NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
136 reportsClear category filterMileage unknown · Aug 11, 2017
EnginePower Train
TL* THE CONTACT OWNS A 2016 TOYOTA TACOMA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBERS: 17V356000 (ENGINE) AND 17V285000 (POWER TRAIN) 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. THE VEHICLE WAS TAKEN TO…
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TL* THE CONTACT OWNS A 2016 TOYOTA TACOMA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBERS: 17V356000 (ENGINE) AND 17V285000 (POWER TRAIN) 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. THE VEHICLE WAS TAKEN TO THE DEALER LITHIA TOYOTA OF REDDING LOCATED AT 250 E CYPRESS AVE, REDDING, CA 96002; (530) 605-2938 AND CONFIRMED THAT THE PARTS WERE NOT AVAILABLE FOR THE RECALL REMEDY. THE MANUFACTURER WAS NOT CONTACTED AND WAS NOT MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.
NHTSA ODI #11014628
14,000 miles · Aug 11, 2017
Power Train
TL* THE CONTACT OWNS A 2016 TOYOTA TACOMA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V285000 (POWER TRAIN); HOWEVER, THE PART FOR THE RECALL REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. DAYTON TOYOTA IN SOUTH BRUNSWICK TOWNSHIP, N…
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TL* THE CONTACT OWNS A 2016 TOYOTA TACOMA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V285000 (POWER TRAIN); HOWEVER, THE PART FOR THE RECALL REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. DAYTON TOYOTA IN SOUTH BRUNSWICK TOWNSHIP, NJ DIAGNOSED THAT THE VEHICLE'S GASKET WAS LEAKING FUEL AND THE VEHICLE WAS DEEMED UNSAFE TO DRIVE. THE DEALER DECIDED TO KEEP THE VEHICLE AT THE DEALER UNTIL THE RECALL REPAIR WAS COMPLETED. THE DEALER WAS UNABLE TO PROVIDE A TIMEFRAME FOR THE REPAIR. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND WAS UNABLE TO PROVIDE AN ESTIMATED TIME FRAME FOR THE REPAIR. THE APPROXIMATE FAILURE MILEAGE WAS 14,000. PARTS DISTRIBUTION DISCONNECT. ... .UPDATED 11/16/17 *BF CONSUMER STATED VEHICLE WAS REPAIRED 7 WEEKS AFTER I BROUGHT IN FOR SERVICE. UPDATE 10/4/18*JB
NHTSA ODI #11014591
Mileage unknown · Aug 7, 2017
Power Train
TL* THE CONTACT OWNS A 2016 TOYOTA TACOMA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V285000 (POWER TRAIN) 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. THE TOYOTA OF SARASOTA DEALER WAS CONTACTED AND …
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TL* THE CONTACT OWNS A 2016 TOYOTA TACOMA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V285000 (POWER TRAIN) 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. THE TOYOTA OF SARASOTA DEALER WAS CONTACTED AND CONFIRMED THAT THE PARTS WERE NOT AVAILABLE FOR THE RECALL REMEDY DUE TO THE PARTS BEING ON BACK ORDER. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE AND WAS NOT ABLE TO CONFIRM WHEN THE PARTS WERE TO BECOME AVAILABLE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.
NHTSA ODI #11013314
1,900 miles · Aug 2, 2017
Power Train
TL* THE CONTACT OWNS A 2016 TOYOTA TACOMA. WHILE DRIVING VARIOUS SPEEDS, AN ABNORMAL NOISE WAS HEARD FROM THE REAR OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE LOCAL DEALER (ALAMO TOYOTA 18019 NORTH U.S. HWY 281, SAN ANTONIO, TX 78232), BUT THE CAUSE OF THE FAILURE WAS NOT DETERMINED. WHILE THE VEHICLE WAS UNDERGOING ROUTINE MAI…
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TL* THE CONTACT OWNS A 2016 TOYOTA TACOMA. WHILE DRIVING VARIOUS SPEEDS, AN ABNORMAL NOISE WAS HEARD FROM THE REAR OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE LOCAL DEALER (ALAMO TOYOTA 18019 NORTH U.S. HWY 281, SAN ANTONIO, TX 78232), BUT THE CAUSE OF THE FAILURE WAS NOT DETERMINED. WHILE THE VEHICLE WAS UNDERGOING ROUTINE MAINTENANCE, IT WAS DISCOVERED THAT THE REAR DIFFERENTIAL HAD AN OIL LEAK. THE DEALER STATED THAT THE PARTS WERE ON BACKORDER. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V285000 (POWER TRAIN) IN APRIL OF 2017. THE MANUFACTURER WAS NOTIFIED AND STATED THAT PARTS WERE NOT AVAILABLE AND THERE WAS NO TIME FRAME FOR WHEN THEY WOULD ARRIVE. THE FAILURE MILEAGE WAS APPROXIMATELY 1,900.
