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2004 Volkswagen Touareg

Owner reports · Recalls · Investigations

More warning signs than most Touareg years

Owner complaints for the 2004 Volkswagen Touareg are substantially higher than the model-year median of 27.5.

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When problems were reported

Mileage at the reported incident

165 reports with mileage · 66 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.

  • Power Train. Review the 50 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 49 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Tires. Review the 36 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

9 crash reports5 fire reports6 injury reports

Suspension complaints

20 reports
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11,000 miles · Mar 29, 2019
SteeringSuspensionWheelsCrash

TAKATA I WAS DRIVING PERFECTLY FINE AND I CAME UPON A TURNING TO MAKE THE LEFT AND OUT OF NO WHERE MY CAR START SLIDING OUT OF CONTROL I TRIED TO CONTROL IT BECAUSE THERE WAS A DITCH CLOSE BY WHERE I WAS IT WAS SLIDING TO THE RIGHT TRIED TO SPIN THE STEERING TO THE LEFT BUT THE CAR WAS JUST DOING WHAT IT FELT LIKE I ENDED UP HIT…

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TAKATA I WAS DRIVING PERFECTLY FINE AND I CAME UPON A TURNING TO MAKE THE LEFT AND OUT OF NO WHERE MY CAR START SLIDING OUT OF CONTROL I TRIED TO CONTROL IT BECAUSE THERE WAS A DITCH CLOSE BY WHERE I WAS IT WAS SLIDING TO THE RIGHT TRIED TO SPIN THE STEERING TO THE LEFT BUT THE CAR WAS JUST DOING WHAT IT FELT LIKE I ENDED UP HITTING IN THE RAIL WHERE THE DITCH WAS AND PUSHING THE CAR BACK INTO THE MIDDLE OF THE ROAD BEAR IN MIND I HAD MY CHILDREN IN MY CAR NO ONE CAN GIVE ME AN EXPLANATION TO MY MY CAR JUST SPIRAL OUT OF CONTROL AND I KNOW I WAS NOT DRIVING FAST I AM NOT A FAST DRIVER ONE THING IS TO BE DONE AND CHECK OUT WITH THIS VEHICLE BEFORE IT CLAIM THE LIFE OF ANYONE THAT GOD MY LOVE AND MY KIDS WAS SPARED THE BRAKES SPEED CONTROL AND BODY OF THE CAR WAS AFFECTED AS WELL BUT IT IS NOT ALLOWING ME TO SELECT ALL OF THE OPTIONS ABOVE

NHTSA ODI #11192399

68,000 miles · Aug 14, 2013
Suspension

AIR SHOCK EXTERIOR HOUSING AND COUPLING ON AIR HOSE ARE MADE OF TWO NON COMPATIBLE METALS CAUSING THE AIR SHOCK TO DETERIORATE. THIS CAUSES THE AIR SHOCK TO LOOSE AIR PRESSURE. *TR

NHTSA ODI #10535351

81,000 miles · Jan 23, 2010
Suspension

DRIVING 2004 TOUAREG EQUIPPED WITH AIR SUSPENSION. SPEED 55 STARTING RIGHT HAND SWEEPING TURN THE RIGHT SIDE AIR SUSPENSION BLEW OUT DROPPING THE FRONT END TO BUMP STOPS CAUSING REAR OF TRUCK TO BOUNCE AND GO SIDEWAYS CAUSING LOSS OF CONTROL OF VEHICLE. APPARENTLY THERE IS A TSB TO CHANGE THE MATERIAL OF THE CONNECTOR THAT BLEW …

