NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
125 reportsMileage unknown · Jan 8, 2016
Air BagsElectrical SystemUnknown Or Other
MY HORN STOPPED WORKING AND WHEN I TOOK MY TRUCK TO THE DEALER HE SAID THAT IT WAS THE CLOCK SPRING CABLE INSIDE OF THE STEERING WHEEL. THE SERVICE AGENT DANIEL ARVIZA AT NORTH BAKERSFIELD TOYOTA IN BAKERSFIELD CALIFORNIA ADVISED ME THAT IF I DIDN'T GET IT FIXED THAT THE AIRBAG COULD FAIL TO DEPLOY IN THE CASE OF AN ACCIDENT. …
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MY HORN STOPPED WORKING AND WHEN I TOOK MY TRUCK TO THE DEALER HE SAID THAT IT WAS THE CLOCK SPRING CABLE INSIDE OF THE STEERING WHEEL. THE SERVICE AGENT DANIEL ARVIZA AT NORTH BAKERSFIELD TOYOTA IN BAKERSFIELD CALIFORNIA ADVISED ME THAT IF I DIDN'T GET IT FIXED THAT THE AIRBAG COULD FAIL TO DEPLOY IN THE CASE OF AN ACCIDENT. THIS SEEMS LIKE A IMPORTANT PART OF THE TRUCK TO FAIL AFTER ONLY 3 YEARS. I BOUGHT THE TRUCK NEW FROM THE DEALERSHIP AND THE WARRANTY HAS EXPIRED. IT'S GOING TO COST ALMOST 500 DOLLARS, BUT BECAUSE IT IS A SAFETY ISSUE I HAVE NO CHOICE BUT TO HAVE THE PART REPLACED.
NHTSA ODI #10818952
70,000 miles · Dec 31, 2015
Air BagsElectrical SystemStructureCrashFireInjury
WE HIT BLACK ICE AND SPUN FLIPPED INTO A DITCH ONTO THE PASSENGER SIDE OF THE TRUCK AIRBAG DEPLOYED ON THE PASSENGER SIDE THE AIRBAG CAUGHT ON FIRE CATCHING THE WHOLE TRUCK ON FIRE.
NHTSA ODI #10817278
55,000 miles · Nov 9, 2015
EngineFire
I AM PROFESSIONAL FIRE INVESTIGATOR ASSIGNED TO INVESTIGATING THE ORIGIN AND CAUSE OF A FIRE INVOLVING THE SUBJECT VEHICLE IDENTIFIED. THE EVIDENCE REVEALED TO DATE SUPPORTS THAT THE CAUSE OF THE FIRE WAS THE RESULT OF THE FAILURE IDENTIFIED IN NHTSA CAMPAIGN NUMBER: 13V557000. MY CONCERN INVOLVES THE CONSEQUENCE SECTION LISTED …
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I AM PROFESSIONAL FIRE INVESTIGATOR ASSIGNED TO INVESTIGATING THE ORIGIN AND CAUSE OF A FIRE INVOLVING THE SUBJECT VEHICLE IDENTIFIED. THE EVIDENCE REVEALED TO DATE SUPPORTS THAT THE CAUSE OF THE FIRE WAS THE RESULT OF THE FAILURE IDENTIFIED IN NHTSA CAMPAIGN NUMBER: 13V557000. MY CONCERN INVOLVES THE CONSEQUENCE SECTION LISTED IN THE CAMPAIGN. SPECIFICALLY THE CONSEQUENCES SECTION DOES NOT INCLUDE THAT IF LEFT UNADDRESSED, A FAILURE OF THE VALVE SPRINGS MAY RESULT IN THE FIRE EVENT. A COMPLETE ORIGIN AND CAUSE WRITTEN REPORT HAS BEEN GENERATED OF THE EFFORTS CONDUCTED AND ANALYSIS TO DATE. I'VE BEEN PROVIDED PERMISSION BY OUR CLIENT SHARE ALL INFORMATION GENERATED TO DATE WITH NHTSA REPRESENTATIVES. HOWEVER, BECAUSE IT IS CONSIDERED A PRIVATE INVESTIGATION I'M CONCERNED ABOUT ATTACHING THE CONFIDENTIAL REPORT THROUGH THIS NHTSA WEBSITE. THE