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: PE18004

Date Opened: 2018-04-23

Date Closed: 2020-11-22

Manufacturer’s Name: Daimler TruckseBay North America, LLC

Component Description: ELECTRICAL SYSTEM

Recall Campaign:

Summary Description: PNDB Electrical Power Distribution


Summary

On April 23, 2018, the Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE18-004) to investigate certain alleged defects affecting the Powernet Distribution Box (PNDB) and associated wiring on certain model year (MY) 2011-2016 FreightlinereBay Cascadia (P3 platform) truck tractors that may result in disruption or loss of electrical power to the PNDB itself and other electrical circuits, thermal events, and/or vehicle fires.On May 7, 2018, ODI sent an Information Request (IR) letter to Daimler TruckseBay North America LLC (DTNA). On June 19, 2018, ODI received an IR response from DTNA that included vehicle production, consumer complaint, field report, warranty, manufacturer actions, changes and other data related to the alleged defects. On April 8, 2019, ODI received a supplemental IR response from DTNA that included their assessment of the alleged defects. Furthermore, ODI engaged in discussions with the manufacturer about the alleged defects on multiple occasions during the course of this investigation. ODI analysis of all available data indicates there is not an apparent defect trend. The most recent field report data reviewed was from 2017Q1 and the most recent complaint data was received by ODI in 2019Q1. The complaint rate is low. Most warranty claims occurred early in the vehicles' service life, and with the newest of the subject vehicles being over four years old, they are all now beyond that point. The warranty claim rates for loose input or output terminals (0.16%), loose fuses (0.25%), PNDB power (B+) supply cable corrosion or improper PNDB power (B+) supply cable routing and/ or securement (0.00%) are all low.The most serious consequence in the warranty claim data alleged engine shutoff with a vehicle in motion. While some vehicles did experience a loss of electrical power resulting in loss of motive power with no immediate restart capability, the bulk of the warranty claims were for vehicles equipped with an optional cab power disconnect switch solenoid with an automatic reset feature that may exhibit a brief, intermittent loss of power. If the input and output voltages differ by an unacceptable amount, potentially due to foreign object debris or corrosion on the solenoid's contacts, the PNDB senses the difference and enters an auto-reset mode in an attempt to correct the condition. The internal contacts open for one second, stopping the flow of electricity, and then close, restoring the flow for two seconds. This cycle is repeated for up to five times; after a maximum of thirteen seconds, the PNDB defaults to the on position and electrical power is restored. This condition exhibits a transient loss of power but it does not cause any permanent engine disablement. As a precaution, the solenoid-equipped PNDB part was modified in August 2017 to eliminate the auto-reset feature. Since 2010, there has been only 1 report of vehicle fire and zero reports of crash, injury or death. Accordingly, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists. The agency reserves the right to take further action if warranted by the circumstances.

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NHTSA Action Number: EA18001

Date Opened: 2018-04-18

Date Closed: 2023-01-17

Manufacturer’s Name: NissaneBay North America, Inc.

