AFTER STARTING THE ENGINE, THE ENGINE RAISED PAST RED LINE RPM FOR SEVERAL SECONDS. AFTER SLOWING, I STARTED TO BACK OUT DRIVE WHEN ENGINE RAISED AGAIN INTO RED LINE RPM. BEFORE I GOT IT PULLED BACK INTO DRIVE, IT RAISED 3 MORE TIMES. EACH TIME I MANAGED TO GET TO NEUTRAL.
2012 Toyota Tundra
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2012 Toyota Tundra do not stand out strongly from the model-year median of 144.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all Tundra 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
119 reports with mileage · 36 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. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Fuel/propulsion System. Review the 25 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 21 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
155 reportsTL* THE CONTACT OWNS A 2012 TOYOTA TUNDRA. THE CONTACT STATED THAT THE STEERING WHEEL WAS SHAKING AND CORRODED. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO A DEALER FOR THE FAILURE AND THE TECHNICIAN CRASHED THE VEHICLE. THE DETAILS OF THE CRASH WERE UNKNOWN. THE VEHICLE WAS TAKEN BACK TO THE DEALER BUT WAS NOT DIAGNOSED OR…
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TL* THE CONTACT OWNS A 2012 TOYOTA TUNDRA. THE CONTACT STATED THAT THE STEERING WHEEL WAS SHAKING AND CORRODED. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO A DEALER FOR THE FAILURE AND THE TECHNICIAN CRASHED THE VEHICLE. THE DETAILS OF THE CRASH WERE UNKNOWN. THE VEHICLE WAS TAKEN BACK TO THE DEALER BUT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURES. A POLICE REPORT WAS NOT FILED AND NO INJURIES WERE SUSTAINED. THE FAILURE MILEAGE WAS 37,000.
MIRROR CONTROL ON INSTRUMENT PA NEL HAS NO LIGHTS. HAD TO TURN ON CAB LIGHTS TO SEE THE MIRROR CONTROLS.
THE PASSENGER SIDE AIRBAG CAME ON WHEN MY SON AND I WENT ON A TRIP TO OUR CABIN. WE STOPPED TO GET GAS, MY SON GOT OUT OF THE TRUCK AND THE LIGHT CAME ON. I TURNED THE IGNITION OFF GOT GAS, AND WHEN I STARTED THE TRUCK AGAIN THE AIRBAG LIGHT REMAINED ON. I AGAIN TURNED THE TRUCK OFF AND STARTED IT AGAIN. MY SON GOT OUT AND THEN …
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THE PASSENGER SIDE AIRBAG CAME ON WHEN MY SON AND I WENT ON A TRIP TO OUR CABIN. WE STOPPED TO GET GAS, MY SON GOT OUT OF THE TRUCK AND THE LIGHT CAME ON. I TURNED THE IGNITION OFF GOT GAS, AND WHEN I STARTED THE TRUCK AGAIN THE AIRBAG LIGHT REMAINED ON. I AGAIN TURNED THE TRUCK OFF AND STARTED IT AGAIN. MY SON GOT OUT AND THEN GOT BACK INTO THE TRUCK. I TOOK THE CONCERN TO THE DEALER AND THEY RESET THE AIRBAG LIGHT. AFTER THE AIRBAG TURNED OFF ON US AT ALMOST THE EXACT SAME PLACE ON OUR TRIPS TO THE CABIN 5 MORE TIMES OVER A YEAR WITH NO FIX TO THE PROBLEM I ASKED THE DEALER TO COME UP WITH A PLAN TO ADDRESS THE ONGOING SAFETY PROBLEM. MY REP. AT THE DEALERSHIP SAID THE TOYOTA CORPORATE REP. WILL STOP IN TO THE DEALERSHIP IN A MONTH OR SO AND THEY WILL CALL ME TO MEET WITH HIM. AFTER THREE MONTHS WITH NO CONTACT I CALLED THE DEALERSHIP, WHEN