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DRIVING 2004 TOUAREG EQUIPPED WITH AIR SUSPENSION. SPEED 55 STARTING RIGHT HAND SWEEPING TURN THE RIGHT SIDE AIR SUSPENSION BLEW OUT DROPPING THE FRONT END TO BUMP STOPS CAUSING REAR OF TRUCK TO BOUNCE AND GO SIDEWAYS CAUSING LOSS OF CONTROL OF VEHICLE. APPARENTLY THERE IS A TSB TO CHANGE THE MATERIAL OF THE CONNECTOR THAT BLEW OUT, HOWEVER DEALERSHIP IS NOT WILLING TO PERFORM IT UNLESS I PAY FOR ANYTHING THEY MAY BREAK IN THE PROCESS OF THE REPAIR. CORROSION IS CAUSING FAILURES IN THE NORTHEAST. *TR

NHTSA ODI #10302021

Mileage unknown · Dec 22, 2008
Electrical SystemEngine And Engine CoolingPower Train

I HAVE HAD MY 2004 VW TOUAREG SINCE JUNE 2006 AND HAVE HAD PROBLEM AFTER PROBLEM WITH THE VEHICLE. THE CATALYTIC CONVERTER WENT OUT WITHIN 6 WEEKS OF BUYING THE CAR, THE DRIVE SHAFT HAD TO BE REPLACED, THE AIR CONDITIONING COMPRESSOR HAD TO BE REPLACED, THE BRAKES HAVE HAD TO BE REPLACED AND I AM GETTING ANOTHER "CHECK BRAKE PA…

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I HAVE HAD MY 2004 VW TOUAREG SINCE JUNE 2006 AND HAVE HAD PROBLEM AFTER PROBLEM WITH THE VEHICLE. THE CATALYTIC CONVERTER WENT OUT WITHIN 6 WEEKS OF BUYING THE CAR, THE DRIVE SHAFT HAD TO BE REPLACED, THE AIR CONDITIONING COMPRESSOR HAD TO BE REPLACED, THE BRAKES HAVE HAD TO BE REPLACED AND I AM GETTING ANOTHER "CHECK BRAKE PADS" ERROR AGAIN, THE TIRE MONITORING SYSTEM CONTINUALLY TELLS ME I HAVE A FLAT, THE RADIO AMPLIFIER WAS MAKING A LOUD CRACKING SO THE DEALERSHIP REPLACED A FUSE AND BLEW THE 2 BACK SPEAKERS (WHICH THEY WOULD NOT FIX, HEWLETT VW IN GEORGETOWN, TEXAS), THE AUTO DIFFERENTIAL IS GOING OUT. THERE SEEMS TO BE NO END IN SIGHT FOR REPAIRS. *TR

NHTSA ODI #10252545

27,895 miles · Aug 27, 2008
Service Brakes, HydraulicSuspension

SCREECHING BRAKES. THE BRAKES WERE SCREECHING FOR THE PAST THREE MONTHS AND THE VW DEALERSHIP REPLACED THE PADS AND DISC. AFTER THREE ATTEMPTS, I WAS TOLD THAT THE SCREECHING IS NORMAL. ALSO, SINCE I BOUGHT THE SUV IN SETPTMBER 2004, I HAVE BEEN HAVING AN ALIGNMENT PROBLEM WHICH RESULTED IN EXCESSIVE TIRE WEAR. THE DEALER D…

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SCREECHING BRAKES. THE BRAKES WERE SCREECHING FOR THE PAST THREE MONTHS AND THE VW DEALERSHIP REPLACED THE PADS AND DISC. AFTER THREE ATTEMPTS, I WAS TOLD THAT THE SCREECHING IS NORMAL. ALSO, SINCE I BOUGHT THE SUV IN SETPTMBER 2004, I HAVE BEEN HAVING AN ALIGNMENT PROBLEM WHICH RESULTED IN EXCESSIVE TIRE WEAR. THE DEALER DID NUMEROUS ALIGNMENTS AND I CHANGED ALL FOUR TIRES( 3 TIMES), BUT THE PROBLEM STILL EXISTS. THE VEHICLE ONLY HAS ABOUT 28,000 MILES. *TR

