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: PE14031
Date Opened: 2014-10-06
Date Closed: 2015-02-27
Manufacturer’s Name: MICHELIN
TIRE CORP.
Component Description: TIRES
Recall Campaign: 14V740
Summary Description: XZA 295/60/R22.5 Steer Tire Failures
Summary
The Office of Defects Investigation (ODI) opened this investigation based on seven (7) Vehicle Owner Questionnaires (VOQ) and a Police Accident Report (PAR) alleging failures of Michelin XZA tires.The PAR reported an auto hauler left the roadway and rolled onto it's side and losingsome of it's load.Fortunately, the driver was unharmed and no other vehicles were involved.ODI received ten (10) additional VOQs during the investigation.The VOQs included both 295/60/R22.5 and 275/70/R22.5 tire sizes.ODI focused on the 295/60 tires as they were specified as original equipment on many auto hauler trucks.Due to their unique loading configuration, auto haulers tend to place a high demand on front tires.The 295/60 has a maximum load and speed rating of 7,390 pounds and 65 mph when maintained at 130 psi (cold) inflation pressure on a 9 rim.Pressure below 130 psi reduces the maximum load and Michelin only approves mounting the 295/60 on a 9 inch rim.While physically possible, mounting on any other size rim compromises the integrity of the 295/60 tire.Alternately, the maximum speed can be raised to 75 mph when the tire is mounted on a 9 rim with 130 psi pressure and the load does not exceed 7,150 pounds.During the investigation, ODI collected and analyzed vehicle, crash, and tire information.In addition to sending an Information Request (IR) letter to Michelin, ODI collected information from several vehicle manufacturers.Electronic data from the subject crash vehicle showed the vehicle was traveling in excess of 75 mph when the tire failure occurred.Michelin investigated all subject tire failure claims they were aware of.In each case the failure could be explained by one of the following: (1) violating the interdependency of tire load, inflation pressure and vehicle speed, (2) misapplication of rim vs. tire size or (3) a road hazard.Some fleets assumed there was a defect with the 295/60 tires and used the 275/70 instead.Michelin does not approve mounting a 275/70 on a 9 rim.In the event that the rim was appropriately changed to a 7.5 or 8.25 inch, the load capability would be reduced.No design changes were reported for the subject tires.This removed the possibility that a design or material specification change caused the recent failures.The more likely explanation of failures is the increase in maximum speed limits in several states.Currently, no truck tire is rated in excess of 81 mph (speed ratingM) with the vast majority rated at 75 mph (speed rating L), yet 16 states have maximum truck speeds equal to or greater then 75 mph.Of these 16, four allow truck speeds of 80 mph or more.To further understand the environment of the subject tires, ODI conducted a special survey (level 4 inspections) with the assistance of the Pennsylvania State Police, Motor Carrier Enforcement.ODI weighed individual steer axle tires and measured the inflation pressure of auto haulers.Of the trucks inspected, 55% had an overloaded tire based on the actual load and inflation pressure (assumed to be cold).When asked, 60% of the drivers did not know the proper inflation pressure as certified by the OEM for the vehicle they were driving.During this investigation, Volvo recalled a population of auto hauler trucks that were originally equipped with tires rated for a maximum speed of 65 mph.As originally built, the recalled vehicles were capable of exceeding the tire speed rating.Volvo's recall sets the speed limiters on the vehicles to prevent exceeding the tire speed rating.This investigation is closed.The agency reserves the right to take further action if warranted.The ODI reports cited above can
NHTSA Action Number: PE14030
Date Opened: 2014-10-02
Date Closed: 2015-09-10
Manufacturer’s Name: Ford Motor Company
Component Description: STEERING:ELECTRIC POWER ASSIST SYSTEM
Recall Campaign: 15V340
Summary Description: Electric power steering failure
Summary
The Office of Defects Investigation (ODI) opened a preliminary evaluation to investigate complaints of the loss of power steering while driving. The subject vehicles are equipped with a rack mounted Electric Power Assisted Steering (EPAS) unit.Some of the complaints alleged that the steering assist failed and resulted in increased steering efforts that contributed to a loss of control and in some cases a crash.The EPAS system was manufactured by TRW Automotive for Ford and was designated as Generation I.These units were first produced and put into vehicle production in July 2008 beginning with the model year (MY) 2010 Ford Fusion and Mercury Milan.The system is comprised of a mechanical steering rack-and-pinion gear with torque sensor, electric assist motor, motor position sensor and a power steering control module (PSCM). The PSCM is self-monitoring and designed to detect faults within the system and can store diagnostic trouble codes (DTCs) if a problem is detected.There are 29 potential DTCs the system can detect.Many of these allow the system