NHTSA issued a notice for a recall on the 2015 Subaru Outback for an exhaust pipe bellows crack which causes exhaust noise and odor which affects emission and engine performance. I had noticed our Subaru's exhaust smoke coming in through the air vents while idling and also a general loss of power for the vehicle. When I dug in…
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NHTSA issued a notice for a recall on the 2015 Subaru Outback for an exhaust pipe bellows crack which causes exhaust noise and odor which affects emission and engine performance. I had noticed our Subaru's exhaust smoke coming in through the air vents while idling and also a general loss of power for the vehicle. When I dug into the causes, I came across this recall and did the VIN look up on the NHTSA website and also the Subaru website for active recalls. The Subaru website states that the recall was completed. I then called the subaru retailer to check if there were any records for the recall work that was completed for NHTSA ID Number: 10199936. They could not find any records. I called in Subaru corporate to see if they could shed any light on the recall. Subaru corporate says that the recall work was performed on August 6th, 2020 but is unable to tell me where it was performed or even if it was actually replaced. My local Subaru dealer has no records and Subaru corporate says that the work was performed. I am stuck with an exhaust leak that is potentially dangerous as time goes on where it might fail emissions. Subaru corporate has not wanted to address this or investigate the discrepancy, but instead asks me to work with the dealer to get records. The dealer says there's no records of the work ever being done. So I'm in limbo with a particularly faulty car.
NHTSA ODI #11746783
Mileage unknown · Sep 22, 2025
EngineService BrakesVehicle Speed ControlCrash
I was within the town limits so I was driving slowly. When I approached the first stop light in town I saw that it was red. There were of three or four vehicles stopped at that light. At that point I was probably only going 5mph. I took my foot off of the gas pedal and put my foot on the brake to make a slow stop. Instead, …
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I was within the town limits so I was driving slowly. When I approached the first stop light in town I saw that it was red. There were of three or four vehicles stopped at that light. At that point I was probably only going 5mph. I took my foot off of the gas pedal and put my foot on the brake to make a slow stop. Instead, the car accelerated rather quickly. I continued to brake but the car seemed to speed up. I was able to avoid hitting the truck in front of me by going around it. No vehicles were coming towards me but there were some stopped at the other side of the light. I drove up on the sidewalk to avoid hitting anyone. At that point the front passenger side of the car hit & snapped a pole. The car did not stop immediately upon impact. It stopped acclerating and came to a stop about 10 feet past the pole. I am not sure how fast the car was moving when it hit the pole but I was only going about 5 mph when I put my foot on the break. I would estimate the distance my car traveled from the moment I put my foot on the break until the car stopped was approximately 100-120 feet. It felt like the car went into the cruise resume mode and was trying to accelerate to a predetermined speed. I had not been using the cruise control that day but that is exactly what it felt like. There was one other time this year that the car lunged forward without using the gas pedal. It stopped quickly for me and I just assumed that I had hit the cruise resume button, although I also hadn't been using the cruise that day. The insurance company took the car to an impound lot two hours away. I am sure there has been no inspection and my insurance has not informed me of the status of having my car totaled or repaired. Because of the age of the car, and damage, they think it will be totaled. Yes, my safety and the safety of anyone near me was at risk. The car malfunctioned and the fact no one was hurt was miraculous. There were no warning messages before this accident.
NHTSA ODI #11689049
Mileage unknown · Dec 5, 2023
Engine
The cam carrier has a leak that is causing oil to slowly leak out of the car. The current issue is causing me to have to regularly add oil to the car. My safety is at risk as the car engine could fail while driving which would be me and others at risk. My understanding is that the leaking oil could also cause other parts to fail…
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The cam carrier has a leak that is causing oil to slowly leak out of the car. The current issue is causing me to have to regularly add oil to the car. My safety is at risk as the car engine could fail while driving which would be me and others at risk. My understanding is that the leaking oil could also cause other parts to fail such as the O2 sensor. The recommended repair from the local Subaru dealer is to reseal the cam carrier at an estimated cost of $4,744. I attempted to contact Subaru after reading that many others have had this same issue and some have received monetary compensation to get the repair completed after complaining. Subaru has been very difficult to get in touch with and doesn't seem to want to respond to the issue. The only warning I have had was the oil engine light coming on multiple times to which I proceeded to add oil to the car.
