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: EA21001
Date Opened: 2021-05-06
Date Closed: 2023-08-25
Manufacturer’s Name: Honda
(American Honda Motor Co.)
Component Description: STEERING
Summary Description: Loss of Direction Control
Summary
On May 6, 2021, the Office of Defects Investigation (ODI) opened Engineering Analysis (EA21-001) to assess a sudden loss of steering control, in Model Year (MY) 2013-2015 Honda Accord vehicles. Consumers alleged while driving the steering wheel would pull to the left or the right independently. Steering pull may pose a risk of loss of directional control. Honda stated that they believed the inadvertent steering input was caused by a loose magnet located within the electronic power steering (EPS) system. Due to poor formulation of the adhesive, this magnet can become loose and move up to 2 degrees around the steering column. When the magnet moves, the torque sensor generates a signal that results in unwanted steering in either direction. Honda stated the steering force required to maintain directional control with a loose magnet is a maximum of 3-pound feet. The maximum force of the unwanted steering input can be overcome by the driver and is similar to driving on grooved pavement.The Vehicle Research Test Center (VRTC) sent over 4,000 questionnaires to 2013-2015 Honda Accord vehicle owners. Of the 637 responses, 58 consumers experienced unwanted steering. Consumers experiencing unwanted steering did not report difficulties maintaining directional control. There were no crashes or injuries reported to VRTC. Testing done by VRTC was not able to reproduce the allegations. Analysis of all relevant data indicates that the subject condition has a relatively low failure rate. The poor adhesive formulation was addressed by the supplier with three (3) counter measures in the manufacturing process.There has been a declining trend in consumer complaints to NHTSA which indicates possible exhaustion of parts prone to failure. In view of the low rate, declining complaint trend, the nature of failure, and resolution of the adhesive formulation, this Engineering Analysis 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 new circumstances.The ODI complaints cited above can be viewed at www.NHTSA.gov under the following ODI identification numbers: 11538714, 11528538, 11528008, 11522953, 11496557, 11495837, 11494328, 11478680, 11477167, 11476758, 11476263, 11471198, 11470001, 11467026, 11466561, 11466016, 11465626, 11464143, 11463558, 11462759, 11461500, 11460777, 11460191, 11455540, 11454334, 11452198, 11448114, 11447666, 11444888, 11444823, 11444172, 11443324, 11443243, 11443105, 11441374, 11439520, 11438345, 11437261, 11436824, 11436350, 11435994, 11435079, 11434969, 11434545, 11434442, 11434381, 11433824, 11433745, 11433555, 11433368, 11433176, 11431206, 11430465, 11430253, 11430009, 11429253, 11428301, 11427449, 11426841, 11426340, 11425928, 11425261, 11425230, 11423611, 11423245, 11422445, 11422395, 11422351, 11422220, 11422138, 11422069, 11421683, 11421589, 11421540, 11420573, 11419338, 11419270, 11418147, 11418143, 11417768, 11417742, 11417570, 11417437, 11416804, 11416699, 11416401, 11416378, 11416375, 11416155, 11416117, 11416084, 11416051, 11416032, 11416028, 11416024, 11416000, 11415933, 11415915, 11414105, 11406220, 11398736 ,11387075, 11387049, 11375580, 11364698, 11361125, 11351660, 11349961, 11327909, 11327170, 11301957, 11289067, 11282525, 11277659, 11258017, 11256914, 11218752, 11208077, 11196050, 11194358, 11189901, 11165075, 11163481, 11154891
NHTSA Action Number: PE21010
Date Opened: 2021-04-09
Date Closed: 2023-08-24
Manufacturer’s Name: General Motors, LLC
Component Description: AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE
Summary Description: Air Bag Malfunction
Summary
On April 9, 2021, the Office of Defects Investigations (ODI) opened PE21-010 to investigate instances of air bag malfunction indicator light (MIL) illumination and potential for frontal air bag non-deployment in several vehicles manufactured by General Motors (GM). The vehicles included model year (MY) 2020 through 2021 CT4 and CT5 passenger cars, Sierra and Silverado trucks (1500/2500/3500 models), XT4 and MY 2021 Escalade, Suburban, Tahoe, Yukon SUVs.Technical Service Bulletin (TSB) 21-NA-005, issued in March 2021, addresses air bag MIL illumination with diagnostic trouble codes (DTCs) B0001-1B or B0012-0D. It cites rust particles in the connection terminal interface of the driver air bag inflator housing as the cause of the air bag MIL illumination. Illumination of the air bag MIL under these circumstances may result in a non-deployment of the frontal driver air bag during a frontal collision and increased risk of injury to the driver.GM stated a correlation exists between production delays due to the pandemic shutdown and premature corrosion initiation on the surface of the air bag inflator housing, which, in some cases, caused rust development during a