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: PE14016

Date Opened: 2014-06-11

Date Closed: 2015-03-02

Manufacturer’s Name: HondaeBay (American HondaeBay Motor Co.)

Component Description: AIR BAGS:FRONTAL

Recall Campaign: 13V172

Summary Description: Air Bag Inflator Rupture


Summary

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with consistently high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly, ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016, four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016, four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The PE is now closed/upgraded to an Engineering Evaluation (EA15-001) to include all manufacturersand vehicles known to be affected at this time.ODI's EA investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The recalls related to this PE are: 14V343, 14V344, 14V348, 14V351, 14V353, 14V655, 14V700, 14V701, 14V752, 14V763, 14V770, 14V773, 14V787, 14V802 and 14V817.The number of vehicles affected are an estimate since some vehicles may have both the driver and passenger side inflators recalled. The five ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

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NHTSA Action Number: EQ14006

Date Opened: 2014-05-30

Date Closed: 2014-09-19

Manufacturer’s Name: Muncie Power Products, Inc.

Component Description: ENGINE AND ENGINE COOLING

Recall Campaign: 14V307

Summary Description: Muncie PTO Switches May Ignite


Summary

The closing report is attached.

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NHTSA Action Number: RQ14001

Date Opened: 2014-05-29

Date Closed: 2015-11-13

Manufacturer’s Name: ChryslereBay (FCAeBay US, LLC)

Component Description: AIR BAGS

Recall Campaign: 15V043

Summary Description: JeepeBay inadvertent air bag deployment


Summary

The Office of Defects Investigation (ODI) opened an investigation based on consumer allegations of inadvertent air bag deployments (IABD) occurring after the recall remedy for NHTSA recall 12V-527 had been installed on recalled model year (MY ) 2002-2003 JeepeBay Liberty and MY 2002-2004 JeepeBay Grand Cherokee vehicles manufactured by FiateBay ChryslereBay Automobiles (FCAeBay).The recall was in response to the Office of Defects Investigation (ODI) investigation EA12-001 during which data provided by FCAeBay indicate that the air bag circuitry inside the Occupant Restraint Control (ORC) module can degrade. ORC degradation can result in an inadvertent air bag deployment, without a crash or impact, while the vehicle is being operated.An IABD may involve frontal, side and belt pretensioner devices, and may result in injuries consisting of burns, cuts and bruises to the upper body region, and or the potential for a loss of control and or crash.The remedy FCAeBay developed for 12V-527 consisted of installing an in-line jumper harness with an integrated electrical filter for the circuits that connect to the air bag modules (squib circuits).This filter is intended to eliminate transient electrical spikes to the ORC which FCAeBay asserted are responsible for the IABDs.ODI has identified a total of 9 NHTSA complaints across all affected vehicles indicating an IABD event occurring after the vehicle had previously been remedied under 12V-527.In addition, FCAeBay reported 12 additional complaints of post-remedy IABD events. The IABD events took place both while driving and while the vehicle was stationary. Six customers incurred injuries consistent with air bag deployments however no crashes were reported.As a response to this investigation, FCAeBay has issued 2 new recalls involving the IABD.On January 27, 2015 FCAeBay notified ODI that it would conduct a safety recall (15V-046) to remedy potential IABD events occurring in 753,176 MY02-03 JeepeBay Liberty vehicles built through 03/28/03 and MY 2002-2004 JeepeBay Grand Cherokee vehicles built through 5/23/03.Note that this recall, which was scoped based on field IABD events does not include all MY 2003 Liberty or MY 2004 Grand Cherokee manufactured with the same level ORC module.According to FCAeBay, the ORC degradation and subsequent electrical overstress condition that causes the air bags to deploy inadvertently is not fully remedied with the filter installed during the 12V-527 campaign.To remedy IABDs under 15V-046, FCAeBay will install a new design ORC module using a next generation electrical architecture.The next generation architecture has been used in other non-subject vehicles for many years without evidence of IABD events occurring.In addition to this recall, on October 15, 2015 FCAeBay advised NHTSA that it would conduct safety recall 15V-673 to remedy potential IABD events in the remaining 284,089 MY 2003 JeepeBay Liberty and MY 2004 JeepeBay Grand Cherokee vehicles manufactured with the earlier generation ORC module that were not previously recalled.FCAeBay initially did not recall these populations due to the lack of known IABD events.However, FCAeBay is now aware of 7 IABD events occurring in this population. After consultation with ODI regarding the long term durability and noise toughness of the earlier ORC architecture, FCAeBay decided to recall this population also.The recall actions initiated by the manufacturer address the safety risks identified by the investigation.Accordingly, the investigation is closed.The ODI reports cited above can be reviewed at http://www-odi.nhtsa.dot.gov/owners/SearchSafetyIssues under the following identification (ODI) numbers: 10622092, 10629705, 10619008, 10618842, 10626762, 106404

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NHTSA Action Number: PE14014

Date Opened: 2014-05-20

Date Closed: 2015-05-13

Manufacturer’s Name: NissaneBay North America, Inc.