to go into reduced-assist steering mode by using the default vehicle speed signal should the live speed signal be lost, if voltage to EPAS system falls below 10.7 or goes above 17 volts, the temperature at the PSCM goes above 105C (221F), or if high friction is detected.Some DTCs will cause the system to go into manual steering mode (no assist). On July 1, 2015, Ford filed a Defect Information Report (DIR) identifying a safety related defect in TRW GEN I EPAS systems installed in some of the subject vehicles (NHTSA Recall 15V-340, Ford No. 15S18).The DIR indicated that intermittent electrical connections caused by quality issues associated with conformal coat contamination and ribbon cable pin misalignment within the steering gear motor may lead to a loss of the motor position sensor signal, resulting in a sudden loss of power assist while driving.The recall covers approximately 393,623 vehicles built from September 2010 through February 2012:2011-12 Fusion built SEP 2010 - FEB 2012; 2011-12 Lincoln MKZ built SEP 2010 - FEB 2012; 2011 Milan built SEP 2010 - DEC 2010; 2011-13 Taurus built SEP 2010 - FEB 2012; 2011-13 Flex with 3.5L GTDI engine built SEP 2010 - FEB 2012; and 2011-13 MKS, MKT with 3.5L GTDI engine built SEP 2010 - FEB 2012.The repair consists of updating the PSCM software to prevent a loss of steering assist while driving. The revised software will provide audible and visual warnings to the driver. If one or more of the following DTCs are stored, C1B00-62, C200B-2F, C200B-61, C200B-62, C200C-2F, C200D-49, U0300-00, U2011-49, U2011-61, U3000-46, U3000-49, U3000-61, U3000-72, U3000-96, P07AE-09, the dealer will replace the EPAS system at no charge to the owner.ODI's analysis of failure data for this PE identified a total of 2,584 complaints to ODI and Ford and 9,967 Ford warranty claims related to the alleged defect.The recalled vehicles account for 1,634 of the complaints and 7,311 of the warranty claims.ODI's analysis identified 40 complaints alleging crashes that may be related to loss of steering assist while driving, 20 of which involved vehicles included in Ford's recall.The information available for the alleged crashes were not sufficient to assess specific causes of the incidents or to verify EPAS malfunctions in each case.Most of the crashes were low-speed impacts with curbs or roadside objects resulting in wheel or minor body damage.None of the injury claims indicated medical attention was required.In addition, statistical modeling of the failure data by NHTSA's National Center for Statistics and Analysis projected 10-year failur
NHTSA Action Number: AQ14002
Date Opened: 2014-09-30
Date Closed: 2015-07-31
Manufacturer’s Name: Forest River, Inc.
Component Description: EQUIPMENT:RECREATIONAL VEHICLE/TRAILER
Summary Description: Safety Act Violations
Summary
In a Consent Order executed on July 8, 2015, Forest River, Inc. (Forest River) admitted that it violated the Safety Act by: failing to submit accurate early warning reports; not filing certain field communications or reports of Canadian safety campaigns; not providing copies of notices, bulletins, and other communications as required; failing to file certain quarterly recall reports in a timely manner or with complete information; sending notices to dealers without required information; failing to submit communications to manufacturers, dealers, owners and purchasers directly related to a defect or noncompliance; failing to notify vehicle owners and dealers of defects and noncompliances; not timely notifying NHTSA of safety-related defects within five days; failing to conduct timely recalls for Recall Nos. 15V-080 and 15V-156; and failing to respond fully to NHTSA's October 2, 2014 Special Order by the deadline.As part of the Consent Order, NHTSA assessed a total civil penalty of $35 million against Forest River for its violations of the Safety Act. The civil penalty consists of a cash payment and stipulated penalties. Forest River paid the $5 million cash penalty on July 17, 2015. Forest River is required to retain an independent monitor to conduct audits of the company's compliance with the Consent Order and Safety Act. Failure to resolve any issues discovered in those audits will result in portions of the stipulated civil penalties coming due. The Consent Order also contains performance obligations, including retention of an in-house consultant, actions to remedy past noncompliances with the Safety Act, creation of publicly available best practices for Safety Act compliance, employee training, and industry outreach. The population listed in this closing resume is based on Forest River?s untimely recalls and does not include other issues addressed by the Consent Order, which relates to Forest River?s entire business.Based on the Consent Order, Forest River's admissions that it violated the law, and its ongoing performance obligations, this audit query investigation, AQ14-002, is closed. Closure of this AQ has no bearing on the terms of the Consent Order, including Forest River's ongoing performance obligations or legal obligations, and does not represent a determination by the agency as to Forest River's performance under the Consent Order to date.
