2020 Chevrolet Malibu

The Office of Defects Investigation (ODI) has become aware of eight vehicle crashes in which a rupture of a Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN) air bag inflator occurred during the deployment of the driver side air bag. All eight drivers in these crashes sustained serious or fatal injuries that appear linked to the ruptures. Six of those drivers sustained fatal injuries and two sustained severe injuries. In all eight incidents, the subject inflators had been installed as replacement equipment after the vehicle was involved in a previous crash. Information gathered during NHTSA’s initial analysis of these incidents indicates that the inflators were potentially imported illegally into the United States. In conjunction with this safety investigation, NHTSA is also working with appropriate authorities to address any illegal activities associated with the importation of these inflators. As a result of the significant safety concerns relating to these inflators, as well as extensive information already obtained by ODI relating to their field ruptures, ODI is moving directly to the Engineering Analysis (EA) stage of its investigative process rather than first opening a Preliminary Evaluation. NHTSA has taken a variety of actions to address the risks posed by the importation of substandard or counterfeit air bag components. However, until recently, these risks appeared spread across a variety of components and manufacturers. As part of ODI’s continuous monitoring of this issue, the agency has obtained information to suggest that at least eight incidents involve ruptures of inflators manufactured by DTN. In parallel with this dedicated investigation into DTN inflators, ODI will continue to monitor reports of field incidents to evaluate risks from other substandard imported air bag components. In 2012, ODI first became aware of substandard or counterfeit air bag modules sold through online marketplaces, such as auction sites. NHTSA obtained examples of these air bag modules and conducted testing. None of the inflators equipped in these modules were manufactured by DTN. This testing revealed that the inflators consistently malfunctioned during deployments, such as by failing to deploy the air bag or expelling metal shrapnel due to a rupture. This led NHTSA to release a consumer advisory in October 2012 to alert the public and repair professionals to the potential dangers of substandard or counterfeit air bag modules. ODI also worked with major vehicle manufacturers, who released advisories and notifications concerning the use of such air bag modules. Since then, NHTSA has continuously monitored for reports of malfunctioning air bags that may be associated with substandard or counterfeit components. These monitoring efforts have been supported by the increased visibility the advisories have brought to the issue, and by several standing general orders in place as part of separate investigations into Takata and ARC inflators, which require certain manufacturers to report any alleged or suspected inflator field ruptures to NHTSA. Until 2017, ODI was not aware of any field incidents involving an abnormal deployment of an imported substandard or counterfeit air bag module. In September 2017, ODI became aware of a crash involving a model year (MY) 2009 Honda Civic where the air bag ruptured during deployment, killing the driver. After inspecting the vehicle and air bag parts, ODI determined that the air bag inflator was not original equipment and that the air bag module was likely a substandard import. Insufficient information existed to determine the manufacturer of the inflator in this incident, however, it does not appear to resemble those manufactured by DTN. On June 16, 2023, ODI received a Vehicle Owner Questionnaire (VOQ #11527380) alleging that the rupture of a driver side air bag caused fatal injuries to the driver of a MY 2020 Chevrolet Malibu. ODI’s assessment of the rupture indicated that the air bag inflator was not original equipment but was instead manufactured by DTN, a Chinese company (also known as Yoshibayashi Toku theanol Automotive Safety Systems Co. Ltd.). From June 2023 to July 2024, ODI became aware of four additional ruptures involving substandard air bag modules equipped on Chevrolet Malibu vehicles. At the time, insufficient information existed for these crashes to determine who manufactured the ruptured inflators. As a result, NHTSA released a consumer advisory on July 10, 2024, alerting car buyers and owners to be aware of cheap, substandard replacement air bag inflators that can cause death or serious injury in a crash. The advisory urged consumers who own or are considering the purchase of a used vehicle to learn the vehicle’s history and ensure the vehicle has genuine air bag inflators. In March 2025, NHTSA learned about another rupture involving a suspected substandard, aftermarket inflator that was equipped in a MY 2017 Hyundai Sonata. The driver of this vehicle sustained fatal injuries that appeared related to the rupture. In August 2025, NHTSA received a similar report of a fatal air bag rupture in a MY 2019 Hyundai Sonata. Most recently, in October 2025, ODI received a report of a fatal air bag rupture in a MY 2020 Chevrolet Malibu. Photographs of the air bag components in these three crashes indicated that the ruptures all involved inflators manufactured by DTN. Further investigation of the inflator fragments in three of the prior incidents confirmed that they also involved DTN inflators. Photographs of the components involved in one of the other incidents also strongly suggest that the ruptured inflator was manufactured by DTN. This opening resume exceeded space limitations and is continued in an attachment uploaded to the investigation.

