXIMA. THE CONTACT STATED THAT THE VEHICLE WAS SERVICED UNDER NHTSA CAMPAIGN NUMBER: 14V361000 (AIR BAGS); HOWEVER, THE AIR BAG WARNING LIGHT ILLUMINATED MONTHS AFTER THE RECALL REPAIR. THE FAILURE RECURRED CONSTANTLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. IN ADDITION, THE CONTACT STATED …
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TL* THE CONTACT OWNS A 2003 NISSAN MAXIMA. THE CONTACT STATED THAT THE VEHICLE WAS SERVICED UNDER NHTSA CAMPAIGN NUMBER: 14V361000 (AIR BAGS); HOWEVER, THE AIR BAG WARNING LIGHT ILLUMINATED MONTHS AFTER THE RECALL REPAIR. THE FAILURE RECURRED CONSTANTLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. IN ADDITION, THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE FAILED TO ACCELERATE WHEN THE ACCELERATOR PEDAL WAS DEPRESSED AND THERE WAS A LOUD CLICKING NOISE. THE ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE BANK 1 AND BANK 2 SENSOR HAD FAILED. THE VEHICLE WAS REPAIRED. THE CONTACT STATED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 03V455000 (ENGINE AND ENGINE COOLING). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURES. THE FAILURE MILEAGE WAS UNKNOWN.
TL* THE CONTACT OWNS A 2003 NISSAN MAXIMA. WHILE DRIVING APPROXIMATELY 50 MPH, THE ENGINE STALLED AND ALL THE WARNING LIGHTS ILLUMINATED. THE VEHICLE WAS MERGED OVER TO THE EMERGENCY LANE, WHERE IT WAS TURNED OFF AND RESTARTED; HOWEVER, THE FAILURE RECURRED MULTIPLE TIMES. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN STAT…
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TL* THE CONTACT OWNS A 2003 NISSAN MAXIMA. WHILE DRIVING APPROXIMATELY 50 MPH, THE ENGINE STALLED AND ALL THE WARNING LIGHTS ILLUMINATED. THE VEHICLE WAS MERGED OVER TO THE EMERGENCY LANE, WHERE IT WAS TURNED OFF AND RESTARTED; HOWEVER, THE FAILURE RECURRED MULTIPLE TIMES. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN STATED THAT THE CRANK SHAFT POSITION SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND THEY INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 03V455000 (ENGINE AND ENGINE COOLING). THE APPROXIMATE FAILURE MILEAGE WAS 80,000. UPDATED 9/25/2015 *LN ..UPDATED 10/19/15 *BF
Official recalls
320V008000 · Air Bags:frontal:passenger Side:inflator Module
Jan 9, 2020
Nissan North America, Inc. (Nissan) is recalling certain 2001-2003 Maxima, 2002-2006 Sentra, 2002-2004 Pathfinder, 2007-2011 Versa Sedan and Versa Hatchback, 2001-2004 Infiniti I30 and I35, 2002-2003 Inifiniti QX4, 2003-2008 Infiniti FX35 and FX45 and 2006-2010 M35 and M45 vehicles. The vehicles are equipped with non-desiccated, frontal passenger air bag inflators containing phase stabilized ammonium nitrate (PSAN) propellant that were used as interim remedy parts for previous Takata recalls. 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: Nissan will notify owners, and dealers will replace the front passenger air bag inflators with alternate desiccated inflators, free of charge. The recall began February 12, 2020. Owners may contact Nissan customer service at 888-737-9511 or Infiniti customer service at 888-810-3715.
15V287000 · Air Bags
May 15, 2015
Nissan North America, Inc. (Nissan) is recalling certain model year 2001-2003 Nissan Maxima, 2002-2004 Pathfinder, 2002-2006 Sentra, 2002-2003 Infiniti QX4 and I35, 2003 FX35 and FX45, and 2001 I30 vehicles. Upon deployment of the passenger side frontal air bag, excessive internal pressure may cause the inflator to rupture.
Consequence & remedy
Consequence: In the event of a crash necessitating deployment of the passenger's frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.
Remedy: Nissan will notify owners, and dealers will replace the passenger air bag inflator, free of charge. The recall began on June 15, 2015. Owners may contact Nissan customer service at 1-800-647-7261. Note: On December 18, 2015 Nissan informed NHTSA of an amendment of this recall to remove 2004-2005 Infiniti FX35 and FX45 vehicles.
03V455000 · Engine And Engine Cooling
Nov 17, 2003
ON CERTAIN PASSENGER VEHICLES, THE CIRCUIT BOARD FOR THE CRANK POSITION SENSOR OR CAM POSITION SENSOR MAY HAVE AN IMPROPER SOLDER JOINT DUE TO SOLDER DEFORMATION CAUSED BY HEAT STRESS ACCELERATED BY THE EXISTENCE OF FLUX RESIDUE DURING THE SOLDERING PROCESS.
Consequence & remedy
Consequence: THIS COULD CAUSE THE "SERVICE ENGINE SOON" WARNING LIGHT TO COME ON, CREATE A NO START CONDITION, CAUSE REDUCED ENGINE POWER, OR CAUSE THE ENGINE TO STOP RUNNING WITHOUT WARNING DURING VEHICLE OPERATION, WHICH COULD RESULT IN A CRASH.
Remedy: DEALERS WILL REPLACE THE CRANK POSITION SENSORS. CAMSHAFT POSITION SENSOR(S), AND IN SOME CASES, THE VARIABLE TIMING CONTROL SENSOR(S). VEHICLES INVOLVED IN A PREVIOUS RECALL CAMPAIGN, 01V357, ARE ALSO INCLUDED IN THIS NEW CAMPAIGN. THE REPLACEMENT SENSORS USED IN THAT CAMPAIGN ARE ALSO AFFECTED. OWNER NOTIFICATION BEGAN ON DECEMBER 22, 2003. OWNERS SHOULD CONTACT NISSAN AT 1-800-647-7261 OR INFINITI AT 1-800-662-6200.
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.