DOCUMENTATION AVAILABLE ALSO INCLUDES 242 DIGITAL IMAGES CAPTURED WHICH INCLUDE THE VEHICLE ON FIRE, EXAMINATION OF THE SUBJECT VEHICLE AT A STORAGE FACILITY, DOCUMENTATION OF THE LOSS LOCATION AND THE EFFORTS CONDUCTED DURING A NONDESTRUCTIVE EXAMINATION. AT THIS POINT OF THE INVESTIGATION WE ARE READY TO DO THE TEARDOWN (DESTRUCTIVE EFFORTS) AND EXAMINATION OF THE CYLINDER HEAD, VALVES AND ASSOCIATED COMPONENTS. MY GOAL IN COMPLETING THIS NHTSA DOCUMENT IS TO DETERMINE IF A REPRESENTATIVE OF THE NHTSA LIKE TO ATTEND OR PROVIDE GUIDANCE DURING THE UPCOMING EXAMINATION. PLEASE FEEL FREE TO CONTACT ME DIRECTLY AT [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10789385
38,423 miles · Nov 7, 2015
Suspension
MASSIVE SQUEAKING NOISE COMING FROM THE DRIVERS SIDE FRONT SUSPENSION. TOOK IT TO THE DEALERSHIP AND THE REPLACED THE UPPER A-ARM AND A CORRODED BOLT THAT'S IN AN AREA THAT WATER CAN'T GET INTO. NOISE WENT AWAY FOR A MONTH AND NOW HAS RETURNED. IN THE SAME AREA. AFTER GETTING SOME INFORMATION FROM A SUSPENSION MECHANIC THEY ARE …
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MASSIVE SQUEAKING NOISE COMING FROM THE DRIVERS SIDE FRONT SUSPENSION. TOOK IT TO THE DEALERSHIP AND THE REPLACED THE UPPER A-ARM AND A CORRODED BOLT THAT'S IN AN AREA THAT WATER CAN'T GET INTO. NOISE WENT AWAY FOR A MONTH AND NOW HAS RETURNED. IN THE SAME AREA. AFTER GETTING SOME INFORMATION FROM A SUSPENSION MECHANIC THEY ARE AWARE OF AN ONGOING ISSUE WITH THE TACOMA FRONT SUSPENSIONS AND A POSSIBLE FIX FROM TOYOTA THAT THAT REPLACES THE FRONT COILS AND STRUTS BUR I HAVE NOT HEARD ANYTHING FROM TOYOTA ABOUT IT. ALL PREVIOUS WORK ON MY VEHICLE DONE BY DEALERSHIP.
NHTSA ODI #10789002
50,250 miles · Oct 31, 2015
Power Train
I WAS ADVISED THAT I HAD A TSB FROM MY TRUCK ,I FELT AS IF I WAS HIT FROM BEHIND AND A THUMP OR CLUNK FELT WHEN COMING TO A STOP OR TAKE OFF FROM STOP.TOLD IT WAS NORMAL BY ALL DEALERS?I DRAINED TO CHECK FLUID FROM AT PAN,ONLY 1 QT. CAME OUT, ADDED REQUIRED 3.2 QTS AS REQUIRED, SOLUTION RESOLVED AND RIDES BETTER THAN NEW, NO HEL…
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I WAS ADVISED THAT I HAD A TSB FROM MY TRUCK ,I FELT AS IF I WAS HIT FROM BEHIND AND A THUMP OR CLUNK FELT WHEN COMING TO A STOP OR TAKE OFF FROM STOP.TOLD IT WAS NORMAL BY ALL DEALERS?I DRAINED TO CHECK FLUID FROM AT PAN,ONLY 1 QT. CAME OUT, ADDED REQUIRED 3.2 QTS AS REQUIRED, SOLUTION RESOLVED AND RIDES BETTER THAN NEW, NO HELP FROM TOYOTA AND DEALERS.VERY UPSET AND HAPPY I FIXED AND NO COMPASSION FROM TOYOTA AND DEALERS ! CHECK TRANNY FLUID LEVEL BY DRAINING PAN AND MEASURE! HAD A TOYOTA FLUSH DONE 4 MONTHS PRIOR AND THAT'S WHE IT BEGAN, TOYOTA DEALER DID IT WRONG???NOT ME !
