20E001 – Frontal Air Bag Inflators May Explode – Takata

January 2, 2020 NHTSA CAMPAIGN NUMBER: 20E001000

Frontal Air Bag Inflators May Explode

An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.

 

NHTSA Campaign Number: 20E001

Manufacturer Takata (TK Global LLC)

Components AIR BAGS

Potential Number of Units Affected 10,000,000

 

Summary

Takata Corporation (Takata) is recalling certain PSPI, PSPI-2, PSPI-6, PSPI-L, SPI, PSDI, PSDI-4, PSDI-5, and SDI non-desiccated, frontal air bag inflators containing phase stabilized ammonium nitrate (PSAN) propellant that were used as interim remedy parts for previous Takata recalls. These inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.

 

Remedy

Numerous vehicle recalls will be announced by the impacted vehicle manufacturers who will conduct recalls to replace the interim replacement air bag inflators with alternate ones as a permanent remedy. The recall began January 2, 2020.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

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DEFECT INFORMATION REPORT FOR DRIVER AND PASSENGER SIDE AIRBAG INFLATORS

January 2, 2020

 

TK Global LLC 

TAKATA NON-DESICCATED FRONTAL AIR BAG INFLATORS CONTAINING PHASE STABLIZED AMMONIUM NITRATE 

 

Number potentially involved: 

Approximately 10 million inflators

 

Estimated Percentage of involved with defect:

1% ^[1]

 

Describe the defect or non-compliance: 

TK Global is submitting this DIR in accordance with the terms specified in the May 4, 2016 Amendment to the November 3, 2015 Consent Order in EA15-001. Per the order, NHTSA concluded that all Takata non-desiccated, frontal, PSAN inflators will reach a threshold level of degradation that could result in the inflator becoming unreasonably dangerous. As such, the Agency determined there was a reasonable and appropriate basis to require Takata to submit five DIRs on a rolling basis, per a defined schedule, that concludes with all vehicles containing Takata non-desiccated, frontal, phase stabilized ammonium nitrate-based (PSAN) inflators will be recalled by December 31, 2019.

This is the final report in the defined schedule, encompassing all vehicles equipped with Takata non-desiccated, frontal, PSAN inflators that were used as an interim remedy, throughout the Unites States. The subject inflators include all “like-for-like” PSPI, PSPI2, PSPI-6, PSPI-L, SPI, PSDI, PSDI-4, PSDI-5, and SDI.

As defined in the Coordinated Remedy Order, some vehicle manufacturers replaced recalled inflators with newly manufactured “like-for-like” inflators while they worked towards an alternative, final remedy. The vehicles received an “interim remedy”, meaning they have been remedied with a Takata non-desiccated, frontal, PSAN inflator and now require a final remedy.

TK Global is not aware of any inflator ruptures during ballistic testing of returned inflators or confirmed field events in the population of inflators used as an interim remedy. However, out of an abundance of caution, TK Global is filing this report in cooperation with NHTSA to promote public safety.

 

Describe the defect or non-compliance: 

Specific Takata non-desiccated, frontal, airbag inflators containing phase stabilized ammonium nitrate propellant that were used as interim remedy parts. Also known as “likefor-like” replacements.

The estimate of 10 million inflators represents the quantity produced for the U.S, market. TK Global does not know the quantity of vehicles affected. Many of these inflators were never installed on vehicles. Several vehicle manufacturers have already initiated their “like-for-like” recalls, replacing the recalled inflator with an alternative final remedy part.

The subject inflators were installed as interim remedy parts in vehicles sold in the United States by the following vehicle manufacturers (listed alphabetically):

Audi USA
Volkswagen Group of America
3800 Hamlin Road
Auburn Hills, MI. 48326 Phone (248) 754-5000

BMW of North America
P.O. Box 1227
Woodcliff Lake, NJ  07677-7731
Phone: (201) 307-4000

American Honda Motor Co.
1919 Torrance Blvd.
Torrance, CA 90501-2746
Phone: (310) 783-2000

Daimler Vans USA LLC
303 Perimeter Center North
Suite 202 Atlanta, GA 30346
Phone: (770) 705-2070

FCA US LLC
800 Chrysler Drive
CIMS 482-00-91 Auburn Hills, MI 48326-2757
Phone: (800) 853-1403

Ferrari North America, Inc.
250 Sylvan Ave.
Englewood Cliffs, NJ 07632
Phone: (201) 816-2600

Ford Motor Company
330 Town Center Drive
Suite 500, Dearborn, MI 48126
Phone: (866) 436-7332

General Motors LLC
30001 Van Dyke Road
Warren, MI 48094-9020.
Phone: (313) 556-5000

Mazda North America Operations
1025 Connecticut Avenue NW
Suite 910 Washington DC 20036
Phone: (800) 222-5500

Mitsubishi Motors North America Inc.
6400 Katella Avenue
Cypress, CA 90630
Phone: (714) 372-6000

Nissan North America Inc.
PO Box 685001
Franklin, TN 37068-5009
Phone: (615) 725-3111

Subaru of America Inc.
One Subaru Drive
Camden, NJ 08103
Phone: (856) 488-8500

Toyota Motor Engineering & Manufacturing
6565 Headquarters Drive
Plano, TX 75024
Phone: 800-331-4331

Volkswagen Group of America
3800 Hamlin Road
Auburn Hills, MI. 48326
Phone (248) 754-5000

 

Describe the safety risk:

Some of the subject non-desiccated ammonium nitrate inflators due to propellant degradation occurring after prolonged exposure to high absolute humidity, high temperatures, and high temperature cycling. Testing and analysis conducted by Takata, TK Global and by independent entities have found that there are wide differences in the time periods in which propellant degradation takes place. The propellant degradation varies in different climate zones, in different vehicle makes and models, and in different inflator and propellant configurations. The Agency has concluded that these Takata non-desiccated, frontal, PSAN inflators do not pose an unreasonable risk to safety under the Safety Act until they reach a certain level of propellant degradation.