Component Description: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

Recall Campaign: 18V916

Summary Description: Extended Braking Distances


Summary

On April 18, 2018, the Office of Defects Investigation (ODI) opened Engineering Analysis (EA) 18-001 to investigate reports of braking concerns in model year (MY) 2009 NissaneBay Murano vehicles. A failure of the hydraulic control unit (HCU) portion of the antilock brake system (ABSeBay), which involves improper operation of an internal hydraulic control valve(s), can cause extended brake pedal travel and may result in a reduction in overall braking effectiveness. Tier-one supplier ContinentaleBay manufactured the HCU for NissaneBay.The corrosion-preventive, zinc coating used on the armatures of the normally closed (NC) valves within ABSeBay HCU may react with brake fluids lacking sufficient corrosion-preventative additives. This reaction can cause the formation of a gelatinous material, which may cause the NC valves to close slowly. Over time, the gel can solidify to an extent such that the spring used to return the valve to the closed position may not be able to overcome the gel buildup, allowing the NC valve to remain open. If any of the four NC valves remains open, fluid will be diverted to one or two accumulator(s). This misdirected fluid has the net effect of causing brake pedal travel to increase, however enough stroke remains in the pedal to generate braking force. Although the hydraulic braking system remains intact and full braking force is maintained once the pedal travels the additional distance, when this condition occurs, the initial increase in brake pedal travel could result in increased stopping distance. An existing NissaneBay Service Campaign was launched for MY 2009 vehicles built prior to 11/1/2007. After consultation with ODI as part of EA18-001, NissaneBay decided to expand this population to the full range of MY2009 Murano vehicles. Later Murano vehicles exhibit significantly lower rates of malfunction.During this investigation 156 complaints were identified that related to the braking concern. Within the complainants 2 allege crashes with 4 injuries. The NissaneBay reports from investigation Information Request letter responses, were similar in content and identified 870 reports with 16 crashes and no injuries.On December 19, 2018, NissaneBay notified ODI it would conduct a safety recall (18V916) to remedy the ABSeBay modules on certain MY 2009 NissaneBay Murano vehicles. The remedy procedure involves dealers flushing the brake system with DOT 4 fluid. The HCU will then be tested to detect a possible stuck valve condition. If necessary, the HCU will be replaced. The 2010-14 Murano SUVs outside the recall population and equipped with zinc-coated armatures will be inspected under a service campaign P0A08 using the same procedure as recall 18V916.ContinentaleBay HCUs with a redesigned armature coating were phased into new vehicle production after December 2014 and do not appear to be experiencing corrosion. The recall action initiated by the manufacturer appears to address the safety risks of concern to ODI. Accordingly, the investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or MY vehicles outside of the recall scope. The agency reserves the right to take further action if warranted by the circumstances.For a complete summary of this investigation and related consumer complaints, please see attached closing resume document.

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NHTSA Action Number: EA18002

Date Opened: 2018-04-18

Date Closed: 2021-01-15

Manufacturer’s Name: FordeBay Motor Company

Component Description: SERVICE BRAKES, AIR:ANTILOCK:CONTROL UNIT/MODULE

Recall Campaign: 19V904

Summary Description: Extended Braking Distance


Summary

On April 18, 2018, the Office of Defects Investigation (ODI) opened Engineering Analysis (EA) 18-002 to investigate reports of braking concerns in model year (MY) 2006-12 FordeBay Fusion and LincolneBay MKZ, and MY 2006-11 MercuryeBay Milan vehicles manufactured with ContinentaleBay Automotive System?s ABSeBay hydraulic control units (HCUs). Complainants report that after an ABSeBay braking event (initiated by slippery or uneven surfaces) the brake pedal moved towards the floor and the vehicle stopping distance increased beyond driver expectations.Inside the HCU are four hydraulic normally closed (NC) valves with zinc-coated moving armatures that control the flow of brake fluideBay. Unstable brake fluideBay can degrade over time, allow the brake fluideBay to gel, and corrosion to form on the armatures. The high-viscosity gelation and corrosion can cause the armatures to become stuck (open). In some cases, braking returns to normal when the armature(s) subsequently become unstuck. The intermittent condition proves difficult to diagnose with complainants reporting having (non-HCU) repairs conducted only to have the condition return.During the investigation, 14 HCUs from complaint vehicles were recovered, including seven from reported crashes. NHTSA?s Vehicle Research and Test Center (VRTC) disassembled the HCUs, removed the four NC valves in each, and confirmed 22 of the 56 NC valves contained stuck armatures. On seven of the 14 HCUs, both front wheel armatures were stuck, on nine of the 14 HCUs two or three armatures were stuck. And 52 of the 56 NC armatures exhibited corrosion of the zinc coating. Forces required to extract stuck armatures from the valve sleeve were measured to range from 1.1 to 18.0 lbs. VRTC also conducted ABSeBay braking tests on a variety of test surfaces that showed HCU failures cause increases in pedal travel and braking distances. Testing also showed that if the driver was able to apply four times the brake pedal force and two times the brake pedal travel, then high-vehicle decelerations could be achieved, however, single or multiple wheel lockups were also occurring.Based on FordeBay?s response to ODI?s July 20, 2018 information request letter, and complainants' reports to NHTSA, ODI identified a population of vehicles with an elevated level of field failure compared to vehicles produced both before and after.Further evaluation of FordeBay?s response identified that the brake fluideBay used to produce these vehicles, a specific formulation of a DOT3 fluid provided by CCI Corporation between February 2006 and July 2009, differed from the brake fluideBay used in other vehicle populations. ODI used the correlation of fluid specification and elevated field failures to identify a vehicle population exhibiting a defect trend. The complaints, crashes and injuries cited above, and the 14 recovered HCUs involve vehicles from this population.On December 18, 2019, FordeBay submitted safety recall (19V-904) to remedy HCU failures on the MY 2006-2010 FordeBay Fusion, LincolneBay MKZ, and MercuryeBay Milan vehicles manufactured with the suspect CCI brake fluideBay formulation. FordeBay will function test the HCU and replace the DOT 3 brake fluideBay with an improved DOT 4 brake fluid. If the HCU fails the function test, FordeBay will install an HCU with a different armature coating (black oxide). HCUs with black oxide coating were fully phased into FordeBay?s new vehicle production by MY 2016; these HCUs do not appear to be experiencing armature corrosion. ODI notes that the non-recalled EA18-002 subject vehicles, which were manufactured with a different specification brake fluideBay, did not display an elevated level of field failures like the recalled vehicles.Based on available information, FordeBay?s rec