NHTSA ODI #11012284
Mileage unknown · Aug 1, 2017
Power Train
TL* THE CONTACT LEASED A 2016 TOYOTA TACOMA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V285000 (POWER TRAIN); HOWEVER, THE PART NEEDED FOR THE REPAIR WAS NOT AVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE VEHICLE WAS TAKEN TO VISALIA TOYOTA …
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TL* THE CONTACT LEASED A 2016 TOYOTA TACOMA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V285000 (POWER TRAIN); HOWEVER, THE PART NEEDED FOR THE REPAIR WAS NOT AVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE VEHICLE WAS TAKEN TO VISALIA TOYOTA DEALER (LOCATED ON BEN MADDOX WAY IN VISALIA, CA), BUT PARTS WERE NOT AVAILABLE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE AND INFORMED THE CONTACT THAT THE REMEDY PART WAS NOT AVAILABLE FOR THE REPAIR. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.
NHTSA ODI #11012076
26,000 miles · Jul 29, 2017
Power Train
TOYOTA RECALL -- RECEIVED NOTICE OF RECALL AND TOOK TRUCK TO LOCAL DEALER JUNE 22, 2017 I WAS ADVISED THE IT FAILED THE REAR DIFFERENTIAL LEAK, AND I WAS INFORMED OF A NEW RECALL FOR THE CRANK SHAFT BUT NEITHER COULD BE FIXED DUE TO NO PARTS. I WAS TOLD I CAN DRIVE IT UNTIL THE PARTS COME IN, BUT THE SERIOUSNESS OF THE NHTSA WEB…
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TOYOTA RECALL -- RECEIVED NOTICE OF RECALL AND TOOK TRUCK TO LOCAL DEALER JUNE 22, 2017 I WAS ADVISED THE IT FAILED THE REAR DIFFERENTIAL LEAK, AND I WAS INFORMED OF A NEW RECALL FOR THE CRANK SHAFT BUT NEITHER COULD BE FIXED DUE TO NO PARTS. I WAS TOLD I CAN DRIVE IT UNTIL THE PARTS COME IN, BUT THE SERIOUSNESS OF THE NHTSA WEBSITE LEADS ME TO BELIEVE THAT I COULD HAVE CRASHED BY CONTINUING TO DRIVE IT. I NEEDED THE TRUCK, TO DRIVE TO CINCINNATI, OH AND BACK ON JULY 11-13 SO I HAD RETRIEVED IT BACK FROM THE DEALER BASED ON THE SERVICE MANAGER'S ASSURANCE THAT IT WAS O.K. TO DRIVE. ON THE WAY BACK FROM THE TRIP TO CINCINNATI ON JULY 13, 2017, I PUT IT IN DRIVE AND APPLIED GAS, BUT NOTHING HAPPENED, JUST AS I WENT TO PUT IT BACK IN PARK, IT LUNGED FORWARD AND I ALMOST HIT A CAR. IT "DELAYED" LIKE THAT ANYTIME I STOPPED TO REST AND STARTED TO CONTINUE BACK ON THE TRIP. I THEN HAD ANOTHER TRIP TO ALABAMA I HAD TO GO ON AND THERE WERE NO RENTAL CARS AVAILABLE, AND AGAIN, I WAS TOLD IT WAS OK TO DRIVE. THE DELAY GOT WORSE ON THAT TRIP AND I TOOK IT BACK TO THE DEALER ON JULY 22, 2017. IT IS STILL AT THE DEALER AND NO RELIEF IN SIGHT YET AFTER 6 WEEKS SO FAR.