NHTSA ODI #10239897

51,750 miles · Aug 26, 2007
Suspension

MESSAGE READS "FAULT-RUNNING GEAR-SUSPENSION-WORKSHOP" SUBSEQUENT CHECK AT DEALERSHIP REVEALED A LEAK IN THE RIGHT FRONT AIR SPRING THAT NEEDS TOTAL REPLACEMENT. WE WERE ADVISED OF"NO SERVICE BULLETINS OR RECALLS" AND THE REPAIR IS AT OUR EXPENSE ($2445.00) SINCE WE WERE NEARLY 3,000 MILES OUT OF WARRANTY. THE VEHICLE HAS NEV…

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MESSAGE READS "FAULT-RUNNING GEAR-SUSPENSION-WORKSHOP" SUBSEQUENT CHECK AT DEALERSHIP REVEALED A LEAK IN THE RIGHT FRONT AIR SPRING THAT NEEDS TOTAL REPLACEMENT. WE WERE ADVISED OF"NO SERVICE BULLETINS OR RECALLS" AND THE REPAIR IS AT OUR EXPENSE ($2445.00) SINCE WE WERE NEARLY 3,000 MILES OUT OF WARRANTY. THE VEHICLE HAS NEVER BEEN OFF ROAD, ALL MILE'S ARE HIGHWAY INCURRED. *TR

NHTSA ODI #10200811

55,000 miles · Aug 2, 2007
Suspension

MY 2004 VW TOUAREG HAS BEEN DIAGNOSED WITH PREMATURE FAILURE OF THE FRONT SUSPENSION BUSHINGS. THE VEHICLE HAS NEVER BEEN USED OFF-ROAD. THE VEHICLE HAS 55K MILES ON IT. I BELIEVE THAT THIS IS AN INHERENT DEFECT IN THE POLYMER USED FOR THE BUSHINGS AND IT SHOULD BE REPLACED AT VW'S EXPENSE. VW HAS NOT BEEN RESPONSIVE TO MY R…

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MY 2004 VW TOUAREG HAS BEEN DIAGNOSED WITH PREMATURE FAILURE OF THE FRONT SUSPENSION BUSHINGS. THE VEHICLE HAS NEVER BEEN USED OFF-ROAD. THE VEHICLE HAS 55K MILES ON IT. I BELIEVE THAT THIS IS AN INHERENT DEFECT IN THE POLYMER USED FOR THE BUSHINGS AND IT SHOULD BE REPLACED AT VW'S EXPENSE. VW HAS NOT BEEN RESPONSIVE TO MY REQUEST. I HAVE HAD MANY CARS IN MY LIFE, AND THIS TYPE OF FAILURE HAS NEVER OCCURRED, EVEN WITH UP TO 105K MILES. THE REPAIR IS ESTIMATED TO COST $1700. THIS TYPE OF FAILURE COULD LEAD TO A SERIOUS ACCIDENT BY THE FAILURE OF THE SUSPENSION SYSTEM AND LOSS OF VEHICLE CONTROL. *TR

NHTSA ODI #10198274

100 miles · Mar 30, 2007
Electrical SystemExterior LightingService Brakes, Hydraulic

TL*THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE WARNING TONE OF THE TIRE PRESSURE MONITORING SYSTEM SOUNDS INTERMITTENTLY. IN ADDITION, THE HEADLIGHTS FAILED, AND THE VEHICLE PULLED TO THE RIGHT SPORADICALLY AND WITHOUT WARNING. THE DEALER WAS UNABLE TO DIAGNOSE THE CAUSE OF FAILURE. THE CONTACT POSSESSED THE REPAIR IN…

