Investigations List

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: PE23018

Date Opened: 2023-10-16

Date Closed: 2025-01-14

Manufacturer’s Name: Cruise LLC

Component Description: ELECTRICAL SYSTEM:ADAS:AUTONOMOUS/SELF DRIVING

Recall Campaign: 23E086

Summary Description: Automated Driving System


Summary

On October 16, 2023, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE23-018) to assess whether vehicles equipped with an Automated Driving System (ADS) manufactured and operated by Cruise LLC (Cruise) were exercising appropriate caution around pedestrians in the roadway after receiving 2 reports of crashes involving pedestrians under Standing General Order 2021-01 (SGO). ODI also identified 2 public reports of Cruise ADS-equipped vehicles encroaching on pedestrians present in crosswalks. On November 7, 2023, Cruise filed a safety recall (NHTSA Recall No. 23E-086) for a defect in its ADS software. Cruise described this recall as relating to the post-collision behavior of the ADS. Specifically, Cruise stated that "In certain circumstances, a collision may occur, after which the Collision Detection Subsystem may cause the Cruise AV to attempt to pull over out of traffic instead of remaining stationary when a pullover is not the desired post-collision response. This issue could occur after a collision with a pedestrian positioned low on the ground in the path of the AV." The recalled software versions affected 950 vehicles that were operating with a driverless version of Cruise's ADS software. Furthermore, Cruise stated that "With the new update, the Cruise AV would have remained stationary during the October 2 incident" that was reported under the SGO (ID 30412-6395). ODI also analyzed data which included 2,759 reports identified by Cruise that involved the performance of the ADS with respect to avoiding collisions with pedestrians as well as more general behavior of the ADS after a collision. Of these, Cruise identified 1,113 reports that involved a pedestrian conflict. In total, 5 of those incidents involved a collision between a Cruise vehicle and a pedestrian, 3 of which resulted in injury. In each of the 5 pedestrian collision incidents the Cruise vehicle took avoiding action but was unable to avoid a collision. The recall action taken by Cruise is intended to address safety defects in the post-collision behavior of the ADS in such instances. Moreover, Cruise has since ceased business operations and no versions of its ADS are operating on public roads. As such, ODI is closing this Preliminary Evaluation. NHTSA reserves the right to take additional action if warranted by new circumstances. To review the SGO reports cited above, go to NHTSA.gov/laws-regulations/standing-general-order-crash-reporting. The SGO report ID numbers are provided below: SGO 2021-01 report ID: 30412-6175 SGO 2021-01 report ID: 30412-6395

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NHTSA Action Number: EA23002