NHTSA Action Number: DP14004
Date Opened: 2014-09-25
Date Closed: 2015-07-24
Manufacturer’s Name: Chrysler (FCA US, LLC)
Component Description: ELECTRICAL SYSTEM
Summary Description: Totally Integrated Power Module Failure
Summary
In a letter dated August 21, 2014, the Center for Auto Safety (CAS) petitioned the National Highway Traffic Safety Administration (NHTSA) to initiate a defect investigation of alleged failures associated with the Totally Integrated Power Module (TIPM) installed in Chrysler SUV?s, trucks, and vans beginning in the 2007 model year. The petitioner alleges that TIPM defects may result in engine stall, airbag non-deployment, failure of fuel pump shutoff resulting in unintended acceleration, fire, and other symptoms. On September 25, 2014, the Office of Defects Investigation (ODI) opened DP14-004 to evaluate the petition for a grant or deny decision. ODI analyzed complaint data provided by CAS as well as complaints submitted to ODI from consumers. In total, there were 296 complaints submitted by the petitioner in the original petition and five supplements, including 271 complaints related to the subject vehicles equipped with TIPM-7. Approximately 3 percent of CAS complaints are related to vehicles equipped with TIPM-6 and ODI?s review of these complaints did not identify any safety defect trends. ODI conducted a detailed review of complaints narratives submitted by CAS and consumers including careful analysis of vehicle repair histories, warranty claims obtained from the manufacturer and any available Customer Assistance Inquiry reports (CAIR). Analysis of the field data indicated that MY2011-2013 Jeep Grand Cherokee and Dodge Durango vehicles exhibited significantly higher complaint rates related to fuel pump relay (FPR) failures than other subject vehicles. In a September 3, 2014 letter to NHTSA, Chrysler submitted a Defect Information Report (DIR) identifying a defect in the FPR within the TIPM-7 which can result in a no start or stall condition in approximately 188,723 model year (MY) 2011 Jeep Grand Cherokee (WK) and Dodge Durango (WD) vehicles manufactured from January 5, 2010 through July 20, 2011 (14V-530).In a February 24, 2015 letter, Chrysler submitted a second DIR expanding the scope of the FPR defect condition to include an additional 338,216 MY 2012 through 2013 Jeep Grand Cherokee vehicles manufactured from September 17, 2010 through August 19, 2013 and MY 2012 through 2013 Dodge Durango vehicles manufactured from January 18, 2011 through August 19, 2013 (15V-115).ODI analysis of the CAS allegations of TIPM defects resulting in stall while driving, airbag non-deployment, unintended acceleration, fire and other faults identified a single defect condition related to 1 of over 60 different circuits in the TIPM assembly. The most common effect of this defect condition, related to the fuel pump relay, was a no-start concern, but it could also result in stall while driving (76 complaints). No valid evidence was presented in support of claims related to airbag non-deployment, unintended acceleration or fire resulting from TIPM faults and these claims were found to be wholly without merit based on review of the field data and design of the relevant systems and components.Except insofar as the petitioner's contentions relate to the defect condition addressed by the Chrysler recalls, the factual bases of the petitioner's contentions that any further investigation is necessary are unsupported. In our view, additional investigation is unlikely to result in a finding that a defect related to motor vehicle safety exists or a NHTSA order for the notification and remedy of a safety-related defect as alleged by the petitioner at the conclusion of the requested investigation. Therefore, in view of the need to allocate and prioritize NHTSA's limited resources to best accomplish the agency's safety mission, the petition is den
