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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
91,000 miles · Feb 21, 2011
Electrical SystemFuel System, Gasoline

CONSTANT REPAIR OF 2004 VW TOUAREG: THIS VEHICLE HAS BEEN CERTIFIED IN ALL STATES OF THE UNION AS BEING A CERTIFIED LEMON. WHEN I PURCHASED THE VEHICLE I HAD NO IDEA OF THIS. I HAVE HAD TO REPLACE A FAN SENSOR WHICH IS A CERTIFIED VW DEFECT, BUT I HAD TO PAY FOR THE COST, REPAIR AND LABOR IN THE AMOUNT OF $550 AND FURTHER, TH…

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CONSTANT REPAIR OF 2004 VW TOUAREG: THIS VEHICLE HAS BEEN CERTIFIED IN ALL STATES OF THE UNION AS BEING A CERTIFIED LEMON. WHEN I PURCHASED THE VEHICLE I HAD NO IDEA OF THIS. I HAVE HAD TO REPLACE A FAN SENSOR WHICH IS A CERTIFIED VW DEFECT, BUT I HAD TO PAY FOR THE COST, REPAIR AND LABOR IN THE AMOUNT OF $550 AND FURTHER, THE VEHICLE LEFT ME STRANDED BECAUSE THE FAULTY SENSOR ALLOWED A FAN TO KEEP BLOWING THEREBY DRAINING MY BATTERY COMPLETELY. REAR WINDSHIELD WIPER DISINTEGRATED DURING HEAVY RAIN AND COST 65 TO REPAIR ALTHOUGH THE PIECE LOOKS LIKE SOMETHING A CHILD PUT TOGETHER. FRONT WINDSHIELD WIPER FLEW OFF OF CAR WHILE RAINING, CAUSING ME TO PULL OVER AND BE STRANDED ONCE AGAIN. I GOT STRANDED AGAIN BECAUSE THE VW ENGINE COILS BURNT OUT WITHOUT NOTICE LEAVING ME STRANDED IN BLIZZARD CONDITIONS IN CHICAGO. I HAD TO GET A NEW BATTERY BUT WAS CHARGED $250 FOR THE BATTERY AND INSTALLATION BECAUSE VW CHOSE TO PUT THE BATTERY UNDER THE FRONT DRIVER'S SEAT. NOT THREE WEEKS HAVE PASSED AND I HAVEN'T EVEN DRIVEN THE VEHICLE BUT BOTH FUEL PUMPS AND THE FLANGE MODULE HAVE GONE OUT. I HAD TO PAY $1500 FOR LABOR, PARTS, SHOP AND REPAIRS. VEHICLE HAS 91,000 AND BRAKES AND ROTORS HAVE GONE OUT AGAIN FOR THE 3RD TIME. RIGHT DOOR OPENS WHEN DRIVING ALTHOUGH THE VEHICLE IS LOCKED, WHICH IS ANOTHER CERTIFIED DEFECT. VEHICLE LUNGES FORWARD FROM A STOPPED POSITION AND THEN HESITATES WHEN TRYING TO SPEED UP ON THE HIGHWAY. *TR

NHTSA ODI #10383882

40,000 miles · Jan 18, 2011
Air Bags

2004 VW TOUREG FAULT WITH AIRBAGS. ELECTRICAL SYSTEM HAS FAILED WHICH HAS RESULTED IN ALL OF THE AIRBAGS TO BE DEACTIVATED. THE WIRING IS ROUTED AROUND THE HORN WHICH HAS RESULTED IN ONE SIDE OF THE HORN TO NOT WORK. UNSAFE AND NEEDS TO BE RECALLED. *TR

NHTSA ODI #10377017

91,000 miles · Dec 30, 2010
Air BagsCrash

I WAS TRAVELING APPROXIMATELY 40 MILES PER HOUR WHEN I REAR ENDED A VEHICLE. MY AIRBAG DEPLOYED, BUT NOT AS MUCH AS I THOUGHT IT WOULD. THE AIRBAG BARELY HIT MY UPPER BODY AND THEN IT SEEMED 3/4 DEFLATED ALMOST IMMEDIATELY. I DON'T THINK THE AIRBAG WAS WORKING PROPERLY BECAUSE I WOULD THINK FROM WHAT I'VE SEEN THAT THE AIRBAG…