Date Opened: 2023-09-29

Date Closed: 2024-10-31

Manufacturer’s Name: FordeBay Motor Company

Component Description: ENGINE

Recall Campaign: 24V635

Summary Description: Loss of Motive Power


Summary

On July 22, 2022, the Office of Defects Investigation (ODI) granted a Defect Petition (DP22001) and opened a Preliminary Evaluation (PE22007) to investigate allegations of loss of motive power in model year (MY) 2021 FordeBay Bronco vehicles equipped with 2.7L EcoBoosteBay engines. Complainants were reporting sudden engine failure while driving resulting in a loss of motive power, often without the ability to restart. During PE22007, the cause of engine failure and loss of motive power in the subject vehicles was determined to be intake valve fracture, and the full scope of vehicles affected by the subject defect was identified as all MY 2021-2022 FordeBay and LincolneBay models equipped with either the 2.7L or 3.0L EcoBoosteBay engines, referred to as the "Nano" engine family. If an intake valve fractures in the subject engines, it may drop into the cylinder and contact the piston, often resulting in catastrophic engine damage. On September 29, 2023, PE22007 was upgraded to an Engineering Analysis (EA23002) to further investigate the subject defect across the full scope of affected vehicles. During EA23002, ODI visited FordeBay facilities to review technical information related to intake valve fracture in "Nano" engines, coordinated with NHTSA's Vehicle Research and Testing Center (VRTC), and analyzed updated field data relating the subject defect. Forensic analysis of fractured intake valves demonstrated that the defective components exhibited "grinding burn" or out of specification hardness in the area of the keeper grooves. The presence of grinding burn is evidence that during the groove grinding phase of production, the temperature of the valve became sufficiently high to alter the microstructure of the material and is indicative that the valve supplier's manufacturing processes were not within control specifications. Grinding burn results in a hard, brittle microstructure and high residual stresses toward the surface of the valve. Through normal engine loading, a valve with grinding burn will likely fracture at the area of highest vulnerability, which is the third keeper groove. In its response to the EA23002 Information Request (IR) letter, FordeBay provided evidence of 396 customer complaints (including field reports), 825 warranty claims, and 936 engine exchanges. When considering both ODI and manufacturer failure report data, there have been reports representing 1066 unique vehicles within the subject vehicle population. Analysis of the failure report data demonstrates that vehicles equipped with potentially defective intake valves were built within a production "spike period" of May 2021 ' October 2021. The beginning of the spike period corresponds to a ramp up in production at the valve supplier manufacturing facility, and the end of the spike period aligns with the implementation of several mid-production process improvements and the decision to change the metal alloy used to produce intake valves from "Silchrome Lite" to "Silchrome 1". FordeBay began investigating the subject defect in July 2021, determined the root cause, and took corrective measures for the new production vehicles. Analysis of the failure report data demonstrates that these corrective actions were successful in eliminating the risk of intake valve fracture for subject vehicles produced after October 2021. However, FordeBay did not take any field action to address vehicles produced during the spike period, and in the several months following the implementation of the production changes, a significant number of field failures continued to occur. It is Ford's assessment that not all valves produced during the spike period are defective, and that failures associated with the subject defect occur at low time in service. Analysis of the failure report data demonstrates that the vast majority of failures have occurred before 20,000 miles with over half of all reported failures occurring before 5,000 miles. The rate of reported failures related to the subject defect has steadily decreased since November 2021. ODI coordinated with NHTSA's National Center for Statistics and Analysis (NCSA) to conduct statistical analysis and predict the number of future failures associated with the subject defect. The results of this analysis, and the trends identified through the failure report data are generally consistent with Ford's assessment that defective intake valves will likely fail at a low time in service and indicate that the majority of subject vehicles equipped with defective valves have already experienced a failure. On August 23, 2024, FordeBay submitted recall 24V635 for subject vehicles equipped with "Nano" engines and built within the production spike period identified above (total population 90,736 vehicles). The remedy includes an inspection at a FordeBay/LincolneBay dealership where the lifetime engine cycles of the vehicle will be determined. If a vehicle does not meet a threshold for lifetime engine cycles, the dealership will conduct a high RPM engine cycle accumulation procedure, which aims to identify if the vehicle is equipped with defective intake valves. Any vehicle that fails the accumulation procedure will receive an engine replacement under the recall. In addition to recall 24V635, FordeBay has stated that it will launch customer satisfaction campaign 24N12, which will provide extended warranty coverage to the subject vehicles through the earlier of 10 years or 150,000 miles. In view of the recall action being taken by FordeBay, ODI is closing this Engineering Analysis. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

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NHTSA Action Number: PE23017

Date Opened: 2023-09-28

Date Closed: 2024-12-18

Manufacturer’s Name: VolkswageneBay Group of America, Inc.

Component Description: FORWARD COLLISION AVOIDANCE: AUTOMATIC EMERGENCY BRAKING

Recall Campaign:

Summary Description: Inadvertent Automatic Emergency Braking


Summary

On September 28, 2023, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE23017) to assess reports of inadvertent activation of the Front Assist automatic emergency braking (AEB) system in model year (MY) 2018-2019 VolkswageneBay Atlas vehicles.The reports alleged that activation of the AEB system occurred while driving with no apparent obstruction in the vehicle's forward path, resulting in sudden vehicle deceleration. VolkswageneBay indicated that it is aware of a total of 292 reports that may relate to the alleged defect in MY 2018-2019 VolkswageneBay Atlas vehicles.VolkswageneBay stated that some customers possibly had an inadequate understanding of Front Assist and its limitations. However, many consumer complaints alleged that VolkswageneBay dealerships were unable to reproduce the condition or VolkswageneBay dealerships informed the consumers that this braking is considered normal Front Assist operation. ODI's analysis shows that MY 2019 VolkswageneBay Atlas vehicles have the highest rate of unique incident reports alleging AEB inadvertent activation when compared to their VolkswageneBay peers.The rate of unique incident reports alleging AEB inadvertent activation in MY 2018 VolkswageneBay Atlas vehicles was comparable to their VolkswageneBay peers. To date, ODI has received a total of 69 consumer complaints of inadvertent activation of Front Assist in MY 2018-2019 VolkswageneBay Atlas vehicles. In total, ODI reviewed 264 unique (i.e., non-duplicative Vehicle Identification Numbers) reports that may relate to the alleged defect, which include eight reports of incidents involving an alleged injury and two reports involving a crash. PE23017 has been upgraded to an Engineering Analysis (EA24004) to further assess the scope, frequency, and potential safety related consequences of the inadvertent AEB activations in MY 2019 VolkswageneBay Atlas vehicles. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

