Driver Side Frontal Air Bag Inflator Permanent Remedy Repair (2218A) – 2006 Mazda B-Series

January 16, 2018

Driver Side Air Bag Inflator May Explode

In the event of a crash necessitating deployment of the driver’s frontal air bag, the inflator could explode with sharp metal fragments striking the vehicle occupants, potentially resulting in serious injury or death.

 

NHTSA Campaign Number: 18V038

Manufacturer Mazda North American Operations

Components AIR BAGS

Potential Number of Units Affected 2,205

 

Summary

Mazda is recalling certain 2006 B-series vehicles. Mazda requests owners NOT TO DRIVE these vehicles until they have been remedied. Upon deployment of the driver side frontal air bag, excessive internal pressure may cause the inflator to explode.

On January 11, 2018, Mazda North American Operations (Mazda) notified NHTSA that they are recalling 160 model year 2006 B-Series vehicles built with driver-side air bags. As of February 9, 2018, Mazda is expanding the recall to a total of 2,205 model year 2006 B-Series vehicles built with driver-side air bags.

Upon deployment of the driver side frontal air bag, excessive internal pressure may cause the inflator to explode.

 

Remedy

Mazda will notify owners instructing them to not drive their vehicles, and dealers will replace the front driver side air bag inflator with an alternate inflator, free of charge. The recall began January 18, 2018. Owners may contact Mazda customer service at 1-800-222-5500. Mazda’s number for this recall is 2218A.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Mazda has a Recall

 

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January 18, 2018

Attention:  Mazda Service and Parts Managers

Subject:   ***CORRECTED*** – Announcing the launch of Safety Recalls 2218A and Safety Recall 2318A.  Driver Side Frontal Air Bag Inflator Permanent Remedy Repair (2218A) and Passenger Side Frontal Air Bag Inflator Permanent Remedy Repair (2318A) for 2006 Mazda B-Series Trucks

 

URGENT – THE VEHICLES IN THIS PROGRAM ARE NOT TO BE DRIVEN UNTIL THIS REPAIR HAS BEEN PERFORMED

The vehicles in this program are equipped with airbag inflators suspected to have a higher risk of inflator rupture during airbag deployment than other Takata airbag inflators.  These vehicles were previously included in safety recall 9116A and were to be recalled under Permanent Remedy Recall 1917L and Recall 1817L. There are 143 affected vehicles in the US.

Dealers are instructed to replace both the Drivers Side Frontal Airbag Inflator (Recall 2218A) and the Passenger Side Frontal Airbag Inflator (Recall 2318A) at the same time. 

Recalls 2218A and 2318A transitioned to modified (“Permanent”) remedy parts and superseded Recalls 9116A and 8315F. Corresponding NHTSA Campaign numbers are as follows:

Affected Vehicles	Location	Parts	Mazda recall	NHTSA recall
2006 B-Series 143 Affected Vehicles	Driver	Permanent	2218A	18V-038
	Driver	Original, like-for-like	9116A	16V-048
	Passenger	Permanent	2318A	18V-039
	Passenger	Original, like-for-like	8315F	15V-346

 

Both Recalls 9116A and 8315F which used non-modified (“Original Like for Like”) remedy Takata Driver and Passenger Air Bag inflators are closed.

The 143 affected vehicles include certain 2006 Mazda B-Series Trucks registered in all states.

Owners of affected vehicles will be notified in 2 mailings, by overnight mail and subsequently also certified mail starting January 17, 2018. The affected vehicles will display OPEN in all States and Parts Are Available.

Owners will be directed to contact dealers in order to arrange towing of their vehicle and a MCVP or Rental vehicle if needed.

It is imperative that all vehicles are located and repaired as soon as possible. As a dealer, MNAO is relying on your ability to assist in locating and repairing these vehicles as quickly as possible. You are authorized to provide a mobile repair at the owner’s residence in place of a tow. For other methods of outreach, please contact the warranty department at warrantydept@mazdausa.com. For full details to claim mobile repairs, please refer to the Parts and Warranty information on MGSS and eMDCS.

Recalls 2218A and 2318A will use these new Permanent Remedy Parts manufactured by TRW.