NHTSA ODI #10787406
46,538 miles · Oct 1, 2015
Electrical System
THE HORN CEASED TO WORK IN THE STRAIGHT AHEAD POSITION OF THE STEERING WHEEL. TOYOTA CHARGED ME $530 TO REPLACE THE SPIRAL CABLE. I CONSIDERED IT A SAFETY ISSUE. CONSIDER DRIVING ON A BUSY HIGHWAY AND THE VEHICLE NEXT TO YOU TRIES TO MOVE INTO YOUR LANE. I WROTE A LETTER OF COMPLAINT TO TOYOTA USA. THEY RESPONDED ONLY THAT …
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THE HORN CEASED TO WORK IN THE STRAIGHT AHEAD POSITION OF THE STEERING WHEEL. TOYOTA CHARGED ME $530 TO REPLACE THE SPIRAL CABLE. I CONSIDERED IT A SAFETY ISSUE. CONSIDER DRIVING ON A BUSY HIGHWAY AND THE VEHICLE NEXT TO YOU TRIES TO MOVE INTO YOUR LANE. I WROTE A LETTER OF COMPLAINT TO TOYOTA USA. THEY RESPONDED ONLY THAT MY VEHICLE WAS OUT OF WARRANTY.
NHTSA ODI #10778956
19,647 miles · Sep 21, 2015
Tires
TL* THE CONTACT LEASED A 2013 TOYOTA TACOMA EQUIPPED WITH BF GOODRICH RUGGED TRAIL T/A TIRES, SIZE P265/70/R16. WHILE THE VEHICLE WAS PARKED, THE CONTACT DISCOVERED THAT ALL FOUR TIRES HAD VISIBLE CRACKS AND WERE DRY ROTTED IN BETWEEN THE TWO EXTERIOR TREADS. THE VEHICLE WAS TAKEN TO THE DEALER, BUT WAS NOT DIAGNOSED OR REPLACED…
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TL* THE CONTACT LEASED A 2013 TOYOTA TACOMA EQUIPPED WITH BF GOODRICH RUGGED TRAIL T/A TIRES, SIZE P265/70/R16. WHILE THE VEHICLE WAS PARKED, THE CONTACT DISCOVERED THAT ALL FOUR TIRES HAD VISIBLE CRACKS AND WERE DRY ROTTED IN BETWEEN THE TWO EXTERIOR TREADS. THE VEHICLE WAS TAKEN TO THE DEALER, BUT WAS NOT DIAGNOSED OR REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE VEHICLE AND TIRE FAILURE MILEAGE WAS 19,647.