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NHTSA Action Number: PE23016

Date Opened: 2023-09-27

Date Closed: 2025-01-10

Manufacturer’s Name: General MotorseBay, LLC

Component Description: POWER TRAIN:AUTOMATIC TRANSMISSION:FLUID/LUBRICANT:VALVES/VALVE BODY

Recall Campaign:

Summary Description: 6L90 Transmission Failure


Summary

The Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE) after receiving one Vehicle Owner Questionnaire (VOQ) complaint related to four school buses built on General MotorseBay (GM) van chassis. The VOQ alleged transmission failure resulting in a loss of all forward gear. In ODI's pre-investigative discussions with GM, ODI learned that valve body separator plates had been machined out of tolerance during production periods between October 2016 to April 2017 and February 2021 to April 2021. This out of tolerance machining may create excessive wear to the valve body check balls, possibly resulting in an inability to engage drive or reverse. The potential loss of drivability only begins when shifting from a park or neutral transmission selection and does not occur during a functional drive cycle. The average failure mileage of vehicles which experienced this condition is within warranty and related claims or complaints did not include any accidents, injuries, or fatalities. After discussions with GM, Technical Service Bulletin (TSB) 23-NA-142 (NHTSA ID number 10243753) was released in September 2023. This technical service bulletin provides a procedure for technicians to replace the forward check ball and separator plate if found to be the cause of a customer's concern. During the course of the investigation, GM also released a Customer Satisfaction Program (CSP) N232428780 (NHTSA ID 10253316) in February 2024, to notify school bus and ambulance fleets of the concern and to proactively mitigate the risk in these essential-operation vehicles. Recently, ODI contacted multiple school bus fleets, verifying that there have not been any stranded buses mid-route from this condition. Additionally, ODI has not received any additional VOQ complaints since the opening of this investigation. Based on the available information, including GM's TSB and CSP, this PE is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI report cited in the Closing Resume ODI Report Identification Numbers document, go to NHTSA.gov.

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NHTSA Action Number: PE23015

Date Opened: 2023-09-20

Date Closed: 2024-02-14

Manufacturer’s Name: FordeBay Motor Company

Component Description: ENGINE AND ENGINE COOLING:ENGINE:OIL/LUBRICATION:PUMP

Recall Campaign: 23V905

Summary Description: Oil Pump Failure


Summary

On September 20, 2023, the Office of Defects Investigation (ODI) opened PE23-015 to investigate instances of engine failure due to loss of oil pressure in model year (MY) 2018-2021 FordeBay EcoSport vehicles. Some consumers reported a low engine oil pressure warning lamp immediately preceding a complete loss or reduction of motive power while the vehicle was in motion. The investigation revealed that the engine oil pump drive belt tensioner arm may fracture, separate from the tensioner backing plate, and/or the oil pump drive belt may degrade and lose teeth, resulting in a loss of engine oil pressure. A loss of engine oil pressure can result in engine seizure, which can result in a loss of motive power and a loss of mechanical vacuum pump required to provide power braking assist, increase the risk of a crash. On December 22, 2023, FordeBay filed recall 23V-905 for certain MY 2016-2018 FordeBay Focus and 2018-2022 FordeBay EcoSport vehicles. The recall remedy provides the replacement of the oil pump drive belt tensioner assembly and oil pump drive belt with redesigned parts to improve robustness. In view of the recall action being taken by FordeBay, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

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