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: AQ20001
Date Opened: 2020-07-20
Date Closed: 2025-01-16
Manufacturer’s Name: Harmony Juvenile Products
Component Description: CHILD SEAT
Summary Description: Timeliness of 49 CFR 579 Reporting (EWR)
Summary
On July 20, 2020, the National Highway Traffic Safety Administration (NHTSA) opened an Audit Query (AQ) to investigate Harmony Juvenile Products' (Harmony) reporting of death and injury claims and foreign recalls under 49 CFR Part 579. NHTSA's investigation was prompted by a fatal incident involving child restraints manufactured by both Harmony and another manufacturer for which NHTSA received death and injury reports from the involved vehicle manufacturer and the other child restraint manufacturer. NHTSA did not receive a report from Harmony until after NHTSA contacted the company. NHTSA was also aware of foreign recalls of Harmony products that NHTSA believed may have been substantially similar to products sold in the United States but were not reported to the Agency. In response to NHTSA's information request issued during this investigation, Harmony asserted that because of the unique requirements for service of process for foreign entities (Harmony is located in Canada) and the limited information available to the company, Harmony did not have enough information regarding the fatal incident to submit a report to NHTSA under Part 579 until after Harmony was contacted by NHTSA. Harmony also responded that there were no foreign recalls involving substantially similar products that Harmony did not report to NHTSA. After NHTSA opened this AQ, Harmony improved its processes for compliance with Part 579 by taking the following actions: (1) formalizing its previously unwritten procedures for reviewing communications to help ensure that future communications would be reported to NHTSA pursuant to 49 CFR 579.5; (2) auditing customer contracts to determine whether any may have met the reporting requirements for consumer complaints under 49 CFR 579.25(c); (3) auditing its records to see whether there were analyses of field incidents that meet the definition of a "field report," which Harmony is required to report to NHTSA; and (4) reviewing charge-back information provided by U.S. retailers to determine whether Harmony had any information that would qualify as a paid warranty claim, which Harmony is required to report to NHTSA. In May 2022, Harmony stopped selling child restraints in the U.S. However, in July 2024, Harmony notified NHTSA that the company had re-entered the U.S. market during the second quarter of 2024 and that it conducted internal training about the early warning reporting requirements for manufacturers of child restraint systems in in 49 CFR 579.25. Given the information obtained through the investigation and Harmony's compliance efforts that are described above, continuing this investigation into Harmony is not warranted and this investigation is closed. The Agency will continue to monitor Harmony's reporting pursuant to 49 CFR Part 579. The Agency reserves the right to take further action if warranted by the circumstances.
Read More...NHTSA Action Number: PE20011
Date Opened: 2020-07-05
Date Closed: 2023-08-17
Manufacturer’s Name: General Motors, LLC
Component Description: FUEL/PROPULSION SYSTEM
Summary Description: Fuel Line Leak
Summary
On July 5, 2020, the Office of Defects Investigations (ODI) opened PE20-011 to investigate instances of metal fuel lines under the vehicle corroding and leaking fuel in model year (MY) 2008 through 2010 Chevrolet Cobalt and 2008 through 2009 Chevrolet HHR passenger cars manufactured by General Motors (GM). The metal fuel lines are corroding and leaking fuel in the area between the front and rear wheels on the driver's side of the vehicle before the muffler. Most consumers allege a fuel odor and/or an observable fuel leak that alerts them to the condition.The subject metal fuel lines have a protective AGE coating and, in the vicinity of the left rear wheel, are further wrapped in a foil heat shield. The AGE coating consists of an annealed zinc aluminum alloy metal coating with extended corrosion protection paint. Under certain conditions, water and corrosive road deicing agents may enter a crevice between the heat shield and the AGE coating. With extended environmental exposure in high corrosive environments, the AGE coating can degrade. If it degrades enough, the base metal lines may begin to corrode beneath the heat shield.Corrosion to the fuel lines may eventually cause a perforation to develop in the line, allowing fuel vapors to escape from between the line and the heat shield, emitting a fuel odor that will be detectable to the vehicle operator. If the corrosion progresses, fuel may begin to weep from the line. Further metal degradation due to corrosion could create a drip or a mist of fuel. If this occurs, vehicle owners may see drips, spots, or puddles on the ground near the rear portion of the vehicle, primarily along the driver's side rear wheel.The majority of allegations (85%) were reported for vehicles that are operated in the salt belt region of the United States. This area includes states in the Northeast, mid-Atlantic, and Midwest regions. Additionally, the average failure mileage in the subject vehicles is approximately 111,000 across all data sources.Considering the low manufacturer complaint/warranty rates of fuel line replacement, the fact that the majority of failures are concentrated in salt belt states, high failure mileages, as well as the field exposure time for the subject vehicles, and the highly detectable and progressive nature of this failure over time, the potential safety consequences of this issue are very low. To date, there have been no reported crashes, injuries, or fatalities related to this issue. There are two reported fires in ODI data and no reported fires in GM data. Both ODI reported fires were minor, occurred after the vehicle was parked, and were extinguished utilizing fire extinguishers.In view of the progressive failure occurring at high mileages, the age of the subject vehicles, the high detectability of the leak, and the majority of failures occurred in salt belt states, this Preliminary Evaluation is closed. 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 attached identification numbers.
