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: RQ04010
Date Opened: 2004-09-28
Date Closed: 2005-04-14
Manufacturer’s Name: General Motors
, LLC
Component Description: LATCHES/LOCKS/LINKAGES:TAILGATE:LATCH
Summary Description: TAILGATE SUPPORT CABLE BREAKAGE
Summary
ODI IS UPGRADING RQ04-010 AND OPENING AN ENGINEERING ANALYSIS TO FURTHER INVESTIGATE THE TAILGATE SUPPORT CABLES INSTALLED IN 1998, 1999, AND PARTIAL YEAR 2000 SILVERADOS AND SIERRAS (C/K MODELS).GENERAL MOTORS IS CONDUCTING RECALL CAMPAIGN 04V-129 TO REPLACE THE TAILGATE SUPPORT CABLES ORIGINALLY INSTALLED IN CERTAIN MODEL YEAR 2000 - 2004 SIERRAS AND SILVERADOS.GENERAL MOTORS HAS ADVISED ODI THAT THE MATERIALS USED FOR THE TAILGATE CABLE SHEATHING INSTALLED IN C/K MODELS HAD INADVERTENTLY CHANGED IN OCTOBER 1999, INCREASING THE PROPENSITY FOR VOIDS IN AND AROUND THE GALVANIZED STEEL CABLE STRANDS WHICH CAN ALLOW MOISTURE TO WICK AMONG THE STRANDS, LEADING TO OXIDATION AND WEAKENING OF THE STRANDS.SINCE ODI INITIATED RQ04-010 IN SEPTEMBER 2004, ODI HAS RECEIVED 10 ADDITONAL NON-INJURY COMPLAINTS ON MY 1998-99 C/K VEHICLES, BUT NO ADDITIONAL INJURY COMPLAINTS.DURING THIS SAME PERIOD, GM HAS RECEIVED 564 NON-INJURY AND 35 INJURY COMPLAINTS. ODI HAS RECEIVED 6 INJURY COMPLAINTS AND 38 NON-INJURY COMPLAINTS FROM OWNERS OF MODEL YEAR 2000 C/K VEHICLES AND REQUIRES FURTHER INVESTIGATION TO DETERMINE WHETHER THESE INCIDENTS OCCURRED IN VEHICLES WITHIN THE SCOPE OF CAMPAIGN 04V-129 OR SHOULD BE ADDED TO THE INJURY SUMMARY FOR RQ04-010.
NHTSA Action Number: PE04067
Date Opened: 2004-09-24
Date Closed: 2005-01-27
Manufacturer’s Name: Kia America, Inc.
Component Description: VEHICLE SPEED CONTROL:CABLES
Recall Campaign: 05V013
Summary Description: THROTTLE CABLE BINDING
Summary
KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.
NHTSA Action Number: PE04065
Date Opened: 2004-09-21
Date Closed: 2005-02-08
Manufacturer’s Name: Kia America, Inc.
Component Description: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM:WHEEL CYLINDERS
Summary Description: REAR DRUM BRAKE WHEEL CYLINDER LEAKAGE
Summary
THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED THIS PRELIMINARY EVALUATION TO INVESTIGATE ALLEGATIONS OF REAR DRUM BRAKE WHEEL CYLINDER LEAKAGE IN 2002 KIA SPECTRA VEHICLES.THIS INVESTIGATION WAS PROMPTED BY KIA?S EARLY WARNING REPORT TO THE AGENCY FOR THE FIRST QUARTER OF 2004, WHICH CONTAINED A SINGLE FIELD REPORT THAT IDENTIFIED 13 INCIDENTS OF WHEEL CYLINDER LEAKAGE IN THE SUBJECT VEHICLES.THE SUBJECT VEHICLES ARE AVAILABLE IN BOTH 4-DOOR SEDAN AND 5-DOOR HATCHBACK BODY STYLES.THE SAME PARTS SUPPLIER PROVIDES WHEEL CYLINDERS FOR BOTH VEHICLE TYPES, ALTHOUGH THEIR PART NUMBERS DIFFER.THESE PARTS ARE USED ON ALL MY2002-2004 SPECTRA ?TYPE-I? VEHICLES MANUFACTURED THROUGH 12/30/2003.ADDITIONALLY, MY2001-2005 KIA RIO VEHICLES BUILT THROUGH 11/17/2004 USE THE SAME WHEEL CYLINDERS AS THE SUBJECT SPECTRA ?TYPE-I? 4-DOOR SEDAN.MY2004 SPECTRA ?TYPE-II? VEHICLES, WHICH STARTED PRODUCTION ON 12/8/2003, DO NOT USE THE SUBJECT COMPONENTS AS THEY ARE EQUIPPED WITH REAR DISC BRAKES.THE MANUFACTURER NOTIFIED ODI OF ONE COMPLAINANT WHOM ALLEGED A CRASH CAUSED BY, ?INADEQUATE BRAKE SYSTEM RESPONSE,? RESULTING IN ONE PERSON INJURED.HOWEVER, IT APPEARS THAT MULTIPLE CAUSAL FACTORS MAY HAVE CONTRIBUTED TO THE CRASH INCIDENT AND NO SINGLE FACTOR HAS BEEN IDENTIFIED AS THE PRIMARY CAUSE.IN TOTAL, ODI IS AWARE OF 5 CONSUMER COMPLAINTS, 1 FIELD REPORT, AND 813 WARRANTY CLAIMS RELATED TO THE ALLEGED DEFECT IN 2002 KIA SPECTRA VEHICLES.NONE OF THE COMPLAINANTS ALLEGED DEGRADED STOPPING PERFORMANCE OR LOSS OF