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I WAS TRAVELING APPROXIMATELY 40 MILES PER HOUR WHEN I REAR ENDED A VEHICLE. MY AIRBAG DEPLOYED, BUT NOT AS MUCH AS I THOUGHT IT WOULD. THE AIRBAG BARELY HIT MY UPPER BODY AND THEN IT SEEMED 3/4 DEFLATED ALMOST IMMEDIATELY. I DON'T THINK THE AIRBAG WAS WORKING PROPERLY BECAUSE I WOULD THINK FROM WHAT I'VE SEEN THAT THE AIRBAG WOULD HAVE BEEN ALOT FULLER AND WOULD HAVE ME PINNED UP AGAINST MY DRIVER SEAT, BUT IT DID NOT. I WAS ABLE TO EXIT MY CAR WITHOUT A STRUGGLE AND DON'T REMEMBER EVEN TOUCHING THE AIRBAG WHEN I EXITED THE VEHICLE. NONE OF THE OTHER AIRBAGS DEPLOYED, ARE THEY SUPPOSED TO WHEN YOU GET INTO AN ACCIDENT. I GUESS I'M LUCKY THAT WHEN I HIT THE VEHICLE IN FRONT OF ME THAT THE IMPACT WAS NOT HARDER, BECAUSE I DON'T BELIEVE THE AIRBAG WOULD HAVE KEPT ME FROM HITTING THE STEERING WHEEL WITH GREAT FORCE OR EVEN SAVING MY LIFE. I PLAN TO CONTACT VOLKSWAGEN DIRECTLY ABOUT MY COMPLAINT AS WELL. *TR

NHTSA ODI #10373515

46,605 miles · Dec 17, 2010
Parking Brake

EVERY TIME THE CAR IS STARTED THE WARNING LIGHT SHOWS THAT THE PARKING BRAKE IS ENGAGED. I NEVER USE THE PARKING BRAKE. I HAVE TALKED TO THE DEALER AND THEY SAY THAT THE PARKING BRAKE PEDAL NEEDS TO BE "HAND LIFTED" TO CLEAR THE WARNING LIGHT. WHEN I TRIED THIS IT DID CLEAR THE WARNING LIGHT FROM THE DASH. MY QUESTION IS WH…

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EVERY TIME THE CAR IS STARTED THE WARNING LIGHT SHOWS THAT THE PARKING BRAKE IS ENGAGED. I NEVER USE THE PARKING BRAKE. I HAVE TALKED TO THE DEALER AND THEY SAY THAT THE PARKING BRAKE PEDAL NEEDS TO BE "HAND LIFTED" TO CLEAR THE WARNING LIGHT. WHEN I TRIED THIS IT DID CLEAR THE WARNING LIGHT FROM THE DASH. MY QUESTION IS WHY WOULD MY PARKING BRAKE BE ENGAGED IF I NEVER HAVE USED THE PARKING BRAKE? IT MAY JUST BE SOME MALFUNCTION WITH THEIR WARNING LIGHTS OR SENSORS, BUT HOW I AM I TO KNOW IF THIS IS A REAL PARKING BRAKE WARNING? *TR

NHTSA ODI #10371126

92,000 miles · Sep 10, 2010
Power Train

AT 94,000 MILES TRANSMISSION PROBLEMS, TOLD TRANSMISSION NON-SERVICEABLE VW DOES NOT RECOMMEND ANY TRANSMISSION FLUID REPLACEMENT. COULD BE GEAR BOX COST $2400 OR ENTIRE TRANSMISSION COST $7,000. VWA WILL PAY $1,000 TO OUR CHOICE OF GEAR BOX OR TRANSMISSION REPLACEMENT BUT IF WE CHOOSE WRONG REPAIR WILL NOT PAY FOR ANYTHING FURT…

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AT 94,000 MILES TRANSMISSION PROBLEMS, TOLD TRANSMISSION NON-SERVICEABLE VW DOES NOT RECOMMEND ANY TRANSMISSION FLUID REPLACEMENT. COULD BE GEAR BOX COST $2400 OR ENTIRE TRANSMISSION COST $7,000. VWA WILL PAY $1,000 TO OUR CHOICE OF GEAR BOX OR TRANSMISSION REPLACEMENT BUT IF WE CHOOSE WRONG REPAIR WILL NOT PAY FOR ANYTHING FURTHER! VWA OBVIOUSLY IS AWARE OF PROBLEM AND DESIGNED THE TRANSMISSION IN SUCH A WAY THAT IT CAN'T BE SERVICED. WE HAVE HAD PRIOR ENGINE COIL RECALL REPLACED, UPDATED COMPUTER SOFTWARE AND REPLACED DRIVE-TRAIN AT COST OF $1900 AT 74,000 MILES. *TR