NHTSA ODI #10766637
51,000 miles · Sep 6, 2015
Fuel/propulsion System
OVER A WEEK MY VEHICLE BEGAN TO START INTERMITTENTLY, THEN IT FINALLY STOPPED STARTING. I HAD IT TOWED TO THE DEALERSHIP AND THEY TOLD ME THE WIRE HARNESS CONNECTION AT THE TOP OF THE FUEL PUMP HAD BURNED UP PINS, AND THEY NEEDED TO REPAIR THE WIRE HARNESS AND REPLACE THE CONNECTOR. TO HAVE BURNED PINS IN A WIRE HARNESS MEANS AR…
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OVER A WEEK MY VEHICLE BEGAN TO START INTERMITTENTLY, THEN IT FINALLY STOPPED STARTING. I HAD IT TOWED TO THE DEALERSHIP AND THEY TOLD ME THE WIRE HARNESS CONNECTION AT THE TOP OF THE FUEL PUMP HAD BURNED UP PINS, AND THEY NEEDED TO REPAIR THE WIRE HARNESS AND REPLACE THE CONNECTOR. TO HAVE BURNED PINS IN A WIRE HARNESS MEANS ARCING OF SOME SORT ON TOP OF MY FUEL TANK. MY CHILDREN SIT RIGHT ABOVE THAT PUMP IN THE BACK OF THE CAB. FUEL VAPOR AND ELECTRICAL ARCING OF ANY KIND DOES NOT MIX.
NHTSA ODI #10761826
51,000 miles · Sep 6, 2015
Fuel/propulsion System
OVER A WEEK MY VEHICLE BEGAN TO START INTERMITTENTLY, THEN IT FINALLY STOPPED STARTING. I HAD IT TOWED TO THE DEALERSHIP AND THEY TOLD ME THE WIRE HARNESS CONNECTION AT THE TOP OF THE FUEL PUMP HAD BURNED UP PINS, AND THEY NEEDED TO REPAIR THE WIRE HARNESS AND REPLACE THE CONNECTOR. TO HAVE BURNED PINS IN A WIRE HARNESS MEANS A…
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OVER A WEEK MY VEHICLE BEGAN TO START INTERMITTENTLY, THEN IT FINALLY STOPPED STARTING. I HAD IT TOWED TO THE DEALERSHIP AND THEY TOLD ME THE WIRE HARNESS CONNECTION AT THE TOP OF THE FUEL PUMP HAD BURNED UP PINS, AND THEY NEEDED TO REPAIR THE WIRE HARNESS AND REPLACE THE CONNECTOR. TO HAVE BURNED PINS IN A WIRE HARNESS MEANS ARCING OF SOME SORT ON TOP OF MY FUEL TANK. MY CHILDREN SIT RIGHT ABOVE THAT PUMP IN THE BACK OF THE CAB. FUEL VAPOR AND ELECTRICAL ARCING OF ANY KIND DOES NOT MIX.
NHTSA ODI #10761823
36,791 miles · Aug 9, 2015
Suspension
DRIVING ON A ROAD, PASSING ANOTHER CAR, TRUCK ROLLS AND JOUNCY , SOFT SHOCKS AND STRUTS, LOOKED UNDER, AT HOME ALL SHOCKS AND STRUTS ARE LEAKING OIL AND BOUNCY VEHICLE AND BAD RIDE IN BUMPY ROADS. I REPLACED REAR SHOCKS AT MY EXPENSE FIRST THEN WEEKS LATER ,I REPLACED THE FRONT STRUTS !ALL LEAKED OIL FROM SHOCKS AND STRUTS WAY T…
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DRIVING ON A ROAD, PASSING ANOTHER CAR, TRUCK ROLLS AND JOUNCY , SOFT SHOCKS AND STRUTS, LOOKED UNDER, AT HOME ALL SHOCKS AND STRUTS ARE LEAKING OIL AND BOUNCY VEHICLE AND BAD RIDE IN BUMPY ROADS. I REPLACED REAR SHOCKS AT MY EXPENSE FIRST THEN WEEKS LATER ,I REPLACED THE FRONT STRUTS !ALL LEAKED OIL FROM SHOCKS AND STRUTS WAY TO EARLY, ONGOING FOR PAST FEW MONTHS EARLIER! REPLACED AND PAID LABOR AT MY OWN EXPENSE SINCE DEALERSHIPS AND TOYOTA WOULD CALL THIS OUT OF WARRANTY AND NORMAL WEAR AND TEAR! CHEAP OEM PARTS INSTAD OF QUALITY? I INSTALLED RANCHO RS 5000 SERIES ALL AROUND! RIDES AND HANDLES VERY MUCH BETTER NOW!!!