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TL*THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE WARNING TONE OF THE TIRE PRESSURE MONITORING SYSTEM SOUNDS INTERMITTENTLY. IN ADDITION, THE HEADLIGHTS FAILED, AND THE VEHICLE PULLED TO THE RIGHT SPORADICALLY AND WITHOUT WARNING. THE DEALER WAS UNABLE TO DIAGNOSE THE CAUSE OF FAILURE. THE CONTACT POSSESSED THE REPAIR INVOICES. THE FAILURE MILEAGE BEGAN AT 100. *AK THE CONSUMER STATED THE FAILURES CONTINUE, SHE HAS HAD MULTIPLE PROBLEMS WITH THIS VEHICLE BRAKE ROTORS REPLACE AT 15,000 MILES, BRAKE PADS HAD TO BE REPLACED AT 18,000 MILES, TWO TIRES REPLACE AT 16,000 MILES, TPS LIGHTS CONTINUE TO GO ON AND OFF BEEN FIXED, FOUR NEW TIRES AT 30,000 MILES. THE CONSUMER STATES THAT THERE HAVE BEEN 9 RECALLS AND TPS LIGHTS STILL IN FAILURE. UPDATE 05/04/07*TR

NHTSA ODI #10186546

39,000 miles · Feb 16, 2007
Suspension

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE DRIVING AT 25 MPH THE CONTACT OBSERVED THAT THE VEHICLE WAS OUT OF ALIGNMENT. 3 TO 4 WHEEL ALIGNMENTS WERE PERFORMED TO CORRECT THE FAILURE AND THE REPAIRS WERE UNSUCCESSFUL. THE FAILURE ALMOST CAUSED THE CONTACT TO HAVE A COLLISION. THE WEATHER NOR SPEED WAS A FACTO…

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TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE DRIVING AT 25 MPH THE CONTACT OBSERVED THAT THE VEHICLE WAS OUT OF ALIGNMENT. 3 TO 4 WHEEL ALIGNMENTS WERE PERFORMED TO CORRECT THE FAILURE AND THE REPAIRS WERE UNSUCCESSFUL. THE FAILURE ALMOST CAUSED THE CONTACT TO HAVE A COLLISION. THE WEATHER NOR SPEED WAS A FACTOR. THE CURRENT MILEAGE WAS 39,000. *AK

NHTSA ODI #10182772

5,000 miles · Jan 30, 2007
Suspension

TL* - THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE VEHICLE WAS PULLING TO THE RIGHT. WHEN THE CAR NEEDED AN ALIGNMENT THE VEHICLE PULLED IN BOTH DIRECTIONS, RIGHT AND LEFT. THE VEHICLE WAS PURCHASED IN AUGUST 2003 , AND THE FAILURE HAS OCCURRED SINCE IT WAS PURCHASED. THERE HAVE BEEN 8 ALIGNMENTS PERFORMED ON THE VEHICL…

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TL* - THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE VEHICLE WAS PULLING TO THE RIGHT. WHEN THE CAR NEEDED AN ALIGNMENT THE VEHICLE PULLED IN BOTH DIRECTIONS, RIGHT AND LEFT. THE VEHICLE WAS PURCHASED IN AUGUST 2003 , AND THE FAILURE HAS OCCURRED SINCE IT WAS PURCHASED. THERE HAVE BEEN 8 ALIGNMENTS PERFORMED ON THE VEHICLE. THE VEHICLE HAS BEEN SERVICED 25 TIMES, AND THE MECHANICWAS UNABLE TO DIAGNOSE THE FAILURE. DUE TO THE WARRANTY THE DEALER AND VOLKSWAGEN AUTHORIZED THE TIRES TO BE REPLACED ON TWO OCCASIONS FOR UNEVEN WEAR AT 9,000 MILES. THE MANUFACTURER STATED THAT THE VEHICLE SHOULD NOT BE RELEASED FROM THE DEALER IF IT WASN'T REPAIRED. THEREFORE, THEY WERE UNABLE TO ASSIST HIM WITH FURTHER DIAGNOSIS. THE CONTACTWAS REQUESTING THAT VOLKWAGEN PURCHASE THE VEHICLE FROM HIM DUE TO THE ONGOING FAILURE. THE CONTACT LIVED IN A CLIMATE WHERE THE TEMPERATURES WER CONSISTENTLY BELOW ZERO. *AK UPDATED 03/19/07. *JB

NHTSA ODI #10181134

Official recalls

4

17V583000 · Fuel System, Gasoline:delivery:fuel Pump

Sep 20, 2017

Volkswagen Group of America, Inc. (Volkswagen) is recalling certain 2004-2007 Touareg vehicles. These gasoline-powered vehicles have a fuel filter flange that may crack, allowing fuel to leak.

