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: PE05009
Date Opened: 2005-02-10
Date Closed: 2005-06-15
Manufacturer’s Name: Toyota
Motor Corporation
Component Description: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER
Summary Description: VACUUM BRAKE BOOSTER FAILURE
Summary
ON FEBRUARY 10, 2005, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED LOSS OF BRAKE POWER-ASSIST IN CERTAIN 2004 MODEL YEAR (MY) LEXUS RX330 VEHICLES BUILT THROUGH APPROXIMATELY JUNE 30, 2004.THE SUBJECT VEHICLES WERE MANUFACTURED AT TOYOTA MOTOR MANUFACTURING CANADA, INC.?S CAMBRIDGE, ONTARIO ASSEMBLY PLANT AND WERE EQUIPPED WITH VACUUM BRAKE BOOSTER ASSEMBLIES SOURCED FROM AISIN SEIKI CO., LTD (AISIN) SUBSIDIARY ADVICS NORTH AMERICA, INC. (ADVICS-NA).TO DATE, ODI IS AWARE OF 146 NON-DUPLICATIVE REPORTS THAT ALLEGE LOSS OF BRAKE POWER-ASSIST AND 6 CRASHES ALLEGEDLY CAUSED BY LOSS OF BRAKE POWER-ASSIST (RESULTING IN 1 MINOR INJURY) ON THE SUBJECT VEHICLES.THE SUBJECT VEHICLES USE A CONVENTIONAL BRAKE BOOSTER ASSEMBLY THAT CONTAINS A RUBBER DIAPHRAGM TO SEPARATE THE FORE AND AFT PRESSURE CHAMBERS.THE OUTER EDGE OF THE RUBBER DIAPHRAGM IS HELD IN PLACE VIA A RETAINING GROOVE ON THE BRAKE BOOSTER BODY.IF THE BOOSTER LOSES VACUUM (E.G., OPERATOR DEPLETES THE VACUUM BY PRESSING THE BRAKE PEDAL SEVERAL TIMES WHILE THE ENGINE IS OFF), IT MAY CAUSE THE DIAPHRAGM TO DEFORM IN THE AREA OF THE RETAINING GROOVE TO THE POINT THAT INSUFFICIENT SEAL EXISTS BETWEEN DIAPHRAGM AND BOOSTER BODY, THUS CAUSING A MOMENTARY LOSS OF BRAKE POWER-ASSIST.THE ADVICS-NA SUPPLIED DIAPHRAGM HAS SLIGHTLY DIFFERENT MATERIAL PROPERTIES COMPARED TO THE DIAPHRAGM INSIDE BRAKE BOOSTERS SUPPLIED BY ADVICS JAPAN, CORP. (ADVICS-J) AND USED ON 2004MY LEXUS RX330 VEHICLES MANUFACTURED AT TOYOTA MOTOR KYUSHU, INC.?S ASSEMBLY PLANT.THE SOFTER RUBBER USED IN THE ADVICS-NA DIAPHRAGM ALLOWS GREATER DEFORMATION AND IS LESS RESILIENT WHEN COMPARED TO THE ADVICS-J DIAPHRAGM.LOSS OF BRAKE POWER-ASSIST MOST OFTEN OCCURS AT VEHICLE START-UP AND APPEARS TO BE MORE PREVALENT IN COLDER TEMPERATURES.MOST OWNERS REPORT THAT BRAKE SYSTEM OPERATION RETURNS TO NORMAL WITHIN A FEW SECONDS AFTER VEHICLE START-UP.TESTING CONDUCTED BY THE MANUFACTURER INDICATES THAT THE ADVICS-NA DIAPHRAGM?S REDUCED ABILITY TO RETURN TO SHAPE IS EXACERBATED BY COLDER TEMPERATURES AND THAT LOSS OF BRAKE POWER-ASSIST AT START-UP MAY LAST FOR A MAXIMUM OF 95 SECONDS AT TEMPERATURES BELOW ?20 DEGREES CELSIUS.HOWEVER, THE SUBJECT VEHICLES HAVE A BACK-UP SYSTEM THAT CAN SENSE A LOSS OF BRAKE POWER-ASSIST AND ENABLE THE ABS ACTUATOR FOR BRAKE HYDRAULIC PRESSURE SUPPORT (I.E., BRAKE PEDAL FORCE ASSIST).THE MANUFACTURER WILL CONDUCT A SERVICE CAMPAIGN (LEXUS SPECIAL SERVICE CAMPAIGN #5LA) TO REPLACE THE VACUUM BRAKE BOOSTER ASSEMBLY ON ALL AFFECTED SUBJECT VEHICLES.THE ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
NHTSA Action Number: PE05006
Date Opened: 2005-02-04
Date Closed: 2005-05-06
Manufacturer’s Name: General Motors, LLC
Component Description: EXTERIOR LIGHTING:TURN SIGNAL:FLASHER UNIT
Recall Campaign: 05V198
Summary Description: TURN SIGNAL FAILURES
Summary
BY LETTER DATED APRIL 29, 2005, GM NOTIFIED THE AGENCY THAT IT IS CONDUCTING ASAFETY RECALL ( NHTSA RECALL NO. 05V198 ) INVOLVING CERTAIN MODEL YEARS (MY) 2003-2004 ISUZU ASCENDER, CHEVROLET TRAILBLAZER, GMC ENVOY, OLDSMOBILE BRAVADA AND MY 2004 BUICK RAINER VEHICLES.THE RECALL APPLIES TO VEHICLES BUILT FROM APRIL 2003 THROUGH NOVEMBER 2003 FOR A TOTAL VEHICLE POPULATION OF 286,478.GM REPORTS THE DIRECTIONAL/HAZARD SIGNALS FAILURE IS DUE TO STICKING CONTACTS ON ROUTING RELAYS IN THE FLASHER MODULE.GM WILL REPLACE THE FLASHER MODULE ON ALL INVOLVED VEHICLES.BASED ON GM'S SAFETY RECALL ACTION, THIS INVESTIGATION IS CLOSED.
