After a preliminary review of consumer complaints and other information related to alleged defects, NHTSA obtains information from the manufacturer(including data on complaints, crashes, injuries, warranty claims, modifications, and part sales) and determines whether further analysis is warranted. If warranted, the investigator will conduct a more detailed and complete analysis of the character and scope of the alleged defect.
NHTSA Action Number: PE09055
Date Opened: 2009-12-07
Date Closed: 2010-04-21
Manufacturer’s Name: Ford
Motor Company
Component Description: ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH
Summary Description: HVAC Switch Failures
Summary
ODI has received 1 complaint and reports from 4 transportation fleets alleging 182 switch failures.Each fleet operates mini buses built on a Ford E350 or E450 cutaway chassis.The OEM HVAC blower switches have melted, smoked, burned or experienced open flame and become inoperable on vehicles in each fleet.Some drivers have reported a burning smell or smoke coming from the dash.One fleet reported a vehicle fire.No injuries were sustained.However, the bus was carrying special needs children when the driver noticed smoke coming from the dash.The driver was able to evacuate the children prior to the vehicle becoming engulfed in flames.This PE has been upgraded to an Engineering Analysis (EA) to determine if the blower motor switch failures create a situation where a vehicle fire is possible and presents a safety risk to the driver and other passengers.
NHTSA Action Number: DP09006
Date Opened: 2009-11-30
Date Closed: 2015-11-20
Manufacturer’s Name: Blue Bird Body Company
Component Description: SUSPENSION:FRONT
Summary Description: Alleged inadequate recall remedy 07V-586
Summary
On December 11, 2007, Blue Bird Corporation (BBC) submitted an uninfluenced recall 07V-586 to the agency.This recall described a defect on fifty eight 2005?2007 Model Year (MY) Wanderlodge Recreational Vehicles (RV) where the curb weight of the front axle could exceed the axle?s 16,000 pound rating. To address the issue, BBC replaced the tie rods on the vehicle to a more robust version increasing the rating of the front axle to 17,000 pounds.In addition, BBC relocated a generator rearward from the front of the vehicle and provided updated storage bay weight limit placards forinstallation in each of the vehicles three storage bays.On March 11, 2008, BBC submitted an amendment to the 07V-586 recall.In this amendment, BBC added three more remedial actions to the original recall.In addition to the original recall remedies, BBC would replace the front tires (with the same model tires) perform a front end alignment, and add new tire data placards instructing operators to maintain the vehicle tire pressure at 130 psi (the maximum tire pressure for that model tire).Following receipt of a consumer complaint (10226544) alleging that some of the vehicles subject to recall 07V-586 had front axle curb weights in excess of 17,000 pounds and that operators did not have a reasonable way to maintain tire pressures at 130 psi (as required by recall 07V-586), NHTSA opened Recall Query RQ08-004.The recall query was(Continued on page 2)
Read More...NHTSA Action Number: PE09054
Date Opened: 2009-11-30
Date Closed: 2010-08-19
Manufacturer’s Name: Toyota Motor Corporation
Component Description: ENGINE AND ENGINE COOLING
Recall Campaign: 10V384
Summary Description: Engine Stalling
Summary
On November 30, 2009, the Office of Defects Investigation (ODI) opened a preliminary evaluation (PE09-054) to investigate alleged engine stalling, while driving in model year (MY) 2006 Toyota Corolla and Corolla Matrix vehicles .In its response to ODI's information request submitted on March 2, 2010, Toyota indicated that it had identified two possible causes of production defects of the engine control units (ECU) used in the MY 2005 through 2007 Corolla and Matrix vehicles equipped with the 1ZZ-FE engine.Failure mode A1 - BGA ball failure caused by improperly cured conformal coating applied to ECU circuit boards. This can cause cracks to form in the soldered joints of some components. Failure mode A2 - Varistor over heating; a glass coating is created on the surface of the Varistor during its production process.In case of an insufficient coating, a crack can occur in the surface of the glass coating. When ions are charged in the plating electrolytes after the glass coating process, the plating electrolytes can penetrate into the Varistor through the glass crack then an electrical short occurs. With respect to these failures, if the condition arises, it can potentially lead to one or more of the following: MIL on, engine stall or engine no start, harsh shifting.Of the approximately 155,000 warranty and extended warranty claims Toyota has analyzedthe projected 5 year failure rate of the ECU associated with an engine stall is 0.8%. This investigation has been upgraded to an Engineering Analysis (EA10-006) to further assess the scope, frequency and safety risks associated with the identified defects.