NHTSA ODI #10747272
Official recalls
6Jul 3, 2017
Southeast Toyota Distributors, LLC (SET) is recalling certain 2011-2016 Toyota Tacoma and 4Runner vehicles equipped with accessory hood scoops installed by SET or SET dealers. The adhesive attaching the hood scoop may weaken, allowing the hood scoop to detach from the vehicle.
Consequence & remedy
Consequence: If the hood scoop detaches, it may become a road hazard, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will mechanically fasten the scoop to the hood, free of charge. The recall began on September 1, 2017. Owners may contact SET customer service at 1-954-429-2000. SET's number for this recall is SET17B.
Additional source detail variants (2)
Equipment
Southeast Toyota Distributors, LLC (SET) is recalling certain 2011-2016 Toyota Tacoma and 4Runner vehicles equipped with accessory hood scoops installed by SET or SET dealers. The adhesive attaching the hood scoop may weaken, allowing the hood scoop to detach from the vehicle.
Consequence: If the hood scoop detaches, it may become a road hazard, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will mechanically fasten the scoop to the hood, free of charge. The recall began on September 1, 2017. Owners may contact SET customer service at 1-954-429-2000. SET's number for this recall is SET17B.
Structure:body:hood:hinge And Attachments
Southeast Toyota Distributors, LLC (SET) is recalling certain 2011-2016 Toyota Tacoma and 4Runner vehicles equipped with accessory hood scoops installed by SET or SET dealers. The adhesive attaching the hood scoop may weaken, allowing the hood scoop to detach from the vehicle.
Consequence: If the hood scoop detaches, it may become a road hazard, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will mechanically fasten the scoop to the hood, free of charge. The recall began on September 1, 2017. Owners may contact SET customer service at 1-954-429-2000. SET's number for this recall is SET17B.
Aug 4, 2014
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2008-2014 FJ Cruiser and Tacoma vehicles equipped with accessory wheels and tires installed by Toyota or dealers prior to the vehicle's first sale. The affected vehicles may list incorrect spare tire size and/or cold tire inflation information on the tire placard. As such, these vehicles fail to comply with Federal Motor Vehicle Safety Standard No. 110, "Tire Selection and Rims for Passenger Cars."
Consequence & remedy
Consequence: If the spare tire is inflated to the incorrect pressure provided on the placard, tire failure may occur while it is being driven on, increasing the risk of a crash.
Remedy: For the involved vehicles, overlay stickers to correct the tire placard will either be mailed to owners or provided to dealers for placement over the incorrect information on the placard. The recall is expected to begin in September 2014. Owners may contact Toyota customer service at 1-800-331-4331.
Feb 12, 2014
Toyota is recalling certain model year 2012 and 2013 Toyota Tacoma and Lexus RX350 vehicles and certain model year 2012 Toyota Rav4 vehicles. In the affected vehicles, the brake system contains a brake actuator that adjusts the fluid pressure of each wheel cylinder. An electrical component within the actuator may experience an increased resistance resulting in the illumination of various warning lights, including those for the Vehicle Stability Control (VSC) system, Antilock Brake System (ABS), and Traction Control system.
Consequence & remedy
Consequence: If this occurs, these systems could become inoperative, reducing the directional control assistance, increasing the risk of a crash.
Remedy: Toyota will notify owners, and Toyota and Lexus dealers will update the software for the Skid Control electronic control unit, free of charge. The recall began on March 28, 2014. Owners may contact Toyota at 1-800-331-4331.
Additional source detail variants (2)
Electronic Stability Control (esc)
Toyota is recalling certain model year 2012 and 2013 Toyota Tacoma and Lexus RX350 vehicles and certain model year 2012 Toyota Rav4 vehicles. In the affected vehicles, the brake system contains a brake actuator that adjusts the fluid pressure of each wheel cylinder. An electrical component within the actuator may experience an increased resistance resulting in the illumination of various warning lights, including those for the Vehicle Stability Control (VSC) system, Antilock Brake System (ABS), and Traction Control system.