NHTSA ODI #11011403
8,700 miles · Jul 26, 2017
Power TrainSuspension
RECEIVED RECALL NOTICE 17V285000 FOR REAR DIFFERENTIAL LEAK. I TOOK THE TRUCK TO THE DEALERSHIP WITH LESS THAN 9K MILES AND THE TRUCK HAD THE DREADED LEAK. DEALERSHIP GROUNDED THE VEHICLE. IT HAS BEEN OVER A MONTH AND 4 CHECK INS WITH THE DEALER AND NO ETA FOR FIX. CALLED CUSTOMER SERVICE AND THEY CANNOT GIVE A TIME FOR A FIX. T…
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RECEIVED RECALL NOTICE 17V285000 FOR REAR DIFFERENTIAL LEAK. I TOOK THE TRUCK TO THE DEALERSHIP WITH LESS THAN 9K MILES AND THE TRUCK HAD THE DREADED LEAK. DEALERSHIP GROUNDED THE VEHICLE. IT HAS BEEN OVER A MONTH AND 4 CHECK INS WITH THE DEALER AND NO ETA FOR FIX. CALLED CUSTOMER SERVICE AND THEY CANNOT GIVE A TIME FOR A FIX. THEY HAVE PROVIDED A RENTAL VEHICLE, FIRST A DODGE TRUCK SINCE I HAD OBLIGATIONS, THEY PROVIDED THAT FOR 2 WEEKS THEN REQUESTED I GET A CAR. I AGREED BUT NOW IT IS TIME FOR VACATION AND NEED A TRUCK AGAIN. CALLED CUSTOMER SERVICE TO EXPLAIN FRUSTRATION WITH DELAY THE GAVE ME A CASE NUMBER 1707241363 AND STATED SINCE I WAS REQUESTING AN IMMEDIATE FIX OR FOR THEM TO PURCHASE A CASE MANAGER WOULD HAVE TO CALL ME WITHIN 24 HOURS. CASE MANAGER DID NOT CALL WITHIN 24 HOURS BUT DID RECEIVE A CALL FROM THE DEALERSHIP THAT ENTERPRISE HAD NO TRUCKS AT THIS TIME BUT AS SOON AS ONE WAS AVAILABLE THEY WOULD PROVIDE ME WITH A TRUCK. I CALLED BACK TO CUSTOMER SERVICE AND WAS CONNECTED TO CASE MANAGER [XXX] WHO SAID, "DID THE DEALERSHIP CALL YOU? " I EXPLAINED YES BUT THERE MUST BE SOME CONFUSION. I WANT MY TRUCK BACK FIXED OR FOR THEM TO PURCHASE TRUCK BACK. SHE GOT VERY LOUD AND UNPROFESSIONAL AND STATED. " IT IS A RECALL AND WE ARE ONLY PROVIDING LOANERS AND NO BUYBACKS". THIS HAS MADE THE SITUATION WORSE AND I EXPLAINED THAT THERE ARE OTHER ISSUES THAT HAVE BEEN REPORTED TO THE DEALER AS WELL SUCH AS TRANSMISSION NOT GOING INTO GEAR AND SQUEAKY LEAF SPRINGS. I LET THEM KNOW THAT I THOUGHT TOYOTA WOULD HAVE HAD A BETTER PLAN IN PLACE TO HAVE THE PARTS AVAILABLE AND THE LENGTH OF WAIT TIME IS UNACCEPTABLE. PERHAPS A CLASS ACTION LAW SUIT NEEDS TO START NOW. I HAD TO ASK 4 TIMES FOR HER MANAGERS NAME AND SHE FINALLY SAID SHE WOULD CALL ME WITHIN 1 BUSINESS DAY AND HER NAME IS [XXX]. THIS IS MY FIRST NEW VEHICLE FOR ME AND NOT A GOOD FEELING. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #11010699
Mileage unknown · Jul 25, 2017
EnginePower Train
TL* THE CONTACT OWNS A 2016 TOYOTA TACOMA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBERS: 17V356000 (ENGINE) AND 17V285000 (POWER TRAIN). THE DEALER (ALL STAR TOYOTA, 9150 AIRLINE HWY, BATON ROUGE, LA 70815, (225) 490-7608) HAD BEEN UNABLE TO DETERMINE WHEN THE REMEDY AND PARTS MAY BE SUPPLIED FOR THE REPAIRS. THE …
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TL* THE CONTACT OWNS A 2016 TOYOTA TACOMA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBERS: 17V356000 (ENGINE) AND 17V285000 (POWER TRAIN). THE DEALER (ALL STAR TOYOTA, 9150 AIRLINE HWY, BATON ROUGE, LA 70815, (225) 490-7608) HAD BEEN UNABLE TO DETERMINE WHEN THE REMEDY AND PARTS MAY BE SUPPLIED FOR THE REPAIRS. THE DEALER INDICATED THAT NHTSA CAMPAIGN NUMBER: 17V356000 (ENGINE) WAS COMPLETED BUT THE CONTACT HAD NO RECORD OF THE REPAIR FROM THE DEALER. THE MANUFACTURER WAS CONTACTED CONCERNING THE TWO RECALL REPAIRS. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.
