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2005 Volkswagen Touareg

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2005 Volkswagen Touareg do not stand out strongly from the model-year median of 27.5.

About this comparison →

When problems were reported

Mileage at the reported incident

58 reports with mileage · 17 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.

  • Fuel/propulsion System. Review the 16 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 14 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 10 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

0 crash reports0 fire reports1 injury reports

What owners actually said

75 reports
17,500 miles · Aug 6, 2006
StructureInjury

JULY 6, 2006 I OPENED THE HATCHBACK TRUNK TO PUT A BAG IN. I WAS STANDING TO THE LEFT SIDE OF THE CAR CLOSE ENOUGH TO LEAN INTO TRUNK. THE TRUNK DOOR OPEN AS USUAL, I LEANED IN TO PLACE MY BAG AND THE TRUNK DOOR DROPPED ON MY HEAD LEAVING ME QUITE DAZED AND BLOOD RUNNING DOWN MY FACE. THE AIR SHOCK ON THE TRUNK FAILED LEAVING …

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JULY 6, 2006 I OPENED THE HATCHBACK TRUNK TO PUT A BAG IN. I WAS STANDING TO THE LEFT SIDE OF THE CAR CLOSE ENOUGH TO LEAN INTO TRUNK. THE TRUNK DOOR OPEN AS USUAL, I LEANED IN TO PLACE MY BAG AND THE TRUNK DOOR DROPPED ON MY HEAD LEAVING ME QUITE DAZED AND BLOOD RUNNING DOWN MY FACE. THE AIR SHOCK ON THE TRUNK FAILED LEAVING AN 1 INCH WIDE AND DEEP HOLE IN THE RIGHT CORNER OF MY FORE HEAD. I WAS TAKEN TO EMERGENCY WHERE THEY PUT STAPLES IN MY HEAD AND SENT ME HOME WITH INSTRUCTIONS TO TAKE CARE OF A CONCUSSION. VW WAS NOTIFIED AND THE CAR WAS TAKEN IN. THE CAR WAS THERE FOR 3 DAYS. I PICKED IT UP AND 3 DAYS AFTER THAT THE DOOR FAILED AGAIN. "THANK GOODNESS I WAS STILL BEING CAUTIOUS OR IT COULD HAVE HAPPENED AGAIN. I THEN TRADED THE CAR IN, NOT WANTING TO WAIT FOR ANOTHER FAILURE. *JB

NHTSA ODI #10164644

12,000 miles · Jul 29, 2006
SuspensionTires

FRONT TIRES WEAR AT 8-10,000 MILES, FIRST SET REPLACED AND GIVEN A NEW ALIGNMENT HOWEVER NOW SECOND SET WORN AS WELL. VOLKSWAGEN REFUSES TO REMEDY EVEN THOUGH THEY KNOW OF THE NUMEROUS COMPLAINTS INVOLVING TIRE WEAR. *JB

NHTSA ODI #10163886

1,000 miles · Jul 20, 2006
Steering

MY 05 VW TOUAREG V8 HAS HAD A FAILED AIR BAG SENSOR, SUNROOF INSULATION, STEERING WHEEL SHAKE AT VARIED SPEEDS, AND A SERIOUS ALIGNMENT ISSUE SINCE THE FIRST DAY OF OWNERSHIP. AFTER 6 DIFFERENT TRIPS BACK TO THE DEALERSHIP, THEY CAN'T SEEM TO FIX THE SHAKING AND THE ALIGNMENT PROBLEM. THERE ARE MANY FORUMS AND BLOGS ON THE NET…

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MY 05 VW TOUAREG V8 HAS HAD A FAILED AIR BAG SENSOR, SUNROOF INSULATION, STEERING WHEEL SHAKE AT VARIED SPEEDS, AND A SERIOUS ALIGNMENT ISSUE SINCE THE FIRST DAY OF OWNERSHIP. AFTER 6 DIFFERENT TRIPS BACK TO THE DEALERSHIP, THEY CAN'T SEEM TO FIX THE SHAKING AND THE ALIGNMENT PROBLEM. THERE ARE MANY FORUMS AND BLOGS ON THE NET REGARDING A GENUINE DEFECT IN DESIGN OF THIS VEHICLE WHICH DOESN'T ALLOW IT TO DRIVE STRAIGHT. ALL OF THE LOANER TOUAREGS MODEL YEARS 06/07 HAVE HAD SIMILAR ALIGNMENT PROBLEMS, SO I DON'T THINK IT IS JUST MY VEHICLE IT IS A GREAT NUMBER OF THESE VEHICLES WITH THE SAME PROBLEMS. VW NEEDS TO STEP UP TO THE PLATE AND TAKE CARE OF THEIR CUSTOMERS. THIS IS NOT A CHEAP VEHICLE AND THE SUPPORT IS WORST THEN ANY COMPANY I'VE EVER DEALT WITH. THE CUSTOMER SERVICE REPRESENTATIVES ANSWER TO MY PROBLEM IS "I RECOMMEND YOU KEEP TAKING THE VEHICLE BACK TO ANY DEALERSHIP OF YOUR CHOICE UNTIL THE ISSUE IS RESOLVED UNDER THE MANUFACTURER'S WARRANTY PERIOD". THIS MEANS THAT FOR THE NEXT FIVE YEARS I HAVE TO TAKE THIS VEHICLE BACK TO THEM ON A WEEKLY BASIS FOR THEM TO TRY TO FIX A PROBLEM IN THEIR DESIGN. I JUST DON'T THINK IT IS FAIR TO A CONSUMER WHO COUGHS UP BIG BUCKS TO PURCHASE A VEHICLE AND THE VEHICLE IS FLAWED FROM THE FIRST DAY. *NM