seven (7) month period of vehicle production. In the rare instance when a rust particle dislodges from the driver air bag inflator housing and enters the air bag connector prior to assembly, an intermittent resistance spike at the air bag connector may result. The condition generates excessive resistance in the air bag electrical system when the steering wheel horn cover is manipulated or the steering wheel is turned. This excessive resistance is momentary. A crash commanding air bag deployment would need to occur exactly when the momentary excessive resistance occurs. Thus, there is a very low likelihood the hazard will present a risk during a crash of sufficient severity to warrant a commanded deployment. This failure mechanism occurs early in life and results in an air bag MIL illumination that corresponds to a DTC warning the driver that the vehicle requires service. The vehicle's air bag remains functional while the MIL is illuminated, and the DTC is present.Once the connection of the driver air bag module to the clockspring is made at the plant, or at the dealership for service, there is no longer an opportunity for rust migration into the connection point. The connector is sealed and has gold terminals, eliminating the expectation of fretting corrosion. All subject vehicles passed standard corrosion validation testing for extensive corrosion with no issue of air bag non-deployment.There is a low rate of occurrence: 1.41 incidents per thousand vehicles (IPTV) for all related occurrences, and 0.04 IPTV for occurrences with a mention of visible rust and/or corrosion on the air bag inflator housing. The average occurrence mileage for the subject vehicles is approximately 2,100. Every occurrence related to the alleged defect experienced an air bag MIL illumination and there are no verified allegations of air bag non-deployment within all data sources.To date, there have been no reported fires, crashes, injuries, or fatalities related to this issue. In view of the low rate, and the nature of early-life failure, the high detectability of failures, and low potential hazard to drivers, this Preliminary Evaluation (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 new circumstances.Review the ODI reports cited above at nhtsa.gov under the following identification numbers: 11537927, 11528888, 11525020, 11521401, 11506057, 11493107, 11486767, 11441525, 11433146, 11425658, 11423440, 11385267, 11376429, 11373466, 11366995.
NHTSA Action Number: EQ21001
Date Opened: 2021-04-07
Date Closed: 2021-12-01
Manufacturer’s Name: Key Safety Systems, Inc. - (DBA Joyson)
Component Description: AIR BAGS:PASSENGER SIDE FRONTAL:CUSHION
Recall Campaign: 21V139
Summary Description: Joyson Passenger Side Air Bag Cushion
Summary
In a Part 573 Report dated July 14, 2019, Mercedes Benz USA, LLC. (MBUSA) notified NHTSA of a safety-related defect in certain 2020 GLE350 4Matic and GLE450 4Matic vehicles. This filing was assigned Recall No. 19V-458. MBUSA stated that these vehicles may have received Joyson Safety Systems (Joyson) passenger air bag assemblies that may cause a delayed or incomplete deployment of the air bag during a crash. On August 28, 2019, Toyota Motor Engineering and Manufacturing (Toyota) notified NHTSA of a safety-related defect in certain 2003-2008 Corolla, 2005-2008 Corolla Matrix, and 2005-2008 Pontiac Vibe vehicles. This filing was assigned Recall No. 19V-627. Toyota stated that these vehicles may have received replacement Joyson Safety Systems (Joyson) air bag assemblies under a previous recall, and the replacement air bags may not unfold as designed during a crash.On January 23, 2020, General Motors, LLC (GM) notified NHTSA of a defect in certain 2003-2004 Pontiac Vibe vehicles. The GM filing was assigned Recall No. 20V-039.On March 4, 2021, Nissan North America, Inc. (Nissan) notified NHTSA of a defect in certain 2006-2008 Infiniti FX35 and FX45 vehicles.Nissan's filing was assigned Recall No. 21V-139.In both GM's and Nissan's recalls, affected vehicles were repaired under previous recalls, and the replacement air bags may not unfold as designed during a crash.The purpose of this EQ was to write to Joyson and other companies that might have purchased this equipment from Joyson, notify them of this defect in any vehicles they manufactured, and to ensure thorough safety recalls are conducted where appropriate.On April 8, 2021, NHTSA's Recall Management Division (RMD) notified Joyson of the EQ and issued an Information Request (IR) letter to Joyson. Responses from Joyson, dated between April 19, 2021 to July 21, 2021, are summarized as follows:Related to MBUSA 19V-458, MBUSA inadvertently installed 11 prototype airbag modules into vehicles for the stream of commerce. JSS has no knowledge of any other vehicles being affected other than those identified by Mercedes Benz. Joyson noted that it will not file a Part 573 Recall Report. Related to Toyota 19V-627 and GM 20V-039, Joyson noted the airbags