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NHTSA Action Number: EA18003

Date Opened: 2018-04-18

Date Closed: 0000-00-00

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

Component Description: AIR BAGS:FRONTAL:DRIVER CLOCKSPRING/SPIRAL CASSETTE

Recall Campaign:

Summary Description: Air Bag Clockspring Failure


Summary

In August 2015, VolkswageneBay Group of America, Inc. (VolkswageneBay) launched Safety Recall 15V-483 to address the loss of the protection provided by the front driver air bag in several models due to the failure of the clockspring.Debris entry into the steering wheel hub can result in contamination and ultimately failure of the clockspring in 2010-2014 Model Year (MY) CC, Passat, Eos, Golf, GTI, Tiguan, Jetta and Jetta Sportwagen models.Contamination of the clockspring can cause the ribbon cable to tear resulting in loss of the electrical connection to the front driver air bag and any steering wheel mounted controls.The loss of the electrical connection to the front driver air bag will result in illumination of the air bag warning light and will prevent operation of the front driver air bag in a crash of sufficient severity requiring a commanded deployment.In November 2017, the Office of Defects Investigation (ODI) opened a Recall Query (RQ17-009) after the agency received 90 complaints alleging failure of the clockspring in the subject models.Several of the complaints allege failure of the clockspring after receiving the recall remedy.The majority of the complaints allege the same failure mode without being included in the original recall, 15V-483.In its March 2018 response to ODI's Information Request under the Recall Query, VolkswageneBay provided approximately 700 consumer complaints and field reports on the recalled vehicles.These reports allege clockspring failure similar to the NHTSA reports described above.To date, NHTSA has received approximately 154 allegations of clockspring failure since the recall has launched.The total of 852 reports shown in the table above eliminates 6 duplicative reports received by ODI and the manufacturer.An Engineering Analysis has been opened to further evaluate the scope and effectiveness of the remedy associated with 15V-483 and perform a thorough review of the design changes implemented by VolkswageneBay and its suppliers to address this issue.The ODI complaints cited above can be viewed at www.NHTSA.gov under the following ODI identification numbers: 11080741, 11079877, 11079805, 11079124, 11076709, 11076645, 11076297, 11076249, 11076133, 11075756, 11075726, 11075358, 11075259, 11075055, 11074920, 11074565, 11073090, 11072745, 11072457, 11072089, 11071933, 11071880, 11071630, 11071592, 11067396, 11067061, 11066738, 11066601, 11066511, 11065909, 11065871, 11065262, 11064701, 11064564, 11064544, 11064531, 11063961, 11063501, 11063095, 11062772, 11062464, 11062353, 11062344, 11061463, 11061310, 11061311, 11060735, 11058154, 11057519, 11057477, 11057341, 11056793, 11056243, 11056063, 11055639, 11054279, 11052812, 11052678, 11052384, 11052228, 11051336, 11051155, 11051074, 11048803, 11047037, 11044226, 11043653, 11039142, 11033893, 11033330, 11032548, 11025475, 11025356, 11024647, 11023423, 11020570, 11020312, 11019415, 11019067, 11015441, 11015431, 11014595, 11014016, 11013709, 11013415, 11012596, 11011753, 11006668, 11006521, 11006307, 11006181, 11005301, 11003865, 11001780, 11001783, 11001334, 10994184, 10993360, 10993524, 10992490, 10985926, 10983678, 10981220, 10980831, 10980941, 10980549, 10979418, 10971152, 10967344, 10967155, 10959968, 10958624, 10957279, 10956488, 10949129, 10947562, 10945122, 10936498, 10936543, 10933950, 10927311, 10925421, 10924034, 10915612, 10915569, 10911171, 10902066, 10898733, 10896537, 10896510, 10895526, 10893938, 10891686, 10864967, 10863742, 10861984, 10851242, 10822505, 10821562, 10818403, 10795068, 10794402, 10788738, 10787804, 10782544, 10780725, 10780145, 10779145, 10776477, 10775448, 10763492, 10763423, 10763289, 10762670, 10760644, 10758777, 10749901, 10748922