• 1FT1-57-K00 for Drivers Inflator (Same as Recall 1917L)
• 1FT1-57-K50A for Passenger Inflator (Same as Recall 1817L)

Note: Recall 2218A is the same repair and part as Recall 1917L which affects the remaining 2004-2006 B-Series Truck.

As of January 16, 2018 these parts can be ordered using the Restricted Parts Ordering Weblink on MXConnect, and selecting Recalls 2218A and 2318A from the menu.  Please note; all orders will be VIN specific and only VINs in an “OPEN” status will be accepted. The Weblink order will send both Driver and Passenger Inflators. You will need to contact the DAG for all other orders.

To help you effectively perform this recall, Mazda has developed the following resources:

1. Parts and warranty information, repair procedures and owner letter are available on MGSS (Mazda Global Service Support) websites via MXConnect.
2. Parts and warranty information is available on eMDCS.
3. For technical assistance, contact the Technical Assistance Hotline at (888) 832-8477, Option 3.
4. For warranty questions, contact the Warranty Hotline at (877) 727-6626, Option 3.
5. For parts questions, contact the Corporate Dealer Assistance Group at (877) 727-6626 Option 2.
6. We recommend using the Recall Customer Identification Report #JS30R192-2 available in Web Reports to encourage customers who received the recall notice to come in for the recall. Dealers may use such customer information for the sole purpose of conducting and performing this recall, and for no other purpose. Using it for marketing activities is strictly prohibited and could subject your dealership to serious fines. The information in the report is protected by state privacy and other applicable laws regarding disclosure of personal and/or confidential, restricted or blocked information. It is the dealer’s responsibility to protect the confidentiality of customer records and prevent the release of information to other parties.

Please make certain the appropriate personnel in your dealership are aware of these resources and are familiar with the details of this recall before responding to customer inquiries.

We apologize for any inconvenience this recall may cause you and your customers.  Your understanding and support in carrying out this campaign is greatly appreciated.

Because Driving Matters, Safety Matters. Your safety is important to Mazda.

 

Sincerely,

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PARTS AND WARRANTY INFORMATION
Safety Recall 2218A

 

CONDITION OF CONCERN

The driver side airbag inflator in your vehicle may be part of a small population of inflators that pose a higher risk of explosion in the event of a crash that causes an air bag deployment.  Two inflators built at Takata on the same day as the driver side air bag inflator in your vehicle have exploded causing fatal injuries. An inflator explosion could result in sharp metal fragments striking the driver or other vehicle occupants, resulting in SERIOUS INJURY OR DEATH.

 

These are the same vehicles subject to Safety Recall 2318A.

 

SUBJECT VEHICLES

Model	VIN range	Build Date Range
2006 B-Series Truck	Varies – 143 vehicles – see MGWS for VIN’s	Vehicles with a specific B-Series Takata air bag manufactured between September 3, 2005 and September 5, 2005

 

MANDATORY AIR BAG INFLATOR RETURN 

All inflator part numbers can be counted and shipped together for these returns. To schedule a return, please contact XPO at (877) 650-3476.  Detailed air bag inflator return instructions are provided in Attachment IV, and can also be found on MGSS and the Dealer Assistance Group website. Failure to return the original inflator will result in a Warranty Claim Debit.

 

OWNER NOTIFICATION

Mazda will notify U.S. owners by overnight and certified mail (2 mailings) beginning January 18, 2018.

 

PARTS INFORMATION

A web page to order parts for this recall is available in MXConnect.  A complete VIN is needed to process the order. 

Description	Part Number	Quantity	Notes
Driver Frontal Air Bag Inflator	1FT1-57-K00	1	Permanent Repair
Campaign Label	9999-95-065A-06	1=50 labels	Obtain in Mazda e-Store  (no charge)

 

WARRANTY CLAIM PROCESSING INFORMATION

Recall 2218A – DAB “Permanent”  Repair **CRITICAL**	Replacement of Driver Frontal Air Bag Inflator
Applicable Model	B-Series
Warranty Type	R
Process Number	J1803A
Symptom Code	99
Damage Code	99
Part Number Main Cause & Quantity	1FT1-57-K00 / 1 pc
Labor Operation Number	YY794XRX
Labor Hours	0.4 hrs.
Sublet Code K1 – Towing	See Note below.  DSM Authorization required
Sublet Code Z9 – Allowable Costs*	See Note below.  DSM Authorization required

 

Note: For K1 Sublet – we are allowing towing charges to be claimed to and from the dealer if Mazda Roadside Assistance (RSA) services were not arranged via the Mazda Customer Experience Center (CEC).  Please keep in mind, warranty towing claim guidelines will apply and DSM Authorization required. If customer is due a refund from towing costs, a dealer refund check copy is required to be attached, please use attachment ID D40 if used.