NHTSA Action Number: EA09017
Date Opened: 2009-11-19
Date Closed: 2011-09-26
Manufacturer’s Name: Kia America, Inc.
Component Description: AIR BAGS:FRONTAL
Recall Campaign: 11V473
Summary Description: Air Bag Occupant Classification System
Summary
The Sorento's front passenger air bag may be turned off when an adult is seated in the passenger seat. The front passenger air bag is designed to be turned off in limited circumstances including when children and small adults are seated in the front passenger seat, there is a child restraint in that seat, or the seat is not occupied.But the Sorento has misclassified adults sitting in the passenger seat.This causes the passenger side frontal air bag to deactivate and the PASSENGER AIR BAG OFF light to illuminate. On May 12, 2009, Kia launched a Technical Service Bulletin campaign (SC076) to address this problem, installing upgraded occupant classification system (OCS) software in vehicles built prior to the 11/27/2007 production date. ODI and Kia identified 908 owner reports and 927 warranty claims related to this OCS issue.Kia also reported one crash where the passenger frontal air bag did not deploy in a frontal crash due to misclassification.Testing of Sorento vehicles built prior to December 2007 shows that misclassification can occur.As of April 2011, Kia reports that approx. 46,000 of the 57,228 vehicles have been upgraded with the revised software.On September 6, 2011, Kia submitted a defect notice and will recall the affected vehicles that have not been upgraded.Owner notification is scheduled to start in late-September 2011.The recall will upgrade the OCS software.Accordingly the investigation is closed.
NHTSA Action Number: EA09016
Date Opened: 2009-11-10
Date Closed: 2012-02-02
Manufacturer’s Name: Ford Motor Company
Component Description: POWER TRAIN:AUTOMATIC TRANSMISSION
Recall Campaign: 12V006
Summary Description: Transmission Torque Converter Failure
Summary
On January 4, 2012 Ford Motor Company submitted a Defect Information Report (NHTSA Recall No. 12V-006) to NHTSA regarding a defect in the performance of the transmission torque converter for approximately 205,896 Ford Freestar and Mercury Monterey vehicles.The supplier of the torque converter manufactured converters containing a pump shaft spline that did not consistently meet the specified heat treatment requirements.In normal use, the spline may wear excessively and eventually fails without warning.If a torque converter malfunctions due to a sheared pump drive spline, the vehicle will abruptly lose motive power.This problem affected model year 2004 and 2005 Freestar and Monterey minivans.During the investigation NHTSA identified 532 complaints alleging incidents of vehicle stall while driving due to torque converter failure.These failures were sudden and without any prior warning.Of the 490 complaints that reported the speed at the time of the failure:218 (44%) occurred at or above 55 mph; and 344 (70%) occurred at or above 40 mph.Of the 382 complaints that reported the position of the vehicle relative to traffic after it came to a stop following the loss of motive power: 122 (32%) alleged that the vehicle came to a stop in the flow of traffic and remained in the flow of traffic until pushed or towed out of the way; 225 (59%) reported that the vehicle was maneuvered to the side of the roadway and remained there until towed; and 35 (9%) reported that they were able to maneuver to a location away from the flow of traffic, such as a parking lot.Two crashes were allegedly caused by torque converter failure, including an incident in which a Freestar suddenly lost power in 65 mph traffic in an area where there was no shoulder available.As a result, the Freestar stopped in a travel lane and when trailing traffic maneuvered to avoid the stalled vehicle, a four vehicle collision occurred.In these types of circumstances NHTSA believes the defect presents an unreasonable risk to motor vehicle safety and so advised Ford.In its Defect Information Report, Ford refers to its response to NHTSA's Preliminary Evaluation information request, which stated that a vehicle that loses motive power due to torque converter malfunction remains readily controllable; the vehicle will coast during which it can be safely maneuvered and stopped because the engine continues to run.Because the engine continues to run, steering and braking are unaffected, and the vehicle's electrical system and directional signals remain functional.In view of the foregoing, NHTSA does not agree with this statement.This investigation is closed based on Ford's recall.
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