NHTSA ODI #11558634
Mileage unknown · Nov 2, 2023
Engine
The car had a recall on it for the catalytic converter and front pipe and bellows being cracked. It was replaced under a service bulletin put out by Subaru at 104,000 miles in 2020. I just went to get the vehicle inspected in 5/2023 and the exact same part is failing once again. It will not pass inspection. This causes exhaust t…
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The car had a recall on it for the catalytic converter and front pipe and bellows being cracked. It was replaced under a service bulletin put out by Subaru at 104,000 miles in 2020. I just went to get the vehicle inspected in 5/2023 and the exact same part is failing once again. It will not pass inspection. This causes exhaust to leak back into the car (including carbon monoxide) given the converter/bellows are parts that come off the engine right under the driver/passenger's front seat. I have called corporate Subaru to see what could be done and they refuse to do anything since they told me the car is a 2015 and had 167,000+ miles. At this point, it will cost me a few thousand dollars to fix at which point has to be done by Subaru and they will replace it with the exact same parts that have proven time and time again to be a poor design and fail. Or I can take it to an exhaust specialist to be fixed.
NHTSA ODI #11553298
Mileage unknown · Aug 17, 2023
Electrical SystemEngine
#1. I replaced the battery in June of 2022 after all the dash warning lights came on. My eyesight safety feature was rendered in operative. After the battery was replaced, all the warning lights eventually went out. In July of 2023 the same scenario happened again. I returned to Advance Auto retailer and the store manager c…
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#1. I replaced the battery in June of 2022 after all the dash warning lights came on. My eyesight safety feature was rendered in operative. After the battery was replaced, all the warning lights eventually went out. In July of 2023 the same scenario happened again. I returned to Advance Auto retailer and the store manager checked the battery. She replaced the battery with a new one of greater cold cranking amps. she was most knowledgeable and extraordinarily gracious. I asked her to check the alternator for proper function and was told it was functioning as it should. #2. On June 07, 2023, I took the automobile in for service: oil and filter change and brake pads and rotors on all four wheels. My Subaru had 68,482 miles on this date. The technician (who previously was employed by a local Subaru dealership) noticed that the engine was leaking oil and diagnosed the timing cover gasket was leaking oil. Oil leaking would contribute to the bad smells entering the passenger compartment. The gasket and three seals were replaced at a cost of $1329.94 plus 8% tax. Online research reveals that Subaru"s boxer engine suffers chronic oil consumption and seal problems. Subaru of America relies on the consumer to eat any repairs rather than fix the problem that has been going on for years.
NHTSA ODI #11539168
80,700 miles · Jun 22, 2023
EngineService Brakes
The contact owns a 2015 Subaru Outback. The contact stated that while driving 67 MPH with the cruise control activated, the vehicle suddenly decelerated to approximately 25-30 MPH while depressing the brake pedal. The contact stated that the vehicle stalled. After pulling over to the side of the roadway, the contact was able to …
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The contact owns a 2015 Subaru Outback. The contact stated that while driving 67 MPH with the cruise control activated, the vehicle suddenly decelerated to approximately 25-30 MPH while depressing the brake pedal. The contact stated that the vehicle stalled. After pulling over to the side of the roadway, the contact was able to restart the vehicle and drove to the residence. The vehicle was taken to the dealer however, the cause of the failure could not be determined. The contact's wife stated that the failure had occurred a year prior while driving approximately 55 MPH. The failure only lasted for several seconds. The vehicle had not been diagnosed or repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 80,700.
NHTSA ODI #11528332
Mileage unknown · Mar 21, 2023
Electrical SystemEngine
Oil consumption issues. The oil is burning more then it should. Oil light would come after 2 to 3 more after an oil change. The dealership has been notified and is working on ordering new parts for the engine. Replacing the small block of the engine. Had less the 100k miles when this problem accured. Electrical issues. The …
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Oil consumption issues. The oil is burning more then it should. Oil light would come after 2 to 3 more after an oil change. The dealership has been notified and is working on ordering new parts for the engine. Replacing the small block of the engine. Had less the 100k miles when this problem accured. Electrical issues. The battery is being drained after the car is turned off. Car would not start in the morning and need to be jumped. Additionally, battery eventually dies and needs to be replaced. Dealership has been notified.
NHTSA ODI #11512993
Mileage unknown · Sep 30, 2022
EngineService Brakes
Intermittant engine acceleration or engine surge while braking at very low speeds.