NHTSA ODI #10162982

Mileage unknown · Jul 20, 2006
Tires

THE TIRES ON MY 2005 TOUREG HAVE EXCESSIVE WEAR DUE TO THE WEIGHT OF THE VEHICLE AND THE PIRELLI TIRE USED. THIS WAS FIXED ON THE 2006 TOUREGS HOWEVER THE 2004 AND 2005 HAVE THE WRONG TIRES SPEC AND THE TIRES COULD BLOW OUT PREMATURELY CAUSING A PERSON TO LOSE CONTROL AND ROLL THEIR VEHICLE. I HAVE CONTACTED VW AND PIRELLI WITH…

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THE TIRES ON MY 2005 TOUREG HAVE EXCESSIVE WEAR DUE TO THE WEIGHT OF THE VEHICLE AND THE PIRELLI TIRE USED. THIS WAS FIXED ON THE 2006 TOUREGS HOWEVER THE 2004 AND 2005 HAVE THE WRONG TIRES SPEC AND THE TIRES COULD BLOW OUT PREMATURELY CAUSING A PERSON TO LOSE CONTROL AND ROLL THEIR VEHICLE. I HAVE CONTACTED VW AND PIRELLI WITH NO SUCCESS IN GETTING MY TIRES REPLACED UNDER ANY TYPE OF WARRANTY CLAIM BECAUSE THEY ARE ORIGINAL EQUIPMENT TIRES. I ONLY HAVE APPROX 20,000 MILES ON THESE TIRES. I WAS ALSO INSTRUCTED TODAY THAT I COULD PAY FOR THE ENTIRE REPLACEMENT OF ALL FOUR TIRES AND THEN I WOULD RECEIVE A WARRANTY ON THEM. *NM

NHTSA ODI #10162948

12,000 miles · Jun 23, 2006
Air Bags

MY 2005 TOUAREG HAS BEEN IN FOR SERVICE ON 5 OUT OF THE 8 AIR BAGS IN THE CAR. THE DRIVER SIDE AIRBAG HAD TO BE REPLACED BECAUSE IF WAS DEFECTIVE, THAN AFTER IT WAS REPLACED IT CAME DISCONNECTED. THE 2 FRONT WINDSHIELD AIRBAG COVERS HAD TO BE PLACED. THE 2 BACK COVERS HAD TO BE REPLACED. SEAT BELT COVER HAD TO BE REPLACED AN…

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MY 2005 TOUAREG HAS BEEN IN FOR SERVICE ON 5 OUT OF THE 8 AIR BAGS IN THE CAR. THE DRIVER SIDE AIRBAG HAD TO BE REPLACED BECAUSE IF WAS DEFECTIVE, THAN AFTER IT WAS REPLACED IT CAME DISCONNECTED. THE 2 FRONT WINDSHIELD AIRBAG COVERS HAD TO BE PLACED. THE 2 BACK COVERS HAD TO BE REPLACED. SEAT BELT COVER HAD TO BE REPLACED AND ANOTHER HAS LOCKED UP AND CAN NOT BE MOVED. *NM

NHTSA ODI #10160589

Mileage unknown · Jun 15, 2006
Seat Belts

WE PURCHASED A VW TOUAREG 2005, IN MAY 2005, THE REAR CENTER SEAT BELT IS JAMMED AND CAN NOT LIFT UP REAR SEAT WITHOUT CUTTING THE SEAT BELT. VW SERVICE HAS HAD TO CUT THE SEAT BELT TO BE ABLE TO PUT THE SEAT BACK UP. THIS HAS OCCURRED THREE TIMES 3/1/06, 4/10/06 & 6/9/06. THIS OCCURS EVERY TIME WE PUT OUR SEATS DOWN TO LOAD …