NO ONE CALLED ME BACK I WENT TO THE DEALERSHIP. MY REP. WAS OUT FOR THE SUMMER AND ANOTHER REP. TOLD ME THE TOYOTA CORPORATE REP QUIT AND THEY DON'T KNOW WHEN THEY WILL HAVE ANOTHER REP ASSIGNED TO THEM. I THEN CALLED TOYOTA COMPLAINT LINE WORKED WITH A REP. WHO LOOKED INTO THE ON GOING PROBLEM. AFTER TWO WEEKS OF TRYING TO GET A PLAN FROM HER SHE TOLD ME THAT THEY WERE NOT RESPONSIBLE BECAUSE THE PASSENGER WAS TOO HEAVY FOR THE AIRBAG AND THE AIRBAG SENSOR. SHE SAID THE FEDERAL GOVERNMENT SETS THE STANDARDS AND THERE IS NOTING THEY CAN DO TO ADJUST THEM. I ASKED IF SHE COULD SEND ME THE AIRBAG SENSOR WEIGHT SINSITIVITY SETTINGS SHE DID NOT RESPOND TO THE REQUEST. I THEN ASKED HER TO PUT TOYOTA'S POSITION IN WRITING, AND THE REP. TOLD ME THAT "YOUR MAINTENANCE RECEIPT IS YOUR COMMUNICATION". THAT IS THE ONLY THING THEY WILL GIVE ME. I HAVE A DANGEROUS SITUATION WITH THIS AIRBAG, AND TOYOTA WILL NOT TAKE RESPONSIBILITY FOR THE DEFECT. I NEED HELP BEFORE SOMEONE GETS KILLED HERE.
DRIVEING 30 MILES EAST OF DICKINSEN NOTH DAKATA FRONT DRIVERS TIRE BLEW CRUISE SET AT 76 MPH SPEED LIMIT 75MPH BOUGHT NEW TIRES IN DULUTH MINNISOTA MICHELIN TIRES TO REPLACE TOYO OPEN COUNTRY BOUGHT FROM LES SCHWAB TIRES BATTLE GROUND WA.. THE WHOLE SIDE WALL SEPERATED COMPLETELY FROM THE TIRE LOOKING AT THE OTHER THREE THEY DET…
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DRIVEING 30 MILES EAST OF DICKINSEN NOTH DAKATA FRONT DRIVERS TIRE BLEW CRUISE SET AT 76 MPH SPEED LIMIT 75MPH BOUGHT NEW TIRES IN DULUTH MINNISOTA MICHELIN TIRES TO REPLACE TOYO OPEN COUNTRY BOUGHT FROM LES SCHWAB TIRES BATTLE GROUND WA.. THE WHOLE SIDE WALL SEPERATED COMPLETELY FROM THE TIRE LOOKING AT THE OTHER THREE THEY DETERMAINED THERE WAS STILL 60% TREAD LIFE AT TIME OF INCIDENT. THEY CREDITED US FOR 2- TIRES THX [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
TL* THE CONTACT OWNS A 2012 TOYOTA TUNDRA. THE CONTACT WAS INVOLVED IN A CRASH AND THE VEHICLE VEERED OFF THE ROAD INTO THE WATER. THE SPECIFICS OF THE CRASH WERE NOT AVAILABLE. THE VEHICLE ALARMED ACTIVATED AND THE DOORS FAILED TO OPEN. THE CONTACT STATED THAT WATER ENTERED THE VEHICLE AND, WHEN THE ALARM DEACTIVATED, HE WAS AB…
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TL* THE CONTACT OWNS A 2012 TOYOTA TUNDRA. THE CONTACT WAS INVOLVED IN A CRASH AND THE VEHICLE VEERED OFF THE ROAD INTO THE WATER. THE SPECIFICS OF THE CRASH WERE NOT AVAILABLE. THE VEHICLE ALARMED ACTIVATED AND THE DOORS FAILED TO OPEN. THE CONTACT STATED THAT WATER ENTERED THE VEHICLE AND, WHEN THE ALARM DEACTIVATED, HE WAS ABLE TO OPEN THE DOORS AND EXIT. A POLICE REPORT WAS NOT FILED AND THERE WERE NO INJURIES REPORTED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 40,000. THE VIN WAS NOT AVAILABLE.
TL* THE CONTACT OWNS A 2012 TOYOTA TUNDRA. WHILE ATTEMPTING TO DRIVE THE VEHICLE, THE CONTACT NOTICED THAT THE CHECK ENGINE INDICATOR ILLUMINATED. THE DEALER STATED THAT THERE WAS A PUNCTURE IN THE FUEL LINE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 51,000.
