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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.

About this comparison →

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

What owners actually said

231 reports
Mileage unknown · Dec 10, 2005
SteeringSuspension

ALIGNMENT ON 2004 VW TOUAREG IS HORRIBLE. TAKEN BACK AT LEAST 3 TIMES AND IT HAS NEVER BEEN FIXED. TIRES ARE NOW SHOT BECAUSE OF THE ALIGNMENT PROBLEMS. COMPUTER KEEPS BEEPING THAT THERE IS A FLAT TIRE WHEN THE AIR PRESSURE IS FINE WHEN CHECKED. TAKEN IN AT LEAST 3 TIMES AND IT STILL HAS NOT BEEN FIXED. SPEAKERS RATTLE AS IF THE…

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ALIGNMENT ON 2004 VW TOUAREG IS HORRIBLE. TAKEN BACK AT LEAST 3 TIMES AND IT HAS NEVER BEEN FIXED. TIRES ARE NOW SHOT BECAUSE OF THE ALIGNMENT PROBLEMS. COMPUTER KEEPS BEEPING THAT THERE IS A FLAT TIRE WHEN THE AIR PRESSURE IS FINE WHEN CHECKED. TAKEN IN AT LEAST 3 TIMES AND IT STILL HAS NOT BEEN FIXED. SPEAKERS RATTLE AS IF THEY ARE BLOWN....ALSO....NEVER BEEN FIXED. *JB

NHTSA ODI #10144895

15,000 miles · Nov 7, 2005
Latches/locks/linkagesSuspensionTires

DOOR HANDLES STICK ON ALL FOUR DOORS. LAST YEAR, MY HUSBAND WAS IN THE PASSENGER SEAT AS I WENT AROUND A CORNER, THE PASSENGER DOOR FLUNG OPEN AND MY HUSBAND ALMOST FELL OUT. LUCKILY HE WAS WEARING HIS SEAT BELT. THE DOOR HANDLES WERE REPLACED BY THE DEALERSHIP. HOWEVER, THE DOOR HANDLES HAVE STARTED STICKING AGAIN. I HAVE …

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DOOR HANDLES STICK ON ALL FOUR DOORS. LAST YEAR, MY HUSBAND WAS IN THE PASSENGER SEAT AS I WENT AROUND A CORNER, THE PASSENGER DOOR FLUNG OPEN AND MY HUSBAND ALMOST FELL OUT. LUCKILY HE WAS WEARING HIS SEAT BELT. THE DOOR HANDLES WERE REPLACED BY THE DEALERSHIP. HOWEVER, THE DOOR HANDLES HAVE STARTED STICKING AGAIN. I HAVE TO PULL THE HANDLE AND LET IT GO QUICKLY TO LOOSEN THE HANDLE SO IT CLOSES FULLY. I NOTICED WITH 1000 MILES ON MY VEHICLE THAT THERE WAS A PULL IN THE FRONT END. I TOOK IT TO THE DEALER AND THEY SAID IT NEEDED TO BE ALIGNED. THEY REFUSED TO PAY FOR THE ALIGNMENT, MY TIRES WERE COMPLETELY WORN TO THE TREAD BARS WITH 15,000 MILES ON ALL FOUR, THEY WERE CUPPED. THE MANUFACTURER REPLACED 2 TIRES AND I PAID FOR 2 TIRES AND A 4 WHEEL ALIGNMENTS. *NM *AK

NHTSA ODI #10142016

Mileage unknown · Oct 27, 2005
Suspension

CONSUMER VOLKSWAGEN TOUAREG DRIFTS TO THE RIGHT. *TS *** NO ANSWER REQUIRED*** *SC

NHTSA ODI #10142123

Mileage unknown · Oct 27, 2005
Visibility

2004 VW TOUAREG WINDSHIELD WIPER SYSTEM. WHEN WIPER IS SET TO WIPE CONTINUOUSLY, WIPER STOPS WHEN VEHICLE COMES TO A FULL STOP, AND WILL NOT BEGIN TO WIPE UNTIL VEHICLE EXCEEDS 5 MPH. DURING HEAVY RAINS, IT IS UNSAFE TO PROCEED TOO 5 MPH WHEN WINDSHIELD WIPER IS NOT WIPING. NO VISIBILITY IN HEAVY DOWNPOUR CONDITIONS, MUST PUT…

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2004 VW TOUAREG WINDSHIELD WIPER SYSTEM. WHEN WIPER IS SET TO WIPE CONTINUOUSLY, WIPER STOPS WHEN VEHICLE COMES TO A FULL STOP, AND WILL NOT BEGIN TO WIPE UNTIL VEHICLE EXCEEDS 5 MPH. DURING HEAVY RAINS, IT IS UNSAFE TO PROCEED TOO 5 MPH WHEN WINDSHIELD WIPER IS NOT WIPING. NO VISIBILITY IN HEAVY DOWNPOUR CONDITIONS, MUST PUT VEHICLE IN FORWARD MOTION TO WIPE AND SEE. ACCIDENT WAITING TO HAPPEN. MANUFACTURER INDICATES THIS IS A "FEATURE" NOT DEFECT! *NM