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WE PURCHASED A VW TOUAREG 2005, IN MAY 2005, THE REAR CENTER SEAT BELT IS JAMMED AND CAN NOT LIFT UP REAR SEAT WITHOUT CUTTING THE SEAT BELT. VW SERVICE HAS HAD TO CUT THE SEAT BELT TO BE ABLE TO PUT THE SEAT BACK UP. THIS HAS OCCURRED THREE TIMES 3/1/06, 4/10/06 & 6/9/06. THIS OCCURS EVERY TIME WE PUT OUR SEATS DOWN TO LOAD THE BACK WITH STUFF, AND THEN TRY TO PUT THE SEAT BACK UP INTO SITTING POSITION. *NM UPDATED *JB

NHTSA ODI #10159901

6,700 miles · Jun 7, 2006
Tires

6700 MILES AND MY FRONT TIRES ARE ALREADY BARE!! *JB

NHTSA ODI #10159274

6,700 miles · Jun 7, 2006
Latches/locks/linkages

INSIDE DOOR HANDLES "STICK" OPEN, AND WHEN YOU CLOSE THE CAR DOOR THEY POP BACK OPEN SINCE THEY CAN'T CATCH THE LOCK. I HAVE HAD THE DOOR LOCK HANDLES MALFUNCTION ON TWO DIFFERENT CARS OF THE SAME MAKE AND MODEL. ON ONE OCCASION WHILE CLOSING THE DOOR MORE GENTLY, IT WASN'T NOTICED THAT THE DOOR DIDN'T ACTUALLY CATCH. WHEN I …

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INSIDE DOOR HANDLES "STICK" OPEN, AND WHEN YOU CLOSE THE CAR DOOR THEY POP BACK OPEN SINCE THEY CAN'T CATCH THE LOCK. I HAVE HAD THE DOOR LOCK HANDLES MALFUNCTION ON TWO DIFFERENT CARS OF THE SAME MAKE AND MODEL. ON ONE OCCASION WHILE CLOSING THE DOOR MORE GENTLY, IT WASN'T NOTICED THAT THE DOOR DIDN'T ACTUALLY CATCH. WHEN I WENT TO DRIVE AWAY, THEN STOP... THE DOOR FLEW OPEN NARROWLY MISSING A PEDESTRIAN. THE DOOR FLEW OPEN SO QUICKLY I ACTUALLY CHECKED THE CAR FOR FRAME DAMAGE SINCE I WAS SURE THE DOOR WOULD BE BENT. IT WAS ACTUALLY OK. WHEN REPORTED TO MY DEALER THE DOOR LOCK WAS FIXED UNDER WARRANTY, BUT NOT CITED AS A KNOWN HAZARD OR RECALL. *JB

NHTSA ODI #10159273

10,000 miles · May 18, 2006
Service Brakes, Hydraulic

I OWN A 2005 VW TOUAREG AND THE BRAKES SQUEAL AT SLOW SPEEDS. THE DEALERSHIP SAYS THIS IS NORMAL FOR BRAKES TO SQUEAL ON A HEAVY SUV. THE CAR IS PRACTICALLY BRAND NEW, AND EVEN THOUGH THE DEALERSHIP CHANGED THE BRAKE PADS DUE TO A TSB FROM VW, THE BRAKES STILL SQUEAL. IT APPEARS VW KNOWS ITS A DESIGN DEFECT BECAUSE THEY'VE AN…

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I OWN A 2005 VW TOUAREG AND THE BRAKES SQUEAL AT SLOW SPEEDS. THE DEALERSHIP SAYS THIS IS NORMAL FOR BRAKES TO SQUEAL ON A HEAVY SUV. THE CAR IS PRACTICALLY BRAND NEW, AND EVEN THOUGH THE DEALERSHIP CHANGED THE BRAKE PADS DUE TO A TSB FROM VW, THE BRAKES STILL SQUEAL. IT APPEARS VW KNOWS ITS A DESIGN DEFECT BECAUSE THEY'VE ANNOUNCED THAT "LARGER BRAKES" WILL BE ADDED TO THE NEW 2007 TOUAREG'S IN THE FUTURE. *NM

NHTSA ODI #10157836

3,500 miles · May 5, 2006
Tires

OEM GRANDTREK TIRES ARE A DISGRACE. 1 SIDE-WALL TEAR, 1 INTERNAL SHREDDING, AND 3 BLOW OUTS WITHIN 15,000. REPLACED SOON THEREAFTER. *JB

NHTSA ODI #10156863

Official recalls

2

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.

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.