2002 Honda Accord

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

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 http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

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

This RQ investigation was opened to collect and analyze additional information to better evaluate the scope and timeliness of Honda's two safety recalls addressing rupturing of the driver's side air bag inflators (08V-593 and 09V-259).In an earlier response to RMD's request for information, Honda indicated that the second recall (09V-259), essentially an expansion of the first (08V-593), was necessary since later information informed that the source of the defect was different than originally postulated, and so the scope of the vehicles affected changed. Honda indicated that it had relied on its supplier of the air bag inflators, Takata, Inc. (Takata), in studying the possible sources of the inflator ruptures and identifying the recall populations.Accordingly, RMD issued a request forinformation to Takata on November 20, 2009, and Takata provided a partial response on December 23, 2009.Takata then provided its complete response on February 19, 2010.Takata informed ODI that, after analysis of several ruptured inflators, Takata and Honda initially attributed the defect to handling of the propellant during inflator assembly that could have yielded increased moisture levels that, when coupled with thermal cycling in automobiles over time, could lead to reduced propellant density and overly aggressive combustion during air bag deployment.However, it discovered upon review of inflators returned from the 08V-593 recall campaign, some of which fell outside the manufacturing range when Takata suspected the propellant was exposed to elevated moisture, that the source of the defect was more likely due to problems with a specific compression press (Stokes press) used to form the inflator's propellant.Specifically, the propellant tablets produced by the press were found to be less dense, and therefore more susceptible to overly aggressive combustion during air bag deployment.Takata identified the manufacturing time frame over which the tablets were shown to have less dense properties as the end of calendar year 2000. Takata informed Honda of its discovery on or about June 12, 2009.Honda made its defect decision and then notified NHTSA of it on June 30, 2009.Honda then supplemented its filing with an identification of the specific vehicles to be included in the campaign, as well as identifying additional models to be included, on July 29, 2009.As with the 08V-593 campaign, Takata examined inflators returned from the 09V-259 campaign, and some of which were manufactured outside of the range when the Stokes press was found to have produced less dense propellant (beyond the end of February 2001).It provided those findings to Honda and Honda decided to expand safety recall 09V-259 to include all vehicles with inflators containing propellant manufactured using the Stokes press.Honda notified NHTSA of its decision on February 9, 2010.Based upon all available information, there is insufficient information to suggest that Honda failed to make timely defect decisions on information it was provided.Also, given that all inflators with propellant manufactured using the Stokes press have been recalled, there are no additional vehicles to be investigated and campaigned.Accordingly, this RQ is closed.

Air Bags never deployed in an accident. Honda shows recall work was done prior to collision. Front end collision

NHTSA ID

11698360

Incident

Dec 15, 2020

See attached document for complaint.

NHTSA ID

11696407

Incident

Oct 2, 2025

-The front subframe on the passenger side completely rusted through and broke. The driver side is perfectly fine and still has factory paint on it, but the passenger side is completely rusted out. Yes the vehicle and issue are available for inspection. -The front subframe is the frame component that holds and supports your front suspension, steering, engine and transmission. With the failure of the subframe the front passenger side of the car dropped down and the steering and suspension were compromised. Very unsafe for the driver and passengers to lose control of the vehicle. Loss of control is also very dangerous for others on the road. -The problem is very prominent for this year and model of car. It is an engineering flaw from the factory for years 1998-2002. The air conditioning evaporator drain hose is routed right onto the passenger side sub frame. The moisture from the drain is what accelerates the rust. The car only has 55,000 miles on it and it has failed this soon. -The car has been inspected by a shop previously and the shop welded a new support piece to “patch” the frame to make back home. -There were no symptoms, there was just a loud clunk on the front end and it dropped down.

NHTSA ID

11693726

Incident

Aug 16, 2023

I am writing to express my concern regarding a significant safety issue with my 2002 Honda Accord's subframe. The subframe is rusting severely in the area where the air conditioning drain line drips directly onto it. This design flaw has caused concentrated corrosion over time, significantly weakening the subframe and making the vehicle unsafe to drive. As the subframe supports essential components such as the engine, transmission, and suspension, its deterioration poses a serious risk of structural failure. This could lead to loss of control while driving, endangering both the driver and others on the road. Considering the critical nature of this defect, I urge Honda to take responsibility for addressing this issue and provide a resolution to ensure the safety and reliability of affected vehicles.

NHTSA ID

11626298

Incident

Nov 19, 2024

SRS bag light has been on for unknown reason(s). Steering is not good and it got checked they said they fixed issue on it but it does not feel fixed

NHTSA ID

11618564

Incident

Sep 16, 2024

The contact owns a 2002 Honda Accord. The contact stated that while operating the vehicle, the driver's side air bag warning light remained illuminated. The cause of the failure was not yet determined. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The failure mileage was 354,000.

NHTSA ID

11611624

Incident

Mar 29, 2024

Mileage

354,000 mi

The right side of the main front subframe of the car broke. The subframe on the right side was completely rusted out and corroded away. However, the left side of the subframe was perfectly intact with no damage and only minor surface rust. The car has only 50,000 miles on it. When the subframe broke my friends [XXX]aunt [XXX] old) was driving and the right side of the car dropped down and the steering was compromised. The broken subframe resulted in a loss of control of the car but an accident was avoided thankfully due to her only driving at low speeds. They took the car to an independent mechanic, who welded