 

For Z9 Sublet – Costs incurred must be pre-approved costs by your DSM or the Mazda Customer Experience Center for items such as remote repairs by a technician. Additional costs may be allowed.

Please contact the warranty department for any questions on items that can or cannot be claimed.  DSM Authorization is required. If customer or dealer is due reimbursement from any other costs, a dealer refund check copy (customer) or proof of payment (dealer) is required to be attached, please use attachment ID D40 if used.

 

RENTAL CAR INFORMATION

Mazda encourages all dealers to utilize MCVP vehicles for any alternate transport requests. We are requesting dealer understanding and partnership regarding rental and MCVP utilization. Please make every effort to utilize MCVP vehicles in place of rental use. Rental is covered if customer has no alternative means of transportation.

 

Rental Car Warranty Claim Information

Please submit rentals on a separate claim problem number as follows:

	MCVP Vehicle Preferred	Rental Agency Vehicle
Warranty Type Code	N/A MCVP does not require claim submission	A
Symptom Code		99
Damage Code		99
Part Number Main Cause		5555-22-18AR
Part Quantity		0
Labor Operation Code		MM024XRX
Labor Hours		0
Sublet – Rental Car
Sublet Invoice Number		Number from Rental Invoice or Dealer Purchase Order
Sublet Type Code		Enter “Z9” (other)
Sublet Amount		Up to $30.00 per day for the number of days customer had rental
Sublet Text		Number of days rental car was supplied to

 

Rental expenses exceeding the two-day limit will require prior DSM Authorization, as outlined in the Mazda Rental Car Reimbursement Program policy. NOTE:  Please make every effort to accommodate the vehicle owner with this critical recall.

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2006 B-SERIES – DRIVER AND PASSENGER AIR BAG SAFETY RECALLS 2218A AND 2318A

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A. VEHICLE INSPECTION PROCEDURE

1. Verify that the vehicle is within the following ranges:

Model	VIN Range
2006 B-Series	All – Currently 143 vehicles are affected

 

• If the vehicle is within the above ranges, proceed to Step 2.
• If the vehicle is not within the above ranges, return vehicle to the customer or inventory.

2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for Campaign Labels Recalls 2218A and 2318A attached to the vehicle’s hood or bulkhead. Refer to eMDCS System – Warranty Vehicle Inquiry Results table below.

               NOTE:  Be sure to verify Recall number as the vehicle may have multiple Recall labels.

 

eMDCS System – Warranty Vehicle Inquiry Results:

If eMDCS displays:	Campaign Label is:	Action to perform:
RECALLS 2218A and 2318A OPEN	Present	Contact the Warranty Hotline at (877) 727-6626 option 3 to update vehicle history.
	Not present	Proceed to “B. REPAIR PROCEDURE”.
RECALLS 2218A and 2318A CLOSED	Present	Return vehicle to inventory or customer.
	Not present	Proceed to “C. CAMPAIGN LABEL INSTALLATION”.
RECALLS 2218A and 2318A are not displayed	Does not apply	Recall does not apply to this vehicle. Return vehicle to inventory or customer.

 

IMPORTANT: Be sure to follow the packing and shipping instructions provided in the carton and in Air Bag Inflator Return Instructions.

 

CAUTION:

• Use the same carton which was used to deliver a new inflator. It is a specialized box that is internationally accepted for shipping an inflator.
• Pack the old inflator in the box exactly in the same manner as the new inflator was packed.

 

B. REPAIR PROCEDURE

Overview:

 Remove the driver and passenger airbags from the vehicle and replace only the inflator portion. The removed  inflators will be placed into the packaging from the new inflator and shipped to Takata using the included return shipping label.