NHTSA Action Number: PE20010
Date Opened: 2020-06-22
Date Closed: 2020-11-22
Manufacturer’s Name: Tesla, Inc.
Component Description: BACK OVER PREVENTION: SENSING SYSTEM: CAMERA
Summary Description: Loss of rearview camera
Summary
On June 22, 2020, the Office of Defects Investigations (ODI) opened Preliminary Evaluation PE20-010 to investigate incidents of media control unit (MCU) failures resulting in loss of rearview camera in model year (MY) 2012-2015 Tesla Model S vehicles equipped with the NVIDIA Tegra 3 processor with an integrated 8GB eMMC NAND flash memory device. EMMC NAND flash devices have a finite lifespan based upon the number of program/erase (P/E) cycles. The subject MCU allegedly fails prematurely due to memory wear-out of the eMMC NAND flash. Tesla used the same MCU with the Tegra 3 processor in approximately 159 thousand 2012-2018 Model S and 2016-2018 Model X vehicles built by Tesla through early-2018. In response to ODI's Information Request (IR) for PE20-010, Tesla provided ODI with 2,399 complaints and field reports, 7,777 warranty claims, and 4,746 non-warranty claims related to MCU replacements. The data show failure rates over 30 percent in certain build months and accelerating failure trends after 3 to 4 years-in-service.According to Tesla, for subject vehicles equipped with the NVIDIA Tegra 3 processor with an integrated 8GB eMMC NAND flash memory device, the eMMC NAND cell hardware can fail when reaching lifetime wear, for which the eMMC controller has no available blocks to recover. With this failure mode, the only recovery available is a replacement of the eMMC device, achieved by physical part replacement of either the MCU assembly or visual control module subcomponent. Tesla provided the effects of MCU failure on vehicle function which result in loss of rearview/backup camera, loss of HVAC (defogging) setting controls (if the HVAC status was OFF status prior to failure.) There is also an impact on the advanced driver assistance support (ADAS) Autopilot system, and turn signal functionality due to the possible loss of audible chimes, driver sensing, and alerts associated with these vehicle functions. There are precedents for addressing defects that result in loss of either backup camera, defogging, or turn signal functions under safety recalls.Tesla has implemented certain Over-The-Air or OTA updates to subject vehicles to mitigate the effects of MCU failure. These updates include firmware changes to reduce memory usage of the subject memory card, improve eMMC error correction and storage management strategies, changing the control logic for turn signal activation, and defaulting the HVAC system to Auto (71.6F) for drives after MCU failure to address windshield defogging. Tesla indicated that the MCU failures are likely to continue to occur in subject vehicles as vehicles continue to operate and use available memory in the 8GB eMMC NAND flash memory until 100% of units have failed. This investigation has been upgraded to an Engineering Analysis (EA20-003). The VOQs associated with the upgrade of this investigation are identified in the attachment to this resume.
NHTSA Action Number: PE20008
Date Opened: 2020-06-01
Date Closed: 2022-01-25
Manufacturer’s Name: Kia America, Inc.