Consequence & remedy

Consequence: A fuel leak in the presence of an ignition source increases the risk of a fire.

Remedy: Volkswagen will notify owners, and dealers will inspect the fuel filter flange for cracks, replacing the flange if cracks are found. If no cracks are found, a protective cover will be installed onto the filter flange. These repairs will be performed free of charge. The recall began March 9, 2018. Owners may contact Volkswagen customer service at 1-800-893-5298. Volkswagen's number for this recall is 20Ai.

04V592000 · Seat Belts

Dec 15, 2004

CERTAIN PASSENGER CARS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, "OCCUPANT CRASH PROTECTION." ALL THREE REAR SEAT POSITIONS AND THE FRONT PASSENGER POSITION ARE EQUIPPED WITH SEAT BELT RETRACTORS THAT HAVE A LOCKING FEATURE WHICH CONVERTS THE RETRACTOR FROM AN EMERGENCY LOCKING RETRACTOR (ELR) MODE TO AN AUTOMATIC LOCKING RETRACTOR (ALR) MODE FOR THE PURPOSES OF CHILD RESTRAINT INSTALLATION. THE BELT MAY DEACTIVATE THE ALR MODE WITH CERTAIN CHILD RESTRAINTS.

Consequence & remedy

Consequence: WHEN INVOLVED IN A CRASH, THE CHILD RESTRAINTS MAY NOT BE PROPERLY SECURED, INCREASING THE RISK OF INJURIES OR DEATH.

Remedy: DEALERS WILL PERMANENTLY INSTALL A 'CLIP' IN EACH OF THE TWO REAR OUTBOARD SEAT BELTS. THE CLIPS WILL PREVENT UNWANTED DEACTIVATION OF THE ALR MODE WITH CHILD SEAT INSTALLATIONS. THE RECALL BEGAN ON APRIL 11, 2005. OWNERS SHOULD CONTACT VW AT 1-800-822-8987.

04V233000 · Seat Belts:rear/other

May 19, 2004

ON CERTAIN SPORT UTILITY VEHICLES, THE REAR SEAT BELT LATCH ATTACHMENT BOLT MAY HAVE BEEN INSUFFICIENTLY RIVETED.

Consequence & remedy

Consequence: IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE BELT BUCKLE. OWNER NOTIFICATION BEGAN ON JUNE 21, 2004. OWNERS SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.

03V266000 · Electrical System:wiring

Jul 25, 2003

ON CERTAIN SPORT UTILITY VEHICLES, THE TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING HARNESS MAY HAVE BEEN IMPROPERLY ROUTED DURING ASSEMBLY. AN IMPROPERLY ROUTED TPMS WIRING HARNESS MAY CONTACT THE PARKING BRAKE CABLE SPRING.

Consequence & remedy

Consequence: IF THIS HAPPENS, THE TPMS WIRING CIRCUIT COULD BE INTERRUPTED, RESULTING IN AN INOPERATIVE TPMS, AND CAUSING A SHORT-TO-GROUND CONDITION THAT COULD POTENTIALLY RESULT IN A FIRE.

Remedy: DEALERS WILL INSPECT THE TPMS WIRING HARNESS ROUTING AND, IF NECESSARY, CORRECT THE WIRING HARNESS ROUTING. OWNER NOTIFICATION BEGAN AUGUST 18, 2003. OWNERS SHOULD CONTACT VWOA AT 1-800-893-5298.