 

DRIVER AIRBAG INFLATOR REPLACEMENT Air Bag Module Removal:

WARNING:

• Perform the replacement in a clean environment. Oil, grease, water, etc. on components may cause the air bag modules to fail to deploy in an accident, which may cause serious injury. Do not allow oil, grease, water, etc., on components.
• Inserting a screwdriver, etc., into the connector of an air bag module may damage the connec- tor and cause the air bag module to deploy improperly, which may cause serious injury. Do not insert any foreign objects into the connector.
• Do not make an attempt to directly supply electrical power to the module and the inflator.
• Keep the module facing of the pad surface upwards at all times, except during replacement.
• Do not use the module and new inflator if they were dropped on the ground.
• Avoid module and inflator exposure to temperatures of 194 degrees F (90 degrees C) or more.

1. Turn the ignition switch to the LOCK position.
2. Record the customer’s preset radio stations.
3. Disconnect the negative battery cable and wait for one (1) minute or more.
4. Remove the driver air bag module. Refer to MGSS online (DRIVER AIR BAG MODULE REMOVAL / INSTALLATION).
5. Lay a protective cloth on the work bench, then place the air bag module on it to avoid any damage or scratches to the surface.

WARNING: Do not allow any debris on or around air bag once the inflator is removed.

 

Inflator Replacement:

1. Release the retaining tab and slide the connector (1) of the air bag inflator (2) off the retainer.

 

2. Remove and discard the four air bag inflator retaining nuts (3).
3. Remove the air bag inflator and set aside for return shipping.

NOTE:  In order to verify the correct airbag inflator is installed, mark the old airbag inflator with a felt tip marker prior to removal.

4. Install the new inflator into the driver air bag. The retainer (1) will be used for the electrical connector.

NOTE:  The new air bag inflator must be installed in the same orientation as the original part to ensure the inflator module and air bag harness electrical connector T-shape indexes are aligned properly.

 

5. Install four new air bag inflator nuts onto the driver airbag.

Tightening torque: 6.5 Nm (57 lb-in) in the specified sequence [1] [2] [3] [4]

6. Align the T-shape index on both the wiring harness electrical connector and the airbag inflator by gently pulling on the wiring harness to ensure it is properly seated.
7. Slide the connector (1) of air bag inflator (2) onto the retainer.

 

Air Bag Module Reinstallation:

1. Install the driver air bag module. Refer to MGSS online (DRIVER AIR BAG MODULE REMOVAL / INSTALLATION).
2. Reconnect the negative battery cable.
3. Turn the ignition switch to the ON position.
4. Verify that the air bag system warning light illuminates for approx. 6 sec., then goes out.

NOTE:  If the air bag system warning light does not operate in the manner described above, there is a mal- function in the system. Inspect the system following the on-board diagnostic system procedure according to MGSS online.

5. Proceed to “PASSENGER SIDE AIRBAG REPLACEMENT”.

 

PASSENGER AIRBAG INFLATOR REPLACEMENT

Air Bag Module Removal:

WARNING:

• Perform the replacement in a clean environment. Oil, grease, water, etc. on components may cause the air bag modules to fail to deploy in an accident, which may cause serious injury. Do not allow oil, grease, water, etc., on components.
• Inserting a screwdriver, etc., into the connector of an air bag module may damage the connec- tor and cause the air bag module to deploy improperly, which may cause serious injury. Do not insert any foreign objects into the connector.
• Do not disassemble the vehicle, other than instructed here.
• Do not make an attempt to directly supply electrical power to the module and the inflator.
• Keep the module facing of the pad surface upwards at all times, except during replacement.
• Do not use the module and new inflator if they were dropped on the ground.
• Avoid module and inflator exposure to temperatures of 194 degrees F (90 degrees C) or more.

1. Turn the ignition switch to the LOCK position.
2. Disconnect the negative battery cable and wait for one (1) minute or more.
3. Remove the passenger air bag module. Refer to MGSS online (PASSENGER AIR BAG MODULE REMOVAL / INSTALLATION).
4. Lay a protective cloth on the work bench, then place the air bag module on it to avoid any damage or scratches to the surface.

WARNING: Do not allow any debris on or around air bag once the inflator is removed.

 

Inflator Replacement:

1. Cut and peel back the wiring sleeve to expose the inflator wiring (1).

 

2. Install a wiring shunt (1) between the inflator wiring connector and the inflator body. This will cause the inflator to become inert.