Component Description: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER

Recall Campaign:

Summary Description: Excessive Brake Pedal Travel


Summary

On May 20, 2014, ODI opened PE14-014 based on eight complaints alleging incidents of excessive brake pedal travel in model year (MY) 2013 through 2014 NissaneBay Sentra, Versa Sedan and Versa Note passenger cars (Figure 1) and information in Early Warning Reporting field reports indicating issues with master cylinder internal seals.In response to an information request letter sent by ODI, NissaneBay identified a condition with the master cylinder in early production subject vehicles that could result in a slow internal leak past one of the recuperating seals to the brake reservoir when the brake pedal is depressed very slowly or lightly (Figure 2).The subject vehicles are equipped with fixed seal master cylinders supplied by TRWeBay.To address concerns with water hammer noise with the standard seal design, the master cylinders in the early production subject vehicles used AWH (anti-water hammer) seals.The AWH seals are sensitive to contamination from assembly plant cleanliness issues, which can produce the internal leak condition during slow or light brake applies but perform as designed with normal or emergency brake applications.TRWeBay indicated that the risk of contamination interacting with the subject seals is greatest after the evacuation and pressure fill process used to fill the brake system during the manufacturing process (early life issue).TRWeBay developed a new master cylinder seal design (EVO seal) that addresses the noise concern and eliminates the internal leak concern associated with contamination by providing a secondary seal (Figure 3).NissaneBay implemented the new master cylinder design in vehicle production on September 23, 2013.ODI's analysis shows that the master cylinder warranty claim rate is much higher in vehicles produced before the change (Figure 4).Statistical analysis showed that the condition is an early-life problem with relatively low failure rates projected through 100,000 miles and approximately 58 percent of the failures projected to occur by that mileage have already occurred (Table 1).Warranty claims are highest (78% of claims) in vehicles with less than 10,000 miles (Figure 5) and 50 percent of claims involved vehicles with less than 90 days in service (Figure 6).ODI evaluated 22 crash claims that included allegations of master cylinder failure, sinking brake pedal or pedal to the floor (Table 2).The analysis identified only three crashes in which a brake performance issue related to the master cylinder was duplicated by post-incident inspection, including one with a different problem than the seal leak issue (a broken plunger).The two crash complaints related to a possible master cylinder concern involved 1 vehicle with the AWH seal and 1 with the EVO seal.Both were minor crashes.The remaining crashes do not appear to be related to any issues with the master cylinder or other brake system fault.In the 4 crashes with Event Data Recorderinformation available, the data indicated that the brakes were applied too late to avoid the collisions.These include 2 crashes with less than a half second of braking before impact and 2 in which brake applications lasting 1.0 to 2.5 seconds resulted in high decelerations consistent with fully functioning brake systems, but too late to avoid the collision.Overall, the rates of crashes adjusted for vehicle exposure (total vehicle years in service) do not show any correlation to the high warranty rates associated with the AWH seal leak concern (Table 3 & Figure 7).Given these circumstances, further use of the agency resources in this matter does not appear to be warranted.Accordingly, this investigation is closed. The closing o

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NHTSA Action Number: PE14013

Date Opened: 2014-05-19

Date Closed: 2014-12-23

Manufacturer’s Name: ChryslereBay (FCAeBay US, LLC)

Component Description: ELECTRICAL SYSTEM:IGNITION:SWITCH

Recall Campaign: 14V795

Summary Description: Clutch Interlock Switch Malfunction


Summary

On December 16, 2104, ChryslereBay Group LLC submitted a Safety Recall Report to NHTSA describing a defect in the clutch ignition interlock switches in approximately 66,819 model year (MY) 2006 through early-2007 DodgeeBay RameBay Trucks, DodgeeBay Dakota, and MitsubishieBay Raider vehicles equipped with manual transmissions and built between July 1, 2005 and July 31, 2006 (NHTSA Recall No. 14V-795, ChryslereBay Recall No. P80), including 38,969 MY 2006 DodgeeBay RameBay 2500 and 3500 vehicles that are part of the subject vehicle population for PE14-013.ChryslereBay's Safety Report states that:1) the clutch ignition interlock switch return springs may experience fatigue failure due to material issues; 2) if the return springs are broken, the switch contacts may not reflect actual clutch pedal position; and 3) the failures could result in a vehicle experiencing unintended movement if the ignition is cranked when the clutch pedal is not being pressed.ChryslereBay's recall remedy will replace the clutch ignition interlock switch on all affected vehicles with a switch with a more robust design.On May 19, 2014, ODI opened PE14-013 to investigate clutch ignition interlock failure in MY 2004 through 2006 DodgeeBay RameBay 2500 and 3500 trucks with manual transmissions, based on two MY 2006 complaints and one MY 2004 complaint.One of the MY 2006 complaints involved a fatality that occurred when a young child was able to start a MY 2006 RameBay 3500 truck that was parked with the transmission in gear, without depressing the clutch.The diesel engine started and the vehicle moved forward under power running over another child resulting in fatal injuries.ODI's analysis of failure data from all sources identified a total of 14 complaints and 16 warranty claims for the subject vehicles.Thirteen (13) of the complaints and all 16 warranty claims were for the 38,969 MY 2006 DodgeeBay RameBay 2500 and 3500 trucks that were included in 14V-795.The single complaint that was outside the scope of ChryslereBay's recall was the MY 2004 ODI complaint identified in the opening resume for PE14-013.Further analysis of this incident indicates that the cause of the clutch switch failure in this vehicle was spring damage caused by hydraulic fluid leakage from the clutch master cylinder into the switch.The field data did not show any other similar incidents of switch failures caused by clutch master cylinder leakage. This investigation is closed based on ChryslereBay's recall.

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