My 2020 Chevrolet Malibu experienced a sudden and severe electrical failure after driving through normal roadway water. Immediately afterward, the vehicle displayed multiple safety‑critical warnings including loss of power steering assist, Electronic Stability Control (ESC) faults, brake control faults, and reduced propulsion. A GM dealership inspected the vehicle, scanned the modules, and found more than a dozen network and chassis‑related diagnostic trouble codes, including: B3979, U0164, B1325, B3122, U0121, C0196, C0460, B1011, B097B, B3205, C056E, C056D, U0420, U1510, C0545, U0422. These codes indicate failures in the steering system, brake control module, stability control system, body control module, and multiple CAN‑bus communication networks. The dealership confirmed: – No physical damage – No evidence of collision or impact – No evidence of flood damage – The suspected failed component is the electric power steering rack (GM part 85621696) – The part is not available, meaning the vehicle cannot be repaired – I would be responsible for diagnostic and repair costs This is a major safety concern. The vehicle can lose steering assist, stability control, and braking support without warning. The inability to obtain the required steering component makes the vehicle unrepairable and unsafe to operate. I am reporting this because this appears to be a systemic electrical/network failure affecting critical safety systems. I believe this defect poses a significant risk to drivers, passengers, and other motorists. The attached photo is a is a picture of the printout the Chevrolet dealership Service Manager provided to me.

NHTSA ID

11755071

Incident

Jul 27, 2026

So while I was driving my car going 60 on the highway it seemed to be having electrical issues all the lights on my dash popped on then popped off and only a few lights actually stayed on I can't remember exactly but the check engine and my abs stayed on and then on my screen it read to me warning power steering fault my headlights were dimming on and off like my car was going to die, so I had to pull over for my safety and other drivers safety, so after I pulled over safely I shut my car completely off and waited about 5 minutes and turned it back on when it turned back on the only light that popped on my dash was the check engine light, but the check engine light had actually been on the dash for a while after I replaced the 21 fuses that were missing that I didn't know were missing when I purchased the vehicle as is from a dealership the only thing that made me decide to check my fuses was because my check engine light was popping on and off and would stay off for a while then come back on a code reader said it was something to do with my turbo that code it was just very odd and the car was shifting weird 3 or 4 months after the purchase date XXX also after I put all the fuses back in a ton of codes popped up others safety and mine were at risk as I didn't really have control of my vehicle when it was doing that and it started breaking itself when I wasn't even hitting the break it was like jolting it's self and stopping slightly. I took my car to AAMCO Total car Care for a free diagnostic test, and then I had recently took my car to a Chevy dealership in Nampa Idaho off garrity boulevard because online it had told me there was recalls for my car and that recall was exactly what I was thinking had started off as the original problem originally leading into the other problems I got told to bring my car in then the fed me information saying pretty much it was a bust and that specific Malibu has no recall I think they just didn't want to work on it

NHTSA ID

11754086

Incident

May 4, 2026

The contact owns a 2020 Chevrolet Malibu. The contact stated that while attempting to shift the vehicle into park, the transmission failed to shift into park after several attempts. The contact referenced TSB: 19-NA-206; as a possible cause for the failure; however, the VIN was not included in the TSB. The vehicle was taken to a dealer where it was diagnosed with gear shifter failure. The gear shifter was replaced, and the vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 50,198.