DRIVER'S SEAT FRAME (BASE) BEGAN INTERMITTENTLY POPPING WHICH PROGRESSED TO A CONSISTENT POPPING FELT EVERY TIME THE VEHICLE CORNERED AT SPEED OR WEIGHT SHIFTED IN THE DRIVER'S SEAT. THE PROBLEM WAS CONFIRMED BY DEALERSHIP AND AN ADJUSTMENT MADE TO THE SEAT RAIL ALIGNMENT PIN. FOR SEVERAL MONTHS, THE PROBLEM APPEARED TO BE F…
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DRIVER'S SEAT FRAME (BASE) BEGAN INTERMITTENTLY POPPING WHICH PROGRESSED TO A CONSISTENT POPPING FELT EVERY TIME THE VEHICLE CORNERED AT SPEED OR WEIGHT SHIFTED IN THE DRIVER'S SEAT. THE PROBLEM WAS CONFIRMED BY DEALERSHIP AND AN ADJUSTMENT MADE TO THE SEAT RAIL ALIGNMENT PIN. FOR SEVERAL MONTHS, THE PROBLEM APPEARED TO BE FIXED. HOWEVER, THE PROBLEM ULTIMATELY RETURNED WITH A SIMILAR POPPING NOISE. I ALLOWED IT TO PROGRESS UNTIL THE DEALERSHIP COULD REPRODUCE THE POPPING NOISE IN THE DRIVER'S SEAT FRAME (BASE). THE PROBLEM WAS IDENTIFIED THE SECOND TIME AS A CRACKED WELD IN THE FRAME NEAR THE POINT WHERE THE SEAT BACK AND BASE ARE CONNECTED. THE DEALERSHIP ORDERED AND REPLACED THE ENTIRE SEAT FRAME WITH A NEW ONE. THE MILEAGE AT THE TIME OF REPAIR WAS 23500 MILES. I AM DOCUMENTING THE ISSUE BECAUSE I HAVE NOTICED SEVERAL OTHERS COMPLAINING ON TRUCK FORUMS OF POPPING IN THE SEAT FRAME. ALSO, I NOTICED THE RECENT TOYOTA RECALL FOR A SIMILAR ISSUE IN OTHER MODEL CARS. *JS
ELECTRICAL BUZZING NOISE FROM DASH AREA WHEN PRESSING GAS PEDAL. DEALER SAYS NOT A WARRANTY ITEM. AFTER RESEARCHING ONLINE MANY PEOPLE EXPERIENCE SAME ISSUE WITH SEVERAL TOYOTA MODELS. *TR
ON 12/24/2012 AROUND 04:00HRS I STRUCK AN ADULT MOOSE IN BEAR LAKE, CANADA WITH THE FRONT END OF MY WIFE'S 2012 TOYOTA TUNDRA CREWMAX ON THE BRITISH COLUMBIA HIGHWAY. THE CONDITION OF THE ROAD WAS SNOW AND ICE BUT WE HAD RECENTLY PURCHASED AFTERMARKET RIMS AND TIRES ON 12/18/2012 IN CALIFORNIA; 18IN MB VOTEX RIMS WITH BFG ALL T…
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ON 12/24/2012 AROUND 04:00HRS I STRUCK AN ADULT MOOSE IN BEAR LAKE, CANADA WITH THE FRONT END OF MY WIFE'S 2012 TOYOTA TUNDRA CREWMAX ON THE BRITISH COLUMBIA HIGHWAY. THE CONDITION OF THE ROAD WAS SNOW AND ICE BUT WE HAD RECENTLY PURCHASED AFTERMARKET RIMS AND TIRES ON 12/18/2012 IN CALIFORNIA; 18IN MB VOTEX RIMS WITH BFG ALL TERRAIN TIRES. THE TRACTION OF THESE TIRES BOOSTED MY CONFIDENCE IN TRAVELING AT SPEEDS OF 30-40MPH AT NIGHT. WE HAD TRAVELED ALL THE WAY FROM GEORGIA WITHOUT SEEING ANY ANIMALS AT NIGHT. THE HID HEAD LAMPS GAVE ME A FALSE SENSE OF SECURITY NAVIGATING THROUGH THE NIGHT IN ORDER TO MAKE THE FINAL LEG TO ANCHORAGE, AK FOR CHRISTMAS DAY. TO MY SURPRISE, A MOOSE TIPTOED FROM THE WOODS ON MY RIGHT ABOUT 20 FEET AHEAD OF ME AS I INTENDED TO PRESS ON PASS IT. BUT ALL OF A SUDDEN IT GOT SPOOKED AND DARTED INTO MY PATH. I STRUCK THE ANIMAL BROAD SIDE WITH THE FRONT END OF THE TRUCK KNOCKING IT INTO THE ENGINE BAY. INITIALLY I THOUGHT THE CONTACT WAS NOT SEVERE BUT INSPECTION PROVED OTHERWISE. THE HOOD WAS CRUMPLED UP UNTO THE WINDSHIELD, AND THE RADIATOR AND MOTOR WAS PUSHED SO FAR BACK THAT IT WAS NO LONGER DRIVABLE. I BELIEVE MY SPEED WAS AROUND 30MPH UPON IMPACT WHICH SURPRISED ME THAT THE ANIMAL WAS DEAD. THE TRUCK WAS TOWED TO A LOCAL BODY SHOP FOR AN INSURANCE ESTIMATE AS A TOTAL LOSS. I WAS CONCERNED AS TO WHY THE AIRBAGS DID NOT DEPLOY SINCE THE DAMAGES WAS SO GREAT. THE TECH EXPLAINED THAT THE SENSORS FOR THE AIRBAGS ARE LOCATED BEHIND THE BUMPER OF THE TRUCK WHERE IMPACT WAS MINIMAL. BECAUSE THE CONTACT TO THE MOOSE KNOCKED HIM OFF HIS LEGS THE LARGE BODY FELL INTO THE ENGINE COMPARTMENT AND COULD HAVE BEEN FATAL HAD IT A FULL RACK OF ANTLERS. THANK GOD HE DID NOT! THOUGH WE HAVE PURCHASED A 2013 REPLACEMENT OF THE SAME TRUCK, THE AIRBAGS NOT DEPLOYING IS STILL A CONCERN AS A DESIGN FLAW AND NEED TO BE ADDRESSED. *TR