NHTSA ODI #10354882

61,525 miles · Aug 7, 2010
Tires

WE HAVE A 2004 VOLKSWAGEN TOUAREG WHICH HAS HAD A CONTINUING PROBLEM SINCE JUNE 2009. THE TIRE PRESSURE MONITORING SYSTEM CONTINUALLY COMES ON WITH LOUD AND SOMETIMES INTERMITTENT AND SOMETIMES CONTINUING BEEPING WARNING OF FLAT TIRES, OR THE SYSTEM IS "LEARNING". EACH WHEEL HAS A BATTERY OPERATED UNIT (WHEEL SENSOR) WHICH W…

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WE HAVE A 2004 VOLKSWAGEN TOUAREG WHICH HAS HAD A CONTINUING PROBLEM SINCE JUNE 2009. THE TIRE PRESSURE MONITORING SYSTEM CONTINUALLY COMES ON WITH LOUD AND SOMETIMES INTERMITTENT AND SOMETIMES CONTINUING BEEPING WARNING OF FLAT TIRES, OR THE SYSTEM IS "LEARNING". EACH WHEEL HAS A BATTERY OPERATED UNIT (WHEEL SENSOR) WHICH WILL NOT BE REPLACED UNDER WARRANTY UNTIL THE BATTERY IS COMPLETELY DEAD. THERE IS A $75- CHARGE EACH TIME TO INFORM YOU THAT THE BATTERY IS NOT YET DEAD. IN THE MEANTIME YOU DRIVE ALONG WITH THE WARNING SIGNAL GOING OFF. *TR

NHTSA ODI #10347945

75,285 miles · Aug 5, 2010
Electrical SystemPower TrainStructure

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE CONTACT STATED THE GEAR SHIFT SELECTOR WOULD NOT MOVE OUT OF PARK AND HE WAS UNABLE TO REMOVE THE KEY FROM THE IGNITION. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER. WHILE THE VEHICLE WAS BEING TOWED, THE ENTIRE CONSOLE AND WARNING LIGHTS ILLUMINATED. IN ADDITION, THE CONTAC…

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TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE CONTACT STATED THE GEAR SHIFT SELECTOR WOULD NOT MOVE OUT OF PARK AND HE WAS UNABLE TO REMOVE THE KEY FROM THE IGNITION. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER. WHILE THE VEHICLE WAS BEING TOWED, THE ENTIRE CONSOLE AND WARNING LIGHTS ILLUMINATED. IN ADDITION, THE CONTACT STATED WATER WAS ENTERING THE VEHICLE AND SETTLING IN THE TRUNK NEAR THE SPARE TIRE. THE DEALER REMOVED THE SHIFTER CABLE AND REPLACED THE HARNESS, A WIRE AND THE SHIFTER COLUMN. THE FAILURE MILEAGE WAS 75,285 AND THE CURRENT MILEAGE WAS 76,065. UPDATED 11/02/10. *LJ THE CONSUMER STATED THE TRUNK WOULD NOT OPEN PROPERLY. THE TIRE SENSORS WOULD COME ON. THE IGNITION SWITCH WAS DEFECTIVE AND HAD TO BE REPLACED. UPDATED 11/04/10

NHTSA ODI #10347465

76,950 miles · Jun 15, 2010
Power Train

HEARD A KNOCKING SOUND FROM BELOW ON MY 2004 VOLKSWAGEN TOUAREG. LOOKED UNDER MY CAR, THE MIDDLE UNDER CARRIAGE WAS GONE. THERE WAS A KNOCKING AND THUMPING NOISE IN THE VEHICLE. THOUGHT IT WAS JUST THE UNDERCARRIAGE, BUT WHEN THE PART CAME IN AND INSTALLED IT, THE KNOCKING WAS STILL THERE. DROVE IT LAST NIGHT BECAUSE I NEED MY C…

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HEARD A KNOCKING SOUND FROM BELOW ON MY 2004 VOLKSWAGEN TOUAREG. LOOKED UNDER MY CAR, THE MIDDLE UNDER CARRIAGE WAS GONE. THERE WAS A KNOCKING AND THUMPING NOISE IN THE VEHICLE. THOUGHT IT WAS JUST THE UNDERCARRIAGE, BUT WHEN THE PART CAME IN AND INSTALLED IT, THE KNOCKING WAS STILL THERE. DROVE IT LAST NIGHT BECAUSE I NEED MY CAR; I HEARD MY CAR HAVE RATTLING NOISES UNDERNEATH. SOUNDS LIKE THERE'S LOSS PARTS UNDER THE CAR. I NEVER TOOK MY CAR OFF ROAD, THE ROADS ON OAHU ARE TERRIBLE, BUT NEVER HAD THIS EVER DONE ON MY OLDER CARS. I WAS RESEARCHING ONLINE AND SAW THAT A LOT OF OTHER TOUAREG OWNERS HAVE/HAD THE SAME PROBLEM. I'M NOT GOING TO PAY FOR A DEFAULT PART, ESPECIALLY WHEN THE DRIVE SHAFT AND ITS BEARINGS ARE THE MAIN PARTS OF THE CAR POWERTRAIN. I HAVEN'T DONE ANYTHING WRONG WITH THIS VEHICLE AND FEEL THAT VOLKSWAGEN WILL NEED TO PAY FOR THIS FIX. *TR