NHTSA ID

11752681

Incident

Feb 1, 2026

Mileage

50,198 mi

While attempting to enter a high-speed expressway, the transmission malfunctioned, preventing normal acceleration. The vehicle could only accelerate very slowly but managed to maintain a limited speed, creating a hazardous situation while trying to merge into fast-moving traffic. I was able to navigate the vehicle off the expressway, at which point the transmission completely failed and the vehicle died. The vehicle was towed to an authorized dealership service center, where technicians diagnosed a total internal failure of the CVT transmission requiring complete replacement. Mind you, the vehicle is under 6 years old and has fewer than 90,000 total miles, and this is the second time the transmission on this vehicle has suffered a total failure and required a complete replacement. Prior to this mechanical breakdown, there were no warning lights, abnormal symptoms, or performance issues indicating an impending transmission failure. The vehicle is currently available for inspection.

NHTSA ID

11749433

Incident

Jun 25, 2026

While driving, the brakes became hard and the vehicle was difficult to stop. The brake pedal required excessive force, brake assist was reduced, and the stopping distance increased, creating a serious safety hazard. The check engine light had been illuminated for approximately two years before the brake failure occurred. In January 2024, I reported brake-related concerns to a Chevrolet dealership while the vehicle was under warranty, but the root cause was not diagnosed. In November 2025, after the brake pedal became hard, an independent repair facility inspected the vehicle and determined the brake problem was caused by a failing engine vacuum pump. They advised that the vehicle be repaired by a Chevrolet dealership. By January 2026, the brake condition had worsened to the point that the vehicle was no longer safe to drive and had to be towed. A Chevrolet dealership later confirmed that the engine vacuum pump had seized and damaged the camshaft, requiring replacement of both components. The vehicle remains inoperable. The failed vacuum pump caused loss of brake assist, resulting in a hard brake pedal, reduced braking ability, and an increased risk of a crash. I believe this represents a serious safety defect because failure of the vacuum pump significantly impairs the driver’s ability to stop the vehicle safely. I understand GM has issued service information regarding vacuum pump failures on this engine, and I am submitting this complaint because I believe other drivers may experience the same dangerous brake failure.

NHTSA ID

11748641

Incident

Oct 31, 2025

Ejesitais to shift. Most of the times. Also shif to park when is o ready park.

NHTSA ID

11745075

Incident

Dec 31, 1969

Shift to park displaying when car is in park so it won't turn off and stalling out randomly with no warning or anything and being hesitant to go

NHTSA ID

11736695

Incident

May 5, 2026

May 7, 2026 National Highway Traffic Safety Administration 1200 New Jersey Avenue SE Washington, DC 20590 RE: Safety Defect Complaint – Brake System / Vehicle Control Concerns 2020 Chevrolet Malibu Dear NHTSA, I am submitting a safety complaint regarding persistent braking and vehicle control issues involving my 2020 Chevrolet Malibu. Prior to December 31, 2025, the vehicle exhibited jerking during braking, all dashboard gauges go to the left, warning lights, reduced power (20-25mph), and inconsistent braking behavior. This situation happens without warning, at any given time, even in the flow of traffic. An independent inspection indicated the brake system was in proper condition, suggesting a more complex underlying safety issue. The vehicle was taken to Reed-Lallier Chevrolet for diagnosis and remained there for approximately five months. During that time, I was not provided documentation confirming completion of a brake system diagnostic or a clear resolution path. Due to the extended delay without diagnosis, I no longer feel safe operating the vehicle. I am also concerned that prolonged inactivity without proper repair may have worsened the condition and increased risk of failure. Given the nature of the symptoms involving braking and vehicle control, I request review for potential safety-related investigation. Vehicle Information: 2020 Chevrolet Malibu VIN: Mileage:

NHTSA ID

11736449

Incident

Dec 31, 2025

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