Consequence: If this occurs, these systems could become inoperative, reducing the directional control assistance, increasing the risk of a crash.
Remedy: Toyota will notify owners, and Toyota and Lexus dealers will update the software for the Skid Control electronic control unit, free of charge. The recall began on March 28, 2014. Owners may contact Toyota at 1-800-331-4331.
Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module
Toyota is recalling certain model year 2012 and 2013 Toyota Tacoma and Lexus RX350 vehicles and certain model year 2012 Toyota Rav4 vehicles. In the affected vehicles, the brake system contains a brake actuator that adjusts the fluid pressure of each wheel cylinder. An electrical component within the actuator may experience an increased resistance resulting in the illumination of various warning lights, including those for the Vehicle Stability Control (VSC) system, Antilock Brake System (ABS), and Traction Control system.
Consequence: If this occurs, these systems could become inoperative, reducing the directional control assistance, increasing the risk of a crash.
Remedy: Toyota will notify owners, and Toyota and Lexus dealers will update the software for the Skid Control electronic control unit, free of charge. The recall began on March 28, 2014. Owners may contact Toyota at 1-800-331-4331.
Nov 7, 2013
Toyota Motor Engineering & Manufacturing North America (Toyota) is recalling certain model year 2013-2014 Tacoma vehicles manufactured July 1, 2013, through October 11, 2013. The engines of the affected vehicles contain valve springs that may break over time.
Consequence & remedy
Consequence: If the valve springs break, the engine could fail and stall while the vehicle is being driven, increasing the risk of a crash.
Remedy: Toyota will notify owners, and dealers will replace the valve springs, free of charge. The recall began on November 27, 2013. Owners may contact Toyota at 1-800-331-4331.
Oct 17, 2013
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2012-2013 Tacoma vehicles equipped with 18" Maverick Alloy Wheels. In the affected vehicles, the spare tire requires the use of a different style of lug nut to attach it to the vehicle than the other wheels use. These lug nuts were not provided with the vehicle.
Consequence & remedy
Consequence: If the spare tire/wheel is installed on the vehicle using the lug nuts from another wheel, damage to the wheel could result and may eventually lead to a loose wheel, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will: (a) Install a Warning Label on the spare tire/wheel, (b) supply a bag containing proper spare wheel lug nuts, and (c) place an Owner's Manual Addendum in the vehicle's glove box. The recall began on January 23, 2014. Owners may contact SET at 1-954-429-2000.
Apr 9, 2013
Southeast Toyota is recalling certain model year 2008 and 2010-2013 Toyota Tundra, 2010-2012 Rav4, 2012 Toyota Sequoia, 2010-2011 Toyota Corolla, 2010-2011 Toyota Camry and Camry Hybrid, 2010-2013 Toyota Highlander and Highlander Hybrid, 2010-2013 Toyota FJ Cruiser, 2011 Toyota Land Cruiser, 2010-2013 Toyota Venza, 2010-2011 Toyota 4Runner, 2010-2013 Toyota Tacoma, 2011-2012 Toyota Sienna, 2012 Toyota Prius, 2013 Scion FR-S, 2011 Scion XD, 2011 Scion XB, and 2012 Scion TC vehicles. These vehicles were sold with labels that were outside the allowable one percent of accuracy of actual weight added. Thus, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) Number 110, "Tire Selection and Rims."
Consequence & remedy
Consequence: An inaccurate label could lead to owners overloading their vehicles and tires. An overloaded vehicle can result in a tire failure which may result in a vehicle crash, personal injury, or property damage.
Remedy: Southeast Toyota will notify owners and provide a corrected label with instructions concerning its installation. A small group of the affected vehicles will need additonal remedies which are still being developed. The recall began on May 28, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.
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
1EA19001 · 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.
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