 

3. Cut the inflator wiring between connector and the shunt (1).

 

4. Remove and discard the four airbag inflator retaining nuts (1) and the bracket (2).

 

5. With an assistant holding the airbag assembly, remove the inflator from the airbag assembly by pushing outward on the inflator (1).

 

6. Remove the airbag inflator harness electrical connector.

 

7. Align and install both new inflator end caps.

NOTE:  Both new inflator connector end caps must be installed with the tab features aligned and fully seated.  Both end caps are specific to either end of the Inflator.

Inflator Connector End Alignment Feature	Connector End Cap Alignment Feature

 

8. Install the inflator (1) into air bag assembly with the connector end cap facing out (2) and tail end cap facing inward (3) so that the alignment feature is aligned directly facing up (4).

 

9. Align and install (1) the new inflator retaining bracket (2) so it is aligned under the tab (3).

 

10. Install the four new nuts, making sure the pop-up indicator (1) on the air bag assembly is present. Tightening torque: 6.5 Nm (57 lb-in) in the specified sequence [1] [2] [3] [4]

 

11. Align the T-shape index on both the wiring harness electrical connector and the airbag inflator, then connect the new airbag wiring harness to the inflator module.
12. Make sure the connection between the wiring harness electrical connector and the airbag inflator (1) is properly seated by gently pulling on the wiring harness.

 

13. Install the inflator harness connector (1) to the air bag assembly bracket.

 

 

Air Bag Module Reinstallation:

1. Install the passenger air bag module. Refer to MGSS online (PASSENGER AIR BAG MODULE REMOVAL / INSTALLATION).
2. Reconnect the negative battery cable.
3. Turn the ignition switch to the ON position.
4. Verify that the air bag system warning light illuminates for approx. 6 sec., then goes out.

NOTE:  If the air bag system warning light does not operate in the manner described above, there is a mal- function in the system. Inspect the system following the on-board diagnostic system procedure according to MGSS online.

5. Re-enter the customer’s preset radio stations.
6. Proceed to “C. CAMPAIGN LABEL INSTALLATION”.

 

C.  CAMPAIGN LABEL INSTALLATION

1. Fill out a blue “Campaign Label” (9999-95-065A-06) with Campaign No: “2218A” and “2318A”, your dealer code, today’s date.

 

2. Affix it to the hood or bulkhead as shown:

 

3. Release the retaining tab and slide the connector (1) of the air bag inflator (2) off the retainer.

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1 Affected Product

Vehicle

MAZDA

B-SERIES TRUCK

2006

 

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34 Associated Documents

Recall Acknowledgement

RCAK-18V038-3582.pdf 245.643KB

 

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Recall 573 Report – AMENDMENT 1

RCLRPT-18V038-8981.PDF 216.352KB

 

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Defect Notice 573 Report

RCLRPT-18V038-7316.PDF 216.35KB

 

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Miscellaneous Document – PARTS AND WARRANTY INFORMATION Safety Recall 2218A

RMISC-18V038-4918.pdf 322.631KB

 

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Remedy Instructions and TSB

RCRIT-18V038-4339.pdf 595.577KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-18V038-8974.pdf 217.787KB

 

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Manufacturer Notices(to Dealers,etc)- January 18, 2018 – CORRECTED -Announcing the launch of Safety Recalls 2218A and Safety Recall 2318A. Driver Side Frontal Air Bag Inflator Permanent Remedy Repair (2218A) and Passenger Side Frontal Air Bag Inflator Permanent Remedy Repair (2318A) for 2006 Mazda B-Series Trucks

RCMN-18V038-0599.pdf 185.508KB

 

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Miscellaneous Document – PARTS AND WARRANTY INFORMATION – Safety Recall 2218A

RMISC-18V038-8404.pdf 360.775KB

 

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Miscellaneous Document – Email Notification

RMISC-18V038-0495.pdf 1215.881KB

 

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Miscellaneous Document – Owner Notification

RMISC-18V038-9969.pdf 288.336KB

 

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Manufacturer Notices(to Dealers,etc)- Subject: *** Updated *** Takata Recall Parts Availability Reminder

RCMN-18V038-9742.pdf 478.881KB

 

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Manufacturer Notices(to Dealers,etc)- April 11, 2018 – Subject: *** Updated *** Takata Recall Parts Availability Reminder

