General Motors and Toyota are expanding an airbag recall for the third time to replace inflators that could explode and shoot shrapnel during deployment. This latest recall is due to a still-undetermined problem affecting at least 10 manufacturers.
Among Toyota-built products, the affected models are 2002–2005 Lexus SC430 and Toyota Sequoia, plus the 2003–2005 Tundra, Corolla, Matrix, and Pontiac Vibe (the joint-venture clone of the Matrix). The latest Toyota recall covers 247,000 vehicles, most of which were already recalled in June, to fix faulty airbag inflators sourced from Japanese supplier Takata, whose poor quality control has now affected roughly 16 million cars worldwide since 2008. At GM, the recall covers 133,321 vehicles, mostly discontinued nameplates from 2002–2003.
The National Highway Traffic Safety Administration says it is working to update its list of affected cars, but as of midday today, these are the cars we understand are at risk (parentheses indicate the total number in the U.S., if known):
BMW (573,935): 2000–2005 3-series sedan and wagon; 2000–2006 3-series coupe and convertible; 2001–2006 M3 coupe and convertible
Chrysler: 2006 Dodge Charger (additional models unknown)
Ford: 2004 Ranger, 2005–2006 GT, 2005–2007 Mustang
General Motors (162,240, not including Pontiac Vibe): 2003–2005 Pontiac Vibe, 2013–2014 Cruze (different Takata module, similar problem); 2002–2003 Buick LeSabre and Rendezvous; Cadillac DeVille; Chevrolet TrailBlazer, Impala, Monte Carlo, Venture; GMC Envoy and Envoy XL; Oldsmobile Aurora, Bravada, Silhouette; Pontiac Bonneville and Montana
Honda/Acura (2,803,214): 2001–2007 Accord, 2001–2005 Civic, 2002–2006 CR-V, 2003–2011 Element, 2002–2004 Odyssey, 2002–2007 Pilot, 2006 Ridgeline; 2002–2003 CL and TL, 2005 RL, 2003–2006 MDX
Mazda (18,050): 2003–2004 Mazda 6, 2004 RX-8
Nissan/Infiniti (437,712): 2001–2003 Nissan Maxima, Pathfinder, and Infiniti I30/I35; 2002–2003 Nissan Sentra and Infiniti QX4; 2003 Infiniti FX
Subaru (8557): 2003–2004 Baja, Legacy, Outback; 2004 Impreza, WRX, WRX STI
Toyota/Lexus (844,227, including Pontiac Vibe): 2002–2005 Lexus SC430 and Toyota Sequoia; 2003–2005 Corolla, Matrix, Tundra
Mitsubishi: 2004–2005 Lancer
Initially, only six makes were involved when Takata announced the fault in April 2013, but Toyota’s second recall in June this year—along with new admissions from Takata that it had little clue as to which cars used its defective inflators, or even what the root cause was—prompted more automakers to issue identical recalls. In July, NHTSA forced additional regional recalls in high-humidity areas including Florida, Hawaii, and the U.S. Virgin Islands to gather removed parts and send them to Takata for review.
Toyota’s latest recalls cover only the passenger-side airbag. Dealers will replace the inflators starting October 25. If replacement parts are not available, dealers will temporarily disable passenger-side airbags (and install a friendly little glove-box tag noting the airbag is nonfunctional).
While Toyota says there have been no related injuries or deaths, a New York Times report in September found a total of at least 139 reported injuries across all automakers. In particular, there have been at least two deaths and 30 injuries in Honda vehicles. According to the Times, Honda and Takata allegedly have known about the faulty inflators since 2004 but failed to notify NHTSA in previous recall filings that the affected airbags had actually ruptured or were linked to injuries and deaths.
- 423,000 Lexus Models Recalled for Fire Risk Due to Leaky Fuel Gaskets
- Recalls Explained: How the Government Forces Automakers to Fix Things
- Honda and Takata Allegedly Knew About Deaths, Injuries from Exploding Airbags for Years Before Recall Expansion
Takata first said that propellant chemicals were mishandled and improperly stored during assembly, which supposedly caused the metal airbag inflators to burst open due to excessive pressure inside. In July, the company blamed humid weather and spurred additional recalls. Now, according to documents reviewed by Reuters , Takata says that rust, bad welds, and even chewing gum dropped into at least one inflator are also at fault. The same documents show that in 2002, Takata’s plant in Mexico allowed a defect rate that was “six to eight times above” acceptable limits, or roughly 60 to 80 defective parts for every 1 million airbag inflators shipped. The company’s study has yet to reach a final conclusion and report the findings to NHTSA.
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