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

2

PE06022 · Srs Warning Light Illumination

Opened Jun 19, 2006 · Closed Oct 30, 2006

Status: closed (inferred from source dates) · Air Bags; Air Bags:side/window

MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN OCTOBER AND NOVEMBER 2003, MAY CONTAIN AN INCORRECTLY MANUFACTURED SIDE AIR BAG MODULE.THIS ALSO MAY PRODUCE ABL ILLUMINATION THAT WOULD BECOME EVIDENT SOON AFTER THE VEHICLE IS PUT INTO SERVICE.WARRANTY DATA INDICATES THAT THESE MODULES HAVE BEEN CORRECTED AND NO LONGER PRESENT A RISK.VW HAS NOT RECEIVED ANY ALLEGED SIDE AIR BAG NON-DEPLOYMENT REPORT.ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUE RAISED BY THIS INVESTIGATION.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Additional source detail variants (2)

Air Bags:side/window

MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN OCTOBER AND NOVEMBER 2003, MAY CONTAIN AN INCORRECTLY MANUFACTURED SIDE AIR BAG MODULE.THIS ALSO MAY PRODUCE ABL ILLUMINATION THAT WOULD BECOME EVIDENT SOON AFTER THE VEHICLE IS PUT INTO SERVICE.WARRANTY DATA INDICATES THAT THESE MODULES HAVE BEEN CORRECTED AND NO LONGER PRESENT A RISK.VW HAS NOT RECEIVED ANY ALLEGED SIDE AIR BAG NON-DEPLOYMENT REPORT.ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUE RAISED BY THIS INVESTIGATION.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Air Bags

MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN OCTOBER AND NOVEMBER 2003, MAY CONTAIN AN INCORRECTLY MANUFACTURED SIDE AIR BAG MODULE.THIS ALSO MAY PRODUCE ABL ILLUMINATION THAT WOULD BECOME EVIDENT SOON AFTER THE VEHICLE IS PUT INTO SERVICE.WARRANTY DATA INDICATES THAT THESE MODULES HAVE BEEN CORRECTED AND NO LONGER PRESENT A RISK.VW HAS NOT RECEIVED ANY ALLEGED SIDE AIR BAG NON-DEPLOYMENT REPORT.ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUE RAISED BY THIS INVESTIGATION.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

PE05042 · Exterior Door Handle Malfunction

Opened Aug 11, 2005 · Closed Dec 21, 2005

Status: closed (inferred from source dates) · Latches/locks/linkages:doors:latch

VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB) DATED JUNE 10, 2005, DESCRIBING A CONDITION OF EXTERIOR DOOR HANDLE STICKS IN THE OPENED POSITION AFTER THE DOOR IS OPENED.VW DESCRIBED THE CAUSE OF THE PROBLEM TO BE A POTENTIAL FOR INCREASED FRICTION BETWEEN THE DOOR HANDLE AND THE LOCK CYLINDER HOUSING . . . BECAUSE SOME GUIDE NUBS THAT WERE MOLDED INTO THE PLASTIC DOOR HANDLE . . . WERE SLIGHTLY HIGHER THAN SPECIFIED.IN ADDITION TO THE TSB, VW HAS INTRODUCED PRODUCTION CHANGES (LUBRICATION, DELETION OF THE GUIDE NUBS, INTRODUCTION OF A LOW FRICTION GUIDE SURFACE ON THE LOCK CYLINDER HOUSING) TO ADDRESS THE PROBLEM.VW REPORTS THAT THE FAILURE OCCURS PREDOMINANTLY IN THE VERY EARLY LIFE STAGE OF THE VEHICLE.ODI EXAMINATION OF VW'S WARRANTY DATA SHOWS FEWER CLAIMS AS THE VEHICLE AGES.THE ONE INJURY RESULTED WHEN THE UNLATCHED DOOR HIT THE OCCUPANT'S HAND.A SAFETY DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.ODI WILL CONTINUE TO MONITOR COMPLAINTS ANDRESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.