NHTSA Action Number: DP14003
Date Opened: 2014-09-19
Date Closed: 2015-04-29
Manufacturer’s Name: Toyota Motor Corporation
Component Description: VEHICLE SPEED CONTROL
Summary Description: Low-speed surging
Summary
The Agency received a petition on September 11, 2014 requesting an investigation into, low-speed surging in the 2006-2010 Toyota Corolla [vehicles] with ETCS-i, in which the brakes fail to stop the vehicle in time to prevent a crash.NHTSA conducted a technical review of the material cited and provided by the petitioner, material Toyota submitted in response to a NHTSA formal request, interviews with complainants and manufacturer representatives, as well as the results of testing of the complaint vehicle.Taking into account the allocation of agency resources, agency priorities, and the likelihood that an additional investigation would result in a finding that a defect related to motor vehicle safety exists, NHTSA has concluded that further investigation of the issues raised by the petition is not warranted.The agency accordingly has denied the petition.The official petition denial, as published in the Federal Register, is available in the document file for this defect petition, as well as copies of reference material related to the denial.Regarding the VOQs associated with the closing of this investigation, the scope as defined by the petitioner is MY 2006 through 2010 Toyota Corollas.Of the 163 VOQs submitted by the petitioner, 149 are within that specific population (11 of the 163 were outside the model and model year scope of investigation as defined by the petitioner and 3 VOQs were submitted by owners from foreign countries) and 6 of the 163 are duplicate submissions.Therefore, there are 143 unique vehicles vins are within the specific population.Of the 143 only 105 fit the alleged defect category as defined by the petitioner.The single complaint and crash noted in the Failure Report above is the petitioner's VOQ.The 143 VOQs are: 10165337, 10166526, 10209540, 10216514, 10256808 (duplicate with 10266580 and 10335955), 10272505, 10293497, 10293688, 10294727, 10297407, 10298012, 10302217, 10302877, 10303106, 10303469, 10303730, 10304192, 10305748, 10305845, 10306012, 10306480, 10307953, 10310973, 10311137, 10311176, 10311185, 10311756, 10312246, 10312272 (duplicate with 10343088), 10312771, 10313972, 10314880, 10315240, 10315442, 10315836, 10315927, 10316192, 10316627, 10316643, 10316800, 10316952, 10317128, 10317598, 10317725, 10317804, 10317894, 10317972, 10317978, 10318562, 10319589, 10320693, 10320720, 10322163, 10322213, 10322333, 10322415, 10324355, 10325755, 10326481, 10327623, 10328492, 10328519, 10329537, 10330026 (duplicate with 10356866), 10330952, 10332679, 10334005 (duplicate with 10340570 and 10547602), 10334028, 10334628, 10334936, 10336649, 10339772, 10339969, 10341515, 10342670, 10342932, 10343174, 10344874, 10345714, 10348120, 10350342, 10351112, 10352668, 10352691, 10353587, 10358767, 10359645, 10360875, 10360905, 10361254, 10363529, 10363685, 10363866, 10364127, 10366100, 10366413, 10369073, 10369494, 10371991, 10376535, 10376721, 10377193, 10379320, 10380210, 10381365, 10381849, 10382018, 10392618, 10396747, 10402827, 10412382, 10433860, 10437011, 10437801, 10450183, 10461118, 10479582, 10482133, 10489344, 10494568, 10496026, 10499932, 10520195, 10521013, 10523677, 10534094, 10537426, 10543949, 10549101, 10551478, 10552563, 10558153, 10562577, 10564980, 10566370, 10572873, 10578871, 10579722, 10587140, 10597296, 10621449, and 10637908 (which is the petitioner's VOQ and not one of the 163 submitted with the petition).The three VOQs that were submitted from foreign countries: 10303105, 10303749, and 10308974. The eleven VOQs that are out of the specified population by model or model year: 10447756, 10453401, 10490200, 10507434, 10521377, 10563214, 10563585, 10575230, 10583796, 10584534,
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