NHTSA ODI #10336523

95,000 miles · Jun 4, 2010
Air BagsElectrical SystemLatches/locks/linkages

2004 VW TOUAREG V-8 MANY PROBLEMS BUT 3 WORTH REPORTING: FOR NO APPARENT REASON PASSENGER DOOR COULD NOT BE OPENED OR UNLATCHED BY USING ANY KNOWN MEANS INCLUDING THE INSIDE DOOR HANDLE OR OUTSIDE DOOR HANDLE, ELECTRIC LOCK ACTUATOR CLICKS AS IF THE DOOR IS UNLOCKED BUT THE DOOR CAN NOT BE OPENED OR UNLATCHED. VEHICLE HAD TO…

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2004 VW TOUAREG V-8 MANY PROBLEMS BUT 3 WORTH REPORTING: FOR NO APPARENT REASON PASSENGER DOOR COULD NOT BE OPENED OR UNLATCHED BY USING ANY KNOWN MEANS INCLUDING THE INSIDE DOOR HANDLE OR OUTSIDE DOOR HANDLE, ELECTRIC LOCK ACTUATOR CLICKS AS IF THE DOOR IS UNLOCKED BUT THE DOOR CAN NOT BE OPENED OR UNLATCHED. VEHICLE HAD TO BE BROUGHT TO VW DEALERSHIP AND WORKED ON BY DESTROYING THE DOOR HANDLE TO OPEN THE DOOR AND PERHAPS CUTTING A WHOLE IN THE BODY PANNEL AT THE COST OF 2 HOURS OF DIAGNOSTICS, 8 HOURS OF LABOR TO OPEN DOOR AND PROBABLY 2 OR 3 ADDITIONAL HOURS OF REPLACING DOOR HANDLE IF BODY OF DOOR IS NOT BENT, PLUS PARTS VEHICLE HAS MANY ELECTRICAL GLITCHES INCLUDING BUT NOT LIMITED TO INTERMITTENT MALFUNCTION OF AIR BAG IGNITERS....ONCE AGAIN HAVING THE POTENTIAL TO CAUSE SERIOUS HARM OCCUPANTS GIVEN THE RIGHT CIRCUMSTANCES THIS IS A POTENTIAL DANGEROUS SITUATION AND HAS MADE ME LOSE ALL FAIH IN THIS MANUFACTURER. VEHICLE LUNGES FORWARD WHEN STOPPED AT TRAFIC LIGHTS AND BEGINNING TO PROCCEED ON A GREEN. *TR

NHTSA ODI #10334661

45,000 miles · May 28, 2010
Power TrainTires

I HAVE A 2004 TOUAREG AND HAVE BEEN HAVING TRANSMISSION ISSUES HARD SHIFTS, BUCKING AND HARD DOWNSHIFTS. I HAVE TAKEN THIS TO THE VW DEALER AND THEY SAY THERE IS NOTHING WRONG WITH THE TRANSMISSION. IT IS VERY VERY DANGEROUS WHEN ACCESS THE HIGHWAY AND IN SEVERAL CASES IT SHIFTS SO HARD THAT IT KNOCKS IT'S SELF OUT AND YOU HAV…

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I HAVE A 2004 TOUAREG AND HAVE BEEN HAVING TRANSMISSION ISSUES HARD SHIFTS, BUCKING AND HARD DOWNSHIFTS. I HAVE TAKEN THIS TO THE VW DEALER AND THEY SAY THERE IS NOTHING WRONG WITH THE TRANSMISSION. IT IS VERY VERY DANGEROUS WHEN ACCESS THE HIGHWAY AND IN SEVERAL CASES IT SHIFTS SO HARD THAT IT KNOCKS IT'S SELF OUT AND YOU HAVE TO PULL OFF THE HIGHWAY UNTIL RESETS TO 4TH GEAR FROM 6TH. I NOW HAVE TO SHIFT MANUALLY. I HAVE THIS ISSU E DAILY AND I KNOW THIS IS A WIDE SPREAD ISSUE. *TR

NHTSA ODI #10332622

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.