NHTSA ODI #10140942

Mileage unknown · Oct 26, 2005
Engine And Engine CoolingLatches/locks/linkagesPower TrainInjury

OUR 2004 VW TOUAREG V-8 HAS THE FOLLOWING PROBLEMS DESPITE FIVE TRIPS TO THE DEALER: I) HESITATION DURING ACCELERATION; II) PULLS HARD TO THE RIGHT; AND III) SHIFTS ROUGHLY AT LOW SPEEDS. PAST PROBLEMS INCLUDE: IV) THE LATCH ON THE REAR DOOR BROKE, SUCH THAT IT CAME CRASHING DOWN ON MY WIFE'S HEAD; V) THE REAR SEAT BELT LATCH…

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OUR 2004 VW TOUAREG V-8 HAS THE FOLLOWING PROBLEMS DESPITE FIVE TRIPS TO THE DEALER: I) HESITATION DURING ACCELERATION; II) PULLS HARD TO THE RIGHT; AND III) SHIFTS ROUGHLY AT LOW SPEEDS. PAST PROBLEMS INCLUDE: IV) THE LATCH ON THE REAR DOOR BROKE, SUCH THAT IT CAME CRASHING DOWN ON MY WIFE'S HEAD; V) THE REAR SEAT BELT LATCH WOULDN'T WORK; VI) THE CAR SHUDDERED BADLY WHEN YOU TRIED TO MAKE A TURN AT LOW SPEEDS (E.G., WHILE PARKING) AND VII) THE FLAT TIRE INDICATOR WENT ON EVEN THOUGH THE TIRE WAS NEITHER FLAT NOR LOW. WE HAVE AN ARBITRATION SCHEDULED FOR 11/9/05 UNDER CALIFORNIA'S LEMON LAW. *NM

NHTSA ODI #10140862

45 miles · Oct 25, 2005
Tires

DT: THE CONTACT STATED THERE WAS A PROBLEM WITH THE TIRE PRESSURE MONITORING SYSTEM. IT GAVE INCORRECT READINGS. THE WARNING INDICATOR LIGHT STAYED ON. THE CONTACT TOOK THE VEHICLE TO THE DEALERSHIP SIX TIMES. THE TIRE PRESSURE HAS BEEN CHECKED, AND THE MONITOR HAS BEEN RESET. THE DEALERSHIP HAS BEEN UNABLE TO CORRECT THE…

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DT: THE CONTACT STATED THERE WAS A PROBLEM WITH THE TIRE PRESSURE MONITORING SYSTEM. IT GAVE INCORRECT READINGS. THE WARNING INDICATOR LIGHT STAYED ON. THE CONTACT TOOK THE VEHICLE TO THE DEALERSHIP SIX TIMES. THE TIRE PRESSURE HAS BEEN CHECKED, AND THE MONITOR HAS BEEN RESET. THE DEALERSHIP HAS BEEN UNABLE TO CORRECT THE PROBLEM. *AK

NHTSA ODI #10140776

1,900 miles · Oct 21, 2005
Power Train

MY 2004 VW TOUAREG HAS HAD AN ONGOING SAFETY ISSUE SINCE PURCHASE IN JULY OF 2004 WITH REGARDS TO THE TRANSMISSION. WHEN ACCELERATING FROM A STOP OR LOW SPEED THE VEHICLE WILL OFTEN HESITATE WHILE RUNNING THE ENGINE RPMS UP TO 3000-4000 THEN DROP INTO GEAR AND LURCH FORWARD. THE TRANSMISSION ALSO ERRATICALLY SHIFTS FROM FIRST TO…

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MY 2004 VW TOUAREG HAS HAD AN ONGOING SAFETY ISSUE SINCE PURCHASE IN JULY OF 2004 WITH REGARDS TO THE TRANSMISSION. WHEN ACCELERATING FROM A STOP OR LOW SPEED THE VEHICLE WILL OFTEN HESITATE WHILE RUNNING THE ENGINE RPMS UP TO 3000-4000 THEN DROP INTO GEAR AND LURCH FORWARD. THE TRANSMISSION ALSO ERRATICALLY SHIFTS FROM FIRST TO SECOND GEAR AND OFTEN HESITATES FOR MORE THAN A FEW SECONDS BEFORE ENGAGING THIS CAUSES A DANGER WHEN MERGING WITH TRAFFIC OR CROSSING INTERSECTIONS. I HAVE CONTACTED THE DEALER AND VOLKSWAGEN OF NORTH AMERICA WITH NO RESOLUTION. *NM