were sold to Toyota, which utilized them on a single vehicle platform, sold as both the Toyota Matrix and Pontiac Vibe.In addition, the reason for GM's recall was due to certain GM dealerships installing the incorrect version of the replacement airbag. Joyson stated they have no reason to believe that any other manufacturer is affected by the circumstances underlaying Recall 20V-039. Joyson also stated no other vehicles utilized the subject airbags. Furthermore, Joyson has not identified any assemblies built in the same facility with angle variations that underwent the same development testing as described in Toyota's Part 573 Recall Report. Joyson noted that it will not file a Part 573 Recall Report. Related to Nissan 21V-139, Joyson stated The combination of components that comprise the airbag modules which are the subject of Recall 21V-139 was supplied only to Nissan for the FX-35 and FX-45 vehicles. Joyson noted that it will not file a Part 573 Recall Report. NHTSA has reviewed the responses from Joyson and has concluded that no additional safety recalls from other manufacturers are required at this time. Accordingly, this Equipment Query is now closed. However, RMD will continue to monitor reports and other data for like conditions and may re-open this query or initiate a new query, as appropriate.
NHTSA Action Number: PE21008
Date Opened: 2021-03-29
Date Closed: 2022-10-03
Manufacturer’s Name: Volkswagen Group of America, Inc.
Component Description: FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM:INJECTORS
Summary Description: Fuel Injector Leak
Summary
On March 29, 2021, the Office of Defects Investigations (ODI) opened PE21-008 to investigate instances of fuel injectors leaking in the engine compartment in model year (MY) 2018 through 2020 Volkswagen Atlas and Atlas Cross Sport SUVs. These vehicles are equipped with either a 3.6 or 2.0 liter engine. The subject investigation concerns vehicles equipped with 3.6L engines. Prior to opening the investigation, ODI also observed that warranty data for the fuel system from TREAD reporting was an outlier for the MY 2018 Atlas.The allegation involved fuel injectors leaking fuel near engine compartment components that operate at high temperatures. Consumers allege a fuel leak, fuel odor, and/or an illuminated check engine malfunction indicator light (MIL) on that alerts them to the condition. Fuel leaking in the engine compartment has a higher potential risk of fire as nearby components are operating at higher temperatures compared to other areas of the vehicle. No fires have been connected to this issue to date.The 3.6L engine is a VR6 type engine. Due to its specific design, the VR6 has two types of injectors with different designs installed. Cylinders 1, 3, and 5 use long injectors and cylinders 2, 4, and 6 use short injectors. Unlike the short injectors, the long injectors require an extension pipe necessary to reach cylinders 1, 3, and 5. Volkswagen stated that the potential root cause for a leaking injector is typically either a damaged, misaligned, or missing supporting ring or a damaged O-ring. These rings assist in connecting the injector to the extension pipe. If one of these conditions is present in a vehicle, the O-ring has difficulty withstanding fuel pressure over time.Volkswagen stated that an analysis of warranty data related to leaking injectors in vehicles equipped with 3.6L engines showed that the vast majority of leaking allegations were related to internal leaks. Fuel can leak into the cylinder causing misfiring in the affected cylinders. This condition would not cause fuel to enter into the engine compartment. Volkswagen states that these internal leaks pose no unreasonable risk to motor vehicle safety.Analysis of all relevant data indicates that the subject condition is an early-life failure with a relatively low failure rate. The average failure mileage calculated from all data sources was determined to be approximately 14,000 miles. Only two failures were reported outside of the vehicles' warranty coverage period. The average time to failure for the subject vehicle population is approximately 12 months in service (MIS). The majority of failures were below the average of 14,000 miles or 12 MIS. Analysis of reported failures showed that the failure rate is approximately 0.08% or 0.8 incidents per thousand vehicles (IPTV).To date, there have been no reported fires, crashes, injuries, or fatalities related to this issue. In view of the low rate of failure, the nature of early-life failure, and low potential hazard to drivers, this Preliminary Evaluation 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 new circumstances.Review the ODI reports cited above at nhtsa.gov under the following identification numbers:11446833, 11438403, 11382958, 11298402, 11291955, 11218819, 11218780
NHTSA Action Number: PE21009
Date Opened: 2021-03-29
Date Closed: 2022-05-27
Manufacturer’s Name: Volkswagen Group of America, Inc.