Component Description: EXTERIOR LIGHTING:HEADLIGHTS:BULBS
Summary Description: Headlight Failure
Summary
The Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE) based on seventy-four Vehicle Owner Questionnaires (VOQs) reporting headlight failures on model year (MY) 2011-2013 KIA Sorento vehicles.In its response to ODI's June 25, 2020, information request letter (portions of which were submitted under request for confidentiality), Kia Motor America (Kia) provided design details of the headlight system showing that each headlight circuit is independently powered by the Smart Junction Box (SJB), a power control module. Kia claimed that the design minimizes the chance of both headlights failing simultaneously due to a headlight connector defect, a component located downstream of the SJB. Kia also advised that the SJB contains a safety feature designed to monitor power consumption for each headlight circuit; if excessive current is being demanded by either headlight the SJB will open the circuit (i.e., stop supplying current). Lastly Kia presented testing showing that the maximum headlight connector temperature achieved prior to the SJB opening the circuit was below the autoignition temperature of the plastic material the connector housing is made of, which Kia maintains eliminates the potential for a fire originating from an electrically overheated headlight connector. In its review of all available data, ODI determined that the majority of both VOQ and Kia customer complaints (1,339 reports in total) involved the loss or dimming of a single low beam headlight assembly caused primarily by a poor or overheated connector terminal located at the headlight. In some cases the failures were momentary in nature (i.e., flickering) with the headlights coming back on without driver intervention. A minority of VOQs and Kia complaints (the 196 Other reports) alleged simultaneous (and persistent) loss of both low beam headlights, and in most cases the driver was able to take an action (e.g., toggle the headlight switch, or use the ON rather than the AUTO setting on the headlight switch) to reinstate the low beam headlights. The high beam headlights were not seen to be affected and were available for drivers to use as alternate lighting.ODI did not identify any crashes or injuries, nor any fire incidents caused by a headlight related defect. While some VOQ and Kia reports alleged or indicated a fire occurrence, the incidents were found to involve melting or smells/odors due to thermal overheating of the plastic headlight connector housing, rather than an open flame fire.ODI notes that in April 2019, Kia initiated a 10 years/unlimited mileage warranty extension program to replace the headlight connector for MY 2011-2013 Sorento vehicles.Based on this analysis, a safety-related defect has not been identified at this time, and ODI is closing the investigation. This does not constitute a finding by the Agency that a safety-related defect is not present; the Agency will take further action if warranted by additional information received.The reference (ODI) numbers for the VOQs cited above are included in the downloadable version of this closing resume available at NHTSA.gov.
NHTSA Action Number: PE20009
Date Opened: 2020-06-01
Date Closed: 2022-06-03
Manufacturer’s Name: General Motors, LLC
Component Description: STEERING:ELECTRIC POWER ASSIST SYSTEM
Summary Description: Momentary Increased Steering Effort
Summary
On June 1, 2020, the Office of Defects Investigations (ODI) opened PE20-009 to investigate instances of a momentary increase in steering effort after the vehicle is driven in a straight line for a period of time due to an issue with the steering gear in model year (MY) 2010 through 2012 Chevrolet Equinox and GMC Terrain SUVs.If the electric power steering system fails to operate as intended, the driver will experience momentary increased effort when attempting to turn the steering wheel from the straight-ahead position. For this condition to occur, the driver would need to have traveled in a straight line at a sustained high speed, without turning the steering wheel, for approximately 30 minutes or longer. The steering gear contains a servo unit that includes a worm gear with a worm and a worm wheel. General Motors (GM) stated that the primary root cause of the increased steering effort is the supplier's inconsistent application of grease in the interface between the worm and the worm wheel. The grease may have been applied in a location on the worm wheel that didn't interface with the worm, depriving the worm gear of proper lubrication.On November 1, 2014, GM issued Special Coverage 14232 to address the power steering stick-slip issue in MY 2010-2014 Chevrolet Equinox and GMC Terrain; MY 2011-2014 Chevrolet Cruze and Volt; MY 2012-2014 Buick Verano; and MY 2013-2014 Chevrolet Malibu vehicles. GM notified consumers via mail.The Special Coverage repair includes the replacement of the steering gear with an improved internal worm gear greasing process for MY 2010-2012 vehicles. For the MY 2013-2014 vehicles, the Special Coverage repair includes a reprogramming of the steering gear control module. The new software has an anti-stick feature which senses and reduces the friction between the worm and worm wheel by oscillating the worm gear. GM stated that the difference in remedy is due to the inability of the MY 2010-2012 steering gear control module to accept the new software.The remedy implemented in GM Special Coverage 14232 appears to be sufficient in addressing the safety-related concerns of this issue. Considering the low complaint and warranty rates of steering rack replacement as well as the field exposure time for the subject vehicles, the potential safety consequences of this issue are very low. To date, there have been no reported crashes, injuries, or fatalities related to this issue. ODI has not identified a safety defect or defect-related failure trend in the subject vehicles. In view of the Special Coverage, low rate of failure, and low potential hazard to drivers, this Preliminary Evaluation is closed. 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:11424633,11421725,11229647,11101375,10919921,10689932,10671557,10664687,10663350, 10593429,10592065,10585476,10585365,10576237,10575693,10532766,10490295,10434128, 10417845,10412535,10403168,10395532,10395171,10391948,10384211,10375515,10366297, 10360999,10360599,10345626,10319530,10305569,10304769,10299745
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