BRAKING CAPABILITY CAUSED BY WHEEL CYLINDER LEAKAGE.TO DATE, THE COMPLAINT RATE IS 7.0 PER 100,000 VEHICLES AND THE WARRANTY RATE IS 1.13%.KIA?S ANALYSIS OF WARRANTY RETURN PARTS INDICATES A SLOW RATE OF FLUID LOSS; TESTS SHOWED A MAXIMUM FLUID LOSS RATE OF 1 CC PER 4000 BRAKE APPLICATIONS (THE MASTER CYLINDER RESERVOIR HAS A 134CC FLUID CAPACITY BETWEEN THE ?FULL? AND THE LEVEL AT WHICH THE BRAKE WARNING LAMP IS ILLUMINATED).KIA TESTING OF A VEHICLE EQUIPPED WITH A LEAKING WHEEL CYLINDER SHOWED THAT AFTER 100 STOPS FROM 100 KM/H THE PEDAL STROKE INCREASED 5%, PEDAL FORCE INCREASED 13%, AND THE BRAKING DISTANCE INCREASED 7% (51.7M VS. 48.1M) WHEN COMPARED TO THE SAME VEHICLE WITH A NON-LEAKING WHEEL CYLINDER.A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.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: PE04066
Date Opened: 2004-09-21
Date Closed: 2005-02-02
Manufacturer’s Name: DAIMLERCHRYSLER MANUFACTURING INTL
Component Description: TIRES
Recall Campaign: 04V600
Summary Description: TIRE VALVE FAILURE
Summary
ODI OPENED PE04-066 TO INVESTIGATE FIVE COMPLAINTS ALLEGING TIRE VALVE FAILURE IN MY 2003-04 SUBJECT VEHICLES.SOME OF THE COMPLAINTS ALLEGED MULTIPLE TIRE VALVE FAILURES FOR A SINGLE VEHICLE.ON DECEMBER 16, 2004, DAIMLERCHRYSLER MANUFACTURING INTERNATIONAL (DCMI) NOTIFIED NHTSA OF A SAFETY DEFECT IN APPROXIMATELY 23,000 MY 2002-05 SPRINTER 2500 VEHICLES EQUIPPED WITH TR-600 TIRE VALVES PRODUCED BY ALLIGATOR VENTILFABRICK GMBH (RECALL 04V-600).THE NOTIFICATION IDENTIFIED THE CHEMICAL SPECIFICATION OF THE RUBBER COMPONENTS AND AN UNSTABLE SUPPLIER PRODUCTION PROCESS, WHICH RESULTED IN INADEQUATE MIXING OF THE RUBBER COMPONENTS, AS THE FACTORS CONTRIBUTING TO THIS DEFECT.AS A RESULT OF THESE FACTORS, CRACKS CAN DEVELOP WITHIN THE RUBBER PART OR BETWEEN THE METAL AND THE RUBBER PARTS OF THE VALVE STEM, WHICH CAN LEAD TO A LOSS OF AIR PRESSURE AT THE VALVE STEM AND MAY POSE A RISK TO MOTOR VEHICLE SAFETY.ALTHOUGH THE TR-600 TIRE VALVE IS USED ONLY ON THE 2500 SERIES SUBJECT VEHICLES WITH 16 INCH TIRES, DCMI WILL CONDUCT A SAFETY RECALL FOR ALL SPRINTER 2500 VEHICLES SOLD IN THE U.S. TO REPLACE THE CURRENT TIRE VALVES WITH A TR-600 VALVE, WHICH USES A SINGLE RUBBER COMPONENT FOR THE VALVES.ALL 24 COMPLAINTS AND ALL 43 WARRANTY CLAIMS IDENTIFIED IN THIS INVESTIGATION INVOLVED MY 2002-04 SPRINTER 2500 VEHICLES, WHICH COMPRISE APPROXIMATELY 84 PERCENT OF THE SUBJECT VEHICLE POPULATION.
NHTSA Action Number: RQ04009
Date Opened: 2004-09-21
Date Closed: 2005-02-02
Manufacturer’s Name: Honda (American Honda Motor Co.)
Component Description: STRUCTURE:FRAME AND MEMBERS
Recall Campaign: 05V027
Summary Description: FRAME CROSSMEMEBER WELD FAILURES
Summary
HONDA IS AMENDING THE SCOPE OF 03V-350 TO ADD 34,919 POTENTIALLY AFFECTED GL1800 GOLD WING MOTORCYCLES.THE INITIAL RECALL RANGE INCLUDED FRAMES MANUFACTURED WITH ONE OF A NUMBER OF WELDING PROCESSES.HONDA BELIEVED, ON THE BASIS OF DATA AVAILABLE AT THAT TIME, THAT ONLY THOSE GL'S BUILT WITH THAT ONE PROCESS WERE AT RISK OF FAILURE.WITH THE ORIGINAL RECALL (IN SEPTEMBER, 2003), HONDA INTRODUCED YET ANOTHER WELD PROCESS.SUBSEQUENTLY, HONDA BECAME AWARE OF INCIDENTS INVOLVING GL'S NOT INCLUDED IN THE ORIGINAL RECALL, BUILT USING ANOTHER EARLY WELDING PROCESS.THUS, HONDA HAS DECIDED TO RECALL ALL GL1800'S BUILT PRIOR TO SEPTEMBER 20, 2003 REGARDLESS OF WHAT WELD PROCESS WAS BEING USED AT THE TIME.THIS RECALL EXPANSION AFFECTS THE 2001, 2002, 2003 AND 2004 MODEL YEARS AND THE TOTAL NUMBER OF AFFECTED U.S. GL1800 MOTORCYCLES INCREASES FROM 8,196 TO 43,115.
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