NHTSA ODI #11487349
Mileage unknown · Sep 10, 2022
Air BagsEngineFuel/propulsion SystemCrash
Entering a residential garage to park; experienced sudden acceleration while braking. Vehicle went through drywall/wall about 2 feet. Placed vehicle in park to stop vehicle. No airbags went off. Driving vehicle to repair shop later; experienced same rapid unexpected acceleration with different driver. No issue with floor mats…
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Entering a residential garage to park; experienced sudden acceleration while braking. Vehicle went through drywall/wall about 2 feet. Placed vehicle in park to stop vehicle. No airbags went off. Driving vehicle to repair shop later; experienced same rapid unexpected acceleration with different driver. No issue with floor mats. OEM mats. Service center cannot provide any insight or reproduction of event.
NHTSA ODI #11483793
120,000 miles · Jun 1, 2022
EngineFireInjury
The contact owned a 2015 Subaru Outback. The contact stated that while driving at 60 MPH, he was alerted by another driver that the vehicle was smoking and flames were coming from under the vehicle. The contact stated that warning lights flashed off and on. The contact stated that he pulled over, exited the vehicle, and saw flam…
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The contact owned a 2015 Subaru Outback. The contact stated that while driving at 60 MPH, he was alerted by another driver that the vehicle was smoking and flames were coming from under the vehicle. The contact stated that warning lights flashed off and on. The contact stated that he pulled over, exited the vehicle, and saw flames coming from underneath the vehicle before it was engulfed in flames and exploded. The contact stated that he sustained minor burns on his hands from the steering wheel however, medical attention was not required. The fire was extinguished by the fire department. A fire department report was filed. The vehicle was towed to a junkyard as it was deemed a total loss. The manufacturer was notified of the failure and a field technician was sent to retrieve information from the EDR. The contact was not aware of the diagnosis. The approximate failure mileage was 120,000.
Subaru of America, Inc. (Subaru) is recalling certain model year 2016-2017 Legacy and Outback vehicles manufactured February 29, 2016, to May 6, 2016. The steering column on the affected vehicles may have been improperly machined, and as a result, turning the steering wheel may have no effect on the direction of the wheels.
Consequence & remedy
Consequence: The loss of steering ability would increase the risk of a crash.
Remedy: Subaru will notify owners, and dealers will inspect the lot number on the steering column, replacing the steering column, as necessary, free of charge. The recall began May 13, 2016. Owners may contact Subaru customer service at 1-800-782-2783 or by visiting http://www.wtd65.service-campaign.com. Subaru's number for this recall is WTD-65. Note: Until the vehicles have been inspected, owners are advised not to drive their vehicles.
Subaru of America, Inc. (Subaru) is recalling certain model year 2015 Legacy and Outback vehicles manufactured on July 20, 2015. The brake fluid used in these vehicles may contain excess moisture which may adversely affect the performance of the electronic stability control system. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 126, "Electronic Stability Control Systems."
Consequence & remedy
Consequence: Poor performance of the electronic stability control system when it is activated may result in a loss of vehicle control, increasing the risk of a crash.
Remedy: Subaru will notify owners, and dealers will perform an ABS activation, then flush and replace the brake fluid, free of charge. The recall began on May 20, 2016. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WTC-64.
Subaru of America, Inc. (Subaru) is recalling certain 2015 and 2016 model year Subaru Legacy 4-Door and Outback vehicles manufactured July 3, 2015, to July 27, 2015. Transmission oil may leak from a deformed seal cap on the propeller shaft yoke.
Consequence & remedy
Consequence: If the transmission oil leaks onto the exhaust pipe, there is a possible risk of fire.
Remedy: Subaru will notify owners, and dealers will replace the propeller shaft, free of charge. The recall began on August 28, 2015. Owners may contact 1-800-782-2783. Subaru's number for this recall is WQU-56.
Additional source detail variants (2)
Power Train:driveline:driveshaft
Subaru of America, Inc. (Subaru) is recalling certain 2015 and 2016 model year Subaru Legacy 4-Door and Outback vehicles manufactured July 3, 2015, to July 27, 2015. Transmission oil may leak from a deformed seal cap on the propeller shaft yoke.
Consequence: If the transmission oil leaks onto the exhaust pipe, there is a possible risk of fire.
Remedy: Subaru will notify owners, and dealers will replace the propeller shaft, free of charge. The recall began on August 28, 2015. Owners may contact 1-800-782-2783. Subaru's number for this recall is WQU-56.