Official recalls
321V920000 · Steering:hydraulic Power Assist System; Steering:rack And Pinion
Nov 23, 2021
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2008-2022 Sequoia and 2007-2021 Tundra vehicles. The power steering gear assembly may have been manufactured incorrectly, which can result in an oil leak.
Consequence & remedy
Consequence: An oil leak may cause a sudden loss of power steering assist, increasing the risk of a crash.
Remedy: Dealers will inspect and replace the power steering gear assembly as necessary, free of charge. Owner notification letters were mailed on January 21, 2022. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's numbers for this recall are 21TB10 and 21TA10.
Additional source detail variants (2)
Steering:hydraulic Power Assist System
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2008-2022 Sequoia and 2007-2021 Tundra vehicles. The power steering gear assembly may have been manufactured incorrectly, which can result in an oil leak.
Consequence: An oil leak may cause a sudden loss of power steering assist, increasing the risk of a crash.
Remedy: Dealers will inspect and replace the power steering gear assembly as necessary, free of charge. Owner notification letters were mailed on January 21, 2022. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's numbers for this recall are 21TB10 and 21TA10.
Steering:rack And Pinion
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2008-2022 Sequoia and 2007-2021 Tundra vehicles. The power steering gear assembly may have been manufactured incorrectly, which can result in an oil leak.
Consequence: An oil leak may cause a sudden loss of power steering assist, increasing the risk of a crash.
Remedy: Dealers will inspect and replace the power steering gear assembly as necessary, free of charge. Owner notification letters were mailed on January 21, 2022. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's numbers for this recall are 21TB10 and 21TA10.
13V123000 · Equipment:other:labels
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.
13V014000 · Air Bags:frontal:sensor/control MODULE-INACTIVE ; Seats
Jan 16, 2013
Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.
Consequence & remedy
Consequence: If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.
Remedy: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.
Additional source detail variants (2)
Seats
Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.
Consequence: If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.
Remedy: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.
Air Bags:frontal:sensor/control MODULE-INACTIVE
Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.
Consequence: If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.
Remedy: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 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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