NHTSA ODI #11010478
Mileage unknown · Jul 24, 2017
Power Train
TOYOTA IMPOUNDED MY 2016 VEHICLE OVER 3 WEEKS AGO ON A RECALL AND THE DEALER AND CORPORATE HAVE TOLD ME ON A FEW OCCASIONS THAT THE PARTS WOULD BE IN IN A COUPLE OF DAYS. NOW THEY ARE TELLING ME THEY REALLY HAVE NO IDEA WHEN THEY ARE GOING TO RECEIVE THE PARTS FOR THE RECALL. THIS IS COMPLETELY UNACCEPTABLE. THEY ARE TELLING THE…
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TOYOTA IMPOUNDED MY 2016 VEHICLE OVER 3 WEEKS AGO ON A RECALL AND THE DEALER AND CORPORATE HAVE TOLD ME ON A FEW OCCASIONS THAT THE PARTS WOULD BE IN IN A COUPLE OF DAYS. NOW THEY ARE TELLING ME THEY REALLY HAVE NO IDEA WHEN THEY ARE GOING TO RECEIVE THE PARTS FOR THE RECALL. THIS IS COMPLETELY UNACCEPTABLE. THEY ARE TELLING THE CONSUMER THAT THEY HAVE NO CHOICE IN THE MATTER. MY TRUCK IS PAID FOR AND I WANT IT BACK.IT'S NOW SITTING IN THEIR BACK LOT IN THE 110 DEGREE HEAT OF ARIZONA. IS TOYOTA GOING TO EXTEND THE WARRANTY FOR ME ON THE PAINT SINCE THE DUST IS JUST BAKING ON IN THE SUMMER SUN? THERE SEEMS TO BE A CULTURE OF DECEIT GOING ON AT TOYOTA TO PROTECT THERE BOTTOM LINE AND SOMETHING NEEDS TO BE DONE. THEIR NONCHALANT ATTITUDE TOWARDS THEIR CONSUMERS NEEDS TO BE ADDRESSED BY SOMEONE WHO HAS THE AUTHORITY TO HOLD THEM ACCOUNTABLE FOR THEIR ACTIONS.
NHTSA ODI #11010271
Mileage unknown · Jul 24, 2017
Power Train
TL* THE CONTACT OWNS A 2016 TOYOTA TACOMA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V285000 (POWER TRAIN) HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. TREASURE COAST TOYOTA OF STUART, FLORIDA LOCATED A…
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TL* THE CONTACT OWNS A 2016 TOYOTA TACOMA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V285000 (POWER TRAIN) HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. TREASURE COAST TOYOTA OF STUART, FLORIDA LOCATED AT 5101 SE FEDERAL HIGHWAY, 34997, (772) 283-8300, WAS MADE AWARE OF THE RECALL AND STATED THAT THE PARTS WERE BEING SHIPPED AND HAD NOT YET ARRIVED. THE MANUFACTURER WAS NOT MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PART DISTRIBUTION DISCONNECT.
NHTSA ODI #11010209
Official recalls
4Jul 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.
Jun 1, 2017
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2016-2017 Tacoma vehicles equipped with a six-cylinder engine. The affected vehicles have a crank position sensor that may malfunction, potentially resulting in an engine stall.
Consequence & remedy
Consequence: An engine stall may increase the risk of a crash.
Remedy: Toyota will notify owners, and dealers will replace the crank position sensor with an improved design, free of charge. The recall began July 26, 2017. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's number for this recall is H0H.
Apr 27, 2017
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2016-2017 Tacoma vehicles. Oil may leak from the area where the rear differential carrier is assembled to rear axle housing.
Consequence & remedy
Consequence: If the vehicle is operated with an insufficient amount of oil in the rear differential, the differential may seize and cause a loss of control, increasing the risk of a crash.
Remedy: Toyota will notify owners, and dealers will inspect the rear differential for oil leakage. Based on the inspection, dealers will either tightening the fastening nuts or replace the fastening nuts and gasket. If the rear differential components are damaged, the rear differential carrier assembly will be replaced. The repairs will be performed free of charge. The recall June 19, 2017. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's number for this recall is H0G.
Oct 14, 2015
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2016 Tacoma trucks manufactured August 20, 2015, to September 10, 2015. In the affected vehicles, incorrect bolts were used to install the driver's knee air bag module.
Consequence & remedy
Consequence: The incorrect bolts may loosen over time and affect the performance of the driver's knee air bag, increasing the risk of driver injury during a crash that necessitates deployment of the air bags.
Remedy: Toyota will notify owners, and dealers will install the correct driver's knee air bag module mounting bolts, free of charge. The recall began on November 19, 2015. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's number for this recall is F0T.
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.