RCMN-18V038-7597.pdf 186.314KB

 

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Miscellaneous Document – PARTS AND WARRANTY INFORMATION – Safety Recall 2218A

RMISC-18V038-6698.pdf 342.035KB

 

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Manufacturer Notices(to Dealers,etc)- February 14, 2018 – Takata Interim Recall Repairs

RCMN-18V038-5859.pdf 111.936KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-18V038-6715.pdf 280.49KB

 

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Manufacturer Notices(to Dealers,etc)- February 15, 2018 – Claim Submission change for Takata Permanent Remedy Safety Recall Repair 1817L, 1917L, 2218A and 2318A

RCMN-18V038-6676.pdf 123.756KB

 

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Recall 573 Report – AMENDMENT 2

RCLRPT-18V038-8315.PDF 217.52KB

 

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Manufacturer Notices(to Dealers,etc)- February 12, 2018 – UPDATE: Notification of Safety Recalls 2218A and 2318A, MY 2006 Mazda B-Series Truck – Takata Driver Side Frontal Airbag Inflator (2218A) and Passenger Side Frontal Airbag Inflator (2318A) – UPDATES IN RED

RCMN-18V038-1569.pdf 140.431KB

 

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Manufacturer Notices(to Dealers,etc)- February 22, 2018 – Dealer Orders for B-Series Takata Airbag Inflators

RCMN-18V038-0643.pdf 97.605KB

 

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Manufacturer Notices(to Dealers,etc)- February 15, 2018 – REMINDER: Dealer Collection Process for Used Takata Airbag Inflators

RCMN-18V038-8699.pdf 360.498KB

 

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Manufacturer Notices(to Dealers,etc)- February 21, 2018 – PART NUMBER CHANGE – RECALL(S) 2218A & 2318A

RCMN-18V038-3492.pdf 102.473KB

 

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Recall Quarterly Report – Report #2, 2018-2

RCLQRT-18V038-3645.PDF 214.626KB

 

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Manufacturer Notices(to Dealers,etc)- May 9, 2018 – Subject: *** Updated *** Takata Recall Parts Availability Reminder

RCMN-18V038-0050.pdf 494.335KB

 

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Manufacturer Notices(to Dealers,etc)- June 13, 2018 – Subject: Re-notification of Safety Recalls 2218A and 2318A, MY 2006 Mazda B-Series Truck – Takata Driver Side Frontal Airbag Inflator (2218A) and Passenger Side Frontal Airbag Inflator (2318A)

RCMN-18V038-9389.pdf 129.218KB

 

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Renotification Notice – 2218A-2318A Renotification Owner Letter 6-14-18

RCRN-18V038-7292.pdf 271.385KB

 

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Manufacturer Notices(to Dealers,etc)- June 13, 2018 Attention: Mazda General Managers, Parts and Service Managers Subject: *** Updated *** Takata Recall Parts Availability Reminder

RCMN-18V038-1742.pdf 288.337KB

 

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Manufacturer Notices(to Dealers,etc)- August 17, 2018 – Dealer Email

RCMN-18V038-5398.pdf 252.258KB

 

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Manufacturer Notices(to Dealers,etc)- DMV Letters to Mazda owners

RCMN-18V038-5084.pdf 90.472KB

 

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Renotification Notice – March 2019

RCRN-18V038-1525.pdf 283.894KB

 

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ISSUED Renotification Notice

RCRN-18V038-7472.pdf 239.4KB

 

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Recall Quarterly Report #1, 2018-1

RCLQRT-18V038-7537.PDF 214.53KB

 

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Manufacturer Notices(to Dealers,etc)- Insurance Email and Letters to CALIFORNIA Mazda owners

RCMN-18V038-9562.pdf 161.029KB

 

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Recall Quarterly Report #3, 2018-3

RCLQRT-18V038-0454.PDF 211.347KB

 

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Recall Quarterly Report #4, 2018-4

RCLQRT-18V038-7012.PDF 211.457KB

 

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1 Associated Investigation

Air Bag Inflator Rupture
NHTSA ID: EA15001
Dated opened: February 24, 2015

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 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 investigation now includes all manufacturers and vehicles known to be affected at this time. ODI’s 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 five ODI reports cited above can be reviewed online at https://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

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Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=18V038&docType=RCL

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