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NHTSA Action Number: RQ18001

Date Opened: 2018-04-18

Date Closed: 2018-12-01

Manufacturer’s Name: BMWeBay of North America, LLC

Component Description: STEERING

Recall Campaign: 18V336

Summary Description: Idler Pulley Bolt Failure


Summary

In a May 23, 2018 letter, BMWeBay of North America, LLC (BMWeBay) notified the National Highway Traffic Safety Administration (NHTSA) of a safety defect that may result in the loss of power steering assist in certain model year (MY) 2009 through 2013 BMWeBay X5 xDrive35d vehicles (Recall 18V-336). The recall, which affects approximately 33,214 vehicles built from March 12, 2008 through June 27, 2013, corrects the remedy and expands the scope of a prior BMWeBay recall (12V-550) which addressed idle pulley bolt failure in approximately 29,800 MY 2009 through 2012 BMWeBay X5 xDrive35d vehicles built from September 1, 2008 through November 15, 2012. BMWeBay's analysis indicates that due to a number of contributing factors it is possible that the bolt's pre-stressing force could drop to an extent that it results in the bolt becoming loosened over time. A loosening of the bolt could cause additional bending stress on top of the bolt. As a result, the bolt could break. If this were to happen, then a sudden loss of power steering assist could occur.If there were a loss of power steering assist, manual steering capability would be retained, although the effort required to steer the vehicle would be greater, and therefore may increase the risk of crash.ODI's analysis of the complaints it has received from the public (VOQ's) and BMWeBay complaint data submitted in response to the information request letter for RQ18-001 identified a total of 93 unique VIN reports alleging failure of the idler pulley bolt after recall 12V-550 was completed on the vehicle, including 31 VOQ's and 72 BMWeBay consumer complaints (5 complaints received by NHTSA and BMWeBay, 3 unique VIN's submitted multiple complaints to BMWeBay, and 1 unique VIN submitted multiple complaints to NHTSA).BMWeBay is developing a new idler pulley fastening system as the remedy for 18V-336.The remedy is planned to begin in February 2019.Based on BMWeBay's safety recall, this recall query is closed.The 31 VOQ's referenced in this resume are: 10499780, 10559422, 10579534, 10655424, 10661614, 10702323, 10819617, 10903433, 10948014, 10984353, 11002447, 11010667, 11013643, 11041551, 11054759, 11054909, 11066063, 11083479, 11097562, 11098865, 11113332, 11128649, 11130277, 10552773, 10817406, 10937632, 10956710, 11032006, 11042259, 11063010, 11091513.

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Technical Service Bulletins TSB’s List


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Complaints List



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