Component Description: ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:TURBO/SUPERCHARGER
Recall Campaign: 22V178
Summary Description: Engine Stall - Turbo Failure
Summary
On March 29, 2021, the Office of Defects Investigation (ODI) opened Preliminary Evaluation (PE) 21-009 after the agency received 58 reports alleging engine stalling in 2013-2016MY Audi vehicle models A8, S6, S7, S8 & RS7. The subject vehicles are equipped with 4.0L, twin-turbocharged engine. Complainants reported that the vehicles stall suddenly with no warning while driving on the highway or in city traffic. Several of the complainants alleged an inability to restart. The complaints allege the major contributing factor to the engine stalling is the failure of the turbochargers. The complaints further allege the turbocharger failure is a result of oil starvation due to a clogged oil strainer.The location of the oil strainer in the turbocharger oil supply line is in the inner valley of the engine. It is not easily accessible, making regular service difficult. The oil strainer removes dirty particles and carbon deposits from the oil before flowing to lubricate the Turbochargers. Overtime if the debris are not removed from the oil strainer, it clogs the strainer and prevents free flow of oil to the turbochargers and makes the turbine bushings to run dry and overheat which causes the turbine shaft to break due to thermal stress. In VW's response to ODI's Information Request letter, VW provided approximately 611 warranty claims with unique VINs, 70 Field Reports and 45 Consumer complaints. These reports allege engine stalling due to turbocharger failure similar to the NHTSA reports described above. To date, NHTSA has received approximately 98 allegations of stall due to turbocharger failures. The total of 824 reports shown in the table above eliminates duplicate reports received by both ODI and the manufacturer.This Preliminary Evaluation is being upgraded to an Engineering Analysis (EA) to further assess the scope, frequency, and potential safety related consequences of the alleged defect of engine stalling due to turbocharger failureThe ODI complaints cited above can be viewed at www.NHTSA.gov under the following ODI identification numbers:11452589, 11452584, 11452383, 11450995, 11450988, 11449661, 11447092, 11442867 11440536, 11440052, 11439959, 11438691, 11436461, 11435619, 11431661, 11429704 11429584, 11426929, 11424203, 11423603, 11423337, 11421084, 11420626, 11420342 11418884, 11418437, 11418433, 11417635, 11417351, 11416095, 11414235, 11413359 11413214, 11413285, 11413133, 11407510, 11407450, 11407289, 11406821, 11406416 11406291, 11406277, 11406273, 11406256, 11406251, 11406229, 11406222, 11406204 11406197, 11406182, 11404665, 11404426, 11404348, 11403430, 11403268, 11399435 11397821, 11396241, 11394763, 11391037, 11388662, 11387166, 11377446, 11363283 11354107, 11344193, 11342497, 11342360, 11340302, 11325065, 11324163, 11322168, 11321144, 11318477, 11306754, 11279429, 11268109, 11256706, 11252723, 11246579 11234853, 11234714, 11231582, 11231013, 11230589, 11229484, 11222281, 11218822 11218749, 11217604, 11209168, 11209142, 11197149, 11191243, 11175842, 11170776 11164032, 11152418.
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