NHTSA ODI #10140405

10,000 miles · Oct 10, 2005
Electrical SystemSuspension

MY 2004 V8 TOUAREG IS ABSOLUTELY THE BIGGEST LEMON EVER BUILT. IT HAS BEEN IN THE DEALERSHIP FOR 11 FULL WEEKS THIS YEAR WITH A VARIETY OF ISSUES. THE TWO MOST SIGNIFICANT WHICH HAVE TAKEN VW 5 WEEKS EACH TO IDENTIFY AND RESOLVE ARE THE ELECTRICAL SYSTEM WAS COMPLETELY MALFUNCTIONING AND THE PUMP TO CHANGE THE SUSPENSION HAS A…

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MY 2004 V8 TOUAREG IS ABSOLUTELY THE BIGGEST LEMON EVER BUILT. IT HAS BEEN IN THE DEALERSHIP FOR 11 FULL WEEKS THIS YEAR WITH A VARIETY OF ISSUES. THE TWO MOST SIGNIFICANT WHICH HAVE TAKEN VW 5 WEEKS EACH TO IDENTIFY AND RESOLVE ARE THE ELECTRICAL SYSTEM WAS COMPLETELY MALFUNCTIONING AND THE PUMP TO CHANGE THE SUSPENSION HAS A LEAK. VW HAS BEEN COMPLETELY IN THE DARK ON THESE MAJOR PROBLEMS AND ONLY AFTER REPEATED TRIPS TO THE DEALER AND MANY DENIALS FROM VW DID THE ADMIT THAT THIS CAR IS AN OVER ENGINEERED AND POORLY BUILT CAR. *JB

NHTSA ODI #10139174

5,000 miles · Oct 6, 2005
Electrical SystemPower Train

MY 2004 V6 VOLKSWAGEN TOUAREG FREQUENTLY STALLS AFTER THE ENGINE IS CRANKED. THIS HAS BEEN A PROBLEM SINCE WE PURCHASED THE VEHICLE IN OCT 2004. AFTER CRANKING YOU CAN PRESS ALL THE WAY DOWN ON THE GAS PEDAL BUT THE CAR WILL NOT MOVE AT ALL. AFTER A FEW SECONDS, IT WILL SPUTTER A LITTLE THEN MOVE THEN SPUTTER AGAIN THEN IT WILL …

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MY 2004 V6 VOLKSWAGEN TOUAREG FREQUENTLY STALLS AFTER THE ENGINE IS CRANKED. THIS HAS BEEN A PROBLEM SINCE WE PURCHASED THE VEHICLE IN OCT 2004. AFTER CRANKING YOU CAN PRESS ALL THE WAY DOWN ON THE GAS PEDAL BUT THE CAR WILL NOT MOVE AT ALL. AFTER A FEW SECONDS, IT WILL SPUTTER A LITTLE THEN MOVE THEN SPUTTER AGAIN THEN IT WILL DRIVE NORMALLY. THERE IS NO WAY TO TELL WHEN THIS WILL HAPPEN AND I AM CONCERNED THAT IT WILL CAUSE AN ACCIDENT IF I START THE VEHICLE THEN PULL OUT INTO ONCOMING TRAFFIC. *JB

NHTSA ODI #10138770

16,000 miles · Sep 28, 2005
Power TrainTires

CONSUMERS VEHICLE IS EXPERIENCING ERRATIC SHIFTING. WHEN ACCELERATING FROM A STOP CAR WILL HESITATE AND JERK. *TS THIS PROBLEM SEEMS TO ONLY OCCURE WHIL THE TRANSMISSION IS IN LOWER GEARS. THE VEHICLE HAS BEEN TAKEN TO THE DELER AT LEAST THREE TIMES BUT THEY HAVE NOT BEEN ABLE TO LOCATE OR FIX THE PROBLEM. THE CONSUEMR HAS AL…

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CONSUMERS VEHICLE IS EXPERIENCING ERRATIC SHIFTING. WHEN ACCELERATING FROM A STOP CAR WILL HESITATE AND JERK. *TS THIS PROBLEM SEEMS TO ONLY OCCURE WHIL THE TRANSMISSION IS IN LOWER GEARS. THE VEHICLE HAS BEEN TAKEN TO THE DELER AT LEAST THREE TIMES BUT THEY HAVE NOT BEEN ABLE TO LOCATE OR FIX THE PROBLEM. THE CONSUEMR HAS ALSO CONTACTED TEHE MANUFCATURE BUT THEY PROVIDED NO ASSISTANCE. THE TIRE HAVE EXCESSIVE WEAR AT ONLY 16000 MILES. *NM

NHTSA ODI #10138832

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.