NHTSA Action Number: EA05002
Date Opened: 2005-02-02
Date Closed: 2006-08-31
Manufacturer’s Name: POLARIS INDUSTRIES, INC.
Component Description: POWER TRAIN:MANUAL TRANSMISSION
Summary Description: SUDDEN, UNFORESEEN TRANSMISSION LOCKU
Summary
THIS INVESTIGATION DETERMINED THAT THE SUBJECT MOTORCYCLE TRANSMISSIONS ARE PRONE TO SHIFTING PERFORMANCE ISSUES THAT OCCUR WELL BEFORE THE TRANSMISSIONS HAVE REACHED THE END OF THE MANUFACTURER'S STATED INTENDED DESIGN LIFE (30,000 MILES).POLARIS HAS TAKEN ACTIONS INCLUDING CARRYING OUT TWO SAFETY RECALLS TO ADDRESS ISSUES IN SOME OF THE SUBJECT VEHICLES, CONDUCTING A SPECIAL POLICY, AND FORMALLY COMMUNICATING WITH ITS DEALERS AND SUBJECT OWNERS TO ADDRESS THESE ISSUES.IN LIGHT OF THE NATURE AND CIRCUMSTANCES OF THE REPORTED PROBLEMS AND THESE ACTIVITIES BY POLARIS, FURTHER USE OF AGENCY RESCOURCES DOES NOT APPEAR TO BE WARRANTED.SEE THE ATTACHED TECHNICAL REPORT FOR FULL DETAILS.
NHTSA Action Number: PE05004
Date Opened: 2005-02-02
Date Closed: 2005-06-01
Manufacturer’s Name: Chrysler (FCA US, LLC)
Component Description: ELECTRICAL SYSTEM
Summary Description: HEADLIGHT MALFUNCTION
Summary
THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED THIS INVESTIGATION AFTER RECEIVING REPORTS FROM CONSUMERS THAT THEIR HEADLIGHTS WOULD MALFUNCTION IN VARIOUS WAYS FROM FLICKERING TO COMPLETE NON-ILLUMINATION.HEADLIGHT OPERATION IS MONITORED BY THE VEHICLE'S BODY CONTROL MODULE (BCM) AND FRONT CONTROL MODULE (FCM).ODI IS UPGRADING THIS PRELIMINARY EVALUATION TO AN ENGINEERING ANALYSIS (EA05-009) TO FURTHER EXAMINE THE ISSUE.
Read More...NHTSA Action Number: PE05005
Date Opened: 2005-02-02
Date Closed: 2005-06-29
Manufacturer’s Name: Mercedes-Benz USA, LLC
Component Description: SEATS:FRONT ASSEMBLY:SEAT HEATER/COOLER
Summary Description: ELECTRIC SEAT WARMER OVERHEATS/BURNS
Summary
THIS INVESTIGATION WAS OPENED BASED ON THREE CONSUMER COMPLAINTS OF ELECTRIC SEAT WARMER OVERHEATING IN MY 2003 MERCEDES BENZ ML-320 VEHICLES.CONSUMERS ALLEGED THAT SUCH FAILURES MAY INFLICT BURN INJURIES TO SEAT OCCUPANTS.INVESTIGATION DISCLOSED THAT THE IDENTICAL SEAT WARMER DESIGN WAS INSTALLED IN 65.5 PERCENT OF ALL M-CLASS VEHICLES PRODUCED DURING MY 2000-2005.THE ALLEGED DEFECT RESULTED FROM BREAKAGE OF THE ELECTRICAL BUS WIRE OF THE HEATER GRID IN THE OUTBOARD SIDE OF THE SEAT BOLSTER.THE FAILURES WERE CAUSED BY REPEATED HIGH STRESS APPLIED DURING OCCUPANT INGRESS AND EGRESS.A SIMILAR FAILURE MODE HAD BEEN PREVIOUSLY IDENTIFIED IN INVESTIGATIONS OF THIS TYPE OF FAILURE IN OTHER VEHICLES.THE RATES OF COMPLAINTS AND WARRANTY CLAIMS FOR THE SUBJECT VEHICLES, AS WELL AS FOR OTHER M-CLASS VEHICLES WITH THE SAME SEAT WARMER DESIGN, WERE IN SOME CASES HIGHER, BUT ON THE SAME ORDER OF MAGNITUDE AS THE RATES SEEN IN OTHER VEHICLES INVESTIGATED.THE INFORMATION DISCLOSED THAT SEAT CUSHION DAMAGE WAS LIMITED TO SMALL, LOCALIZED AREAS AND THAT NO RISK OF FIRE EXISTED.THE INJURIES REPORTED WERE CONSISTENTLY VERY MINOR IN SEVERITY AND AT RATES COMPARABLE TO THOSE SEEN ON OTHER INVESTIGATIONS.ODI CONCLUDED THAT A SAFETY-RELATED DEFECT TREND WAS NOT IDENTIFIED IN THIS MATTER AT THIS TIME.ACCORDINGLY, THIS PE HAS BEEN 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 FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
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