Power Train:automatic Transmission
Subaru of America, Inc. (Subaru) is recalling certain 2015 and 2016 model year Subaru Legacy 4-Door and Outback vehicles manufactured July 3, 2015, to July 27, 2015. Transmission oil may leak from a deformed seal cap on the propeller shaft yoke.
Consequence: If the transmission oil leaks onto the exhaust pipe, there is a possible risk of fire.
Remedy: Subaru will notify owners, and dealers will replace the propeller shaft, free of charge. The recall began on August 28, 2015. Owners may contact 1-800-782-2783. Subaru's number for this recall is WQU-56.
Subaru of America, Inc. (Subaru) is recalling certain model year 2015 Legacy vehicles manufactured March 10, 2014, to April 16, 2015, Outback vehicles manufactured February 24, 2014, to April 16, 2015, Impreza vehicles manufactured September 9, 2014, to April 14, 2015, XV Crosstrek vehicles manufactured October 16, 2014, to April 15, 2015, and 2016 WRX vehicles manufactured March 23, 2015, and equipped with the Eyesight Driver Assist System. If the switch that activates the brake lights fails, the automatic pre-collision braking component of the driver assist system will not function.
Consequence & remedy
Consequence: If the automatic pre-collision braking system does not function as intended, the vehicle will not react to an obstacle in its path, increasing the risk of a crash.
Remedy: Subaru will notify owners, and dealers will reprogram the driver assist system, free of charge. The recall began on July 20, 2015. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WQS-54.
Subaru of America, Inc. (Subaru) is recalling certain model year 2015 Legacy vehicles manufactured March 10, 2014, to April 16, 2015, Outback vehicles manufactured February 24, 2014, to April 16, 2015, Impreza vehicles manufactured September 9, 2014, to April 14, 2015, XV Crosstrek vehicles manufactured October 16, 2014, to April 15, 2015, and 2016 WRX vehicles manufactured March 23, 2015, and equipped with the Eyesight Driver Assist System. If the switch that activates the brake lights fails, the automatic pre-collision braking component of the driver assist system will not function.
Consequence: If the automatic pre-collision braking system does not function as intended, the vehicle will not react to an obstacle in its path, increasing the risk of a crash.
Remedy: Subaru will notify owners, and dealers will reprogram the driver assist system, free of charge. The recall began on July 20, 2015. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WQS-54.
Exterior Lighting:brake Lights:switch
Subaru of America, Inc. (Subaru) is recalling certain model year 2015 Legacy vehicles manufactured March 10, 2014, to April 16, 2015, Outback vehicles manufactured February 24, 2014, to April 16, 2015, Impreza vehicles manufactured September 9, 2014, to April 14, 2015, XV Crosstrek vehicles manufactured October 16, 2014, to April 15, 2015, and 2016 WRX vehicles manufactured March 23, 2015, and equipped with the Eyesight Driver Assist System. If the switch that activates the brake lights fails, the automatic pre-collision braking component of the driver assist system will not function.
Consequence: If the automatic pre-collision braking system does not function as intended, the vehicle will not react to an obstacle in its path, increasing the risk of a crash.
Remedy: Subaru will notify owners, and dealers will reprogram the driver assist system, free of charge. The recall began on July 20, 2015. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WQS-54.
Subaru of America, Inc. (Subaru) is recalling certain model year 2015 Outback vehicles manufactured January 22, 2014, to August 18, 2014, and equipped with a Subaru accessory trailer hitch assembly. During installation, the trailer hitch mounting nuts may have been overtightened, potentially resulting in failure of the trailer hitch mounting studs.
Consequence & remedy
Consequence: The mounting nut(s) may not provide sufficient force to remain attached to the studs or the studs themselves might break. If this were to happen while a trailer is being towed, the driver might not be able to operate the vehicle as desired or the trailer may detach from the vehicle. Either situation could increase the risk of a crash.
Remedy: Subaru will notify owners, and dealers will replace all eight mounting nuts for the trailer hitch assembly, and will inspect all eight mounting studs for damage, free of charge. The recall began on October 7, 2014. Owners may contact Subaru customer service at 1-800-782-2783. Subaru's number for this recall is WQN-50.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1
EA21002 · Desiccated Air Bag Inflator Rupture
Opened Sep 17, 2021 · No close date supplied
Status: open (inferred from source dates) · Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:passenger Side:inflator Module
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.
Additional source detail variants (2)
Air Bags:frontal:driver Side:inflator Module
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.
Air Bags:frontal:passenger Side:inflator Module
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.
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