Activation of a non-desiccated ammonium nitrate inflator with degraded propellant may result in an inflator rupture. An inflator rupture may cause metal fragments to pass through the air bag and into the vehicle interior at high speed, which may result in injury or death to vehicle occupants.

 

Describe the cause:

The propellant in some of the subject inflators may degrade over time, which could lead to over-aggressive combustion in the event the air bag is activated. Overly aggressive combustion creates excessive internal pressure when the inflator is activated, which may cause the inflator body to rupture. Based upon Takata’s and TK Global’s investigations to date, the potential for such ruptures occurs in some of the subject inflators after several years of exposure to persistent conditions of high absolute humidity, high temperatures, and high temperature cycling. The potential for rupture may also be influenced by other factors, including the specific vehicle environment, the inflator and propellant configuration, and manufacturing variability.

 

Chronology:

November 3, 2015 – NHTSA and Takata entered into a Consent Order in EA15-001 to resolve issues raised in that investigation, to mitigate and control risks of harm, and to promote public safety.

May 4, 2016 – NHTSA and Takata entered into an Amendment to the November 3, 2015 Consent Order. As stated in that Amendment, on the basis of testing and analysis conducted by Takata and by independent research organizations, NHTSA has concluded that, “at some point in the future all non-desiccated frontal Takata PSAN inflators will reach a threshold level of degradation that could result in the inflator becoming unreasonably dangerous”. As a result of this conclusion, and pursuant to Paragraph 29 of the November 3, 2015 Consent Order, NHTSA ordered Takata to file certain defect information reports (“DIR”), in accordance with the schedule set forth in Paragraph 14 of the Amendment.

May 16, 2016 – Takata submitted DIRs per the schedule specified by NHTSA in the Amendment to the Consent Order.

January 3, 2017 – Takata submitted DIRs per the schedule specified by NHTSA in the Amendment to the Consent Order. The schedule called for certain DIRs to be submitted by Dec. 31, 2016. NHTSA agreed that the DIRs would be submitted on Jan. 3, 2017.

January 2, 2018 – Takata submitted DIRs per the schedule specified by NHTSA in the Amendment to the Consent Order. The schedule called for certain DIRs to be submitted by Dec. 31, 2017. NHTSA agreed that the DIRs would be submitted on Jan. 2, 2018.

April 10, 2018 – Due to the company bankruptcy and sale of the majority of Takata assets, the successor company responsible for PSAN inflators is TK Global LLC. TK Global LLC is responsible for investigations and necessary field actions for all Phase Stabilized Ammonium Nitrate (PSAN) airbag inflators, originally manufactured by Takata.

January 2, 2019 – TK Global submitted DIRs per the schedule specified by NHTSA in the Amendment to the Consent Order. The schedule called for all subject inflators installed as original equipment in all remaining vehicles to be submitted by Dec 31, 2018. NHTSA agreed that the DIRs would be submitted on Jan. 2, 2019.

January 2, 2020 – TK Global is submitting this DIR per the schedule specified by NHTSA in the Amendment to the Consent Order. The schedule calls for all Takata nondesiccated, frontal, PSAN inflators used as interim remedy parts be submitted by Dec. 31, 2019. NHTSA agreed that this DIR could be submitted on Jan. 2, 2020.

With the filing of this DIR, all Takata non-desiccated, frontal, PSAN inflators used in frontal airbag systems, throughout the United States, are under recall.  

 

Describe the defect / noncompliance remedy program:

Per the sale of the majority of Takata assets to Joyson Safety Systems (JSS) and the bankruptcy agreement, the supplier of remedy parts is JSS.  The Coordinated Remedy Program, being administered by the Independent Monitor, has prioritized the supply of remedy parts.

 

[1] Estimated Percentage of involved with defect is unknown, 1% is used here because submission within NHTSA’s safety portal will not allow a non-numeric value.

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9 Affected Products

Equipments

BRAND	PART NO.	PRODUCTION DATES
TAKATA	PSDI INFLATOR
TAKATA	PSDI-4 INFLATOR
TAKATA	PSDI-5 INFLATOR
TAKATA	PSPI AIR BAG INFLATOR
TAKATA	PSPI-2 AIR BAG INFLATOR
TAKATA	PSPI-6 AIR BAG INFLATOR
TAKATA	PSPI-L AIR BAG INFLATOR
TAKATA	SDI INFLATOR
TAKATA	SPI AIR BAG INFLATOR

 

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3 Associated Documents

Recall Acknowledgement

RCAK-20E001-9916.pdf 244.608KB

 

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Defect Notice 573 Report

RCLRPT-20E001-2842.PDF 218.059KB

 

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Miscellaneous Document – 573 Report

RMISC-20E001-4050.pdf 59.061KB

 

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20E001&docType=RCL

 

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1 Associated Investigation

Air Bag Inflator Rupture
NHTSA ID: EA15001
Dated opened: February 24, 2015

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers. All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.

During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers. Nonetheless, at ODI’s insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation. The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures. As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.

Takata’s initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida. Accordingly ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas. Takata’s testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions. During PE14-016 four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.

Also during PE14-016 four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina. Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls. Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity. Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing. All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.

The investigation now includes all manufacturers and vehicles known to be affected at this time. ODI’s investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.

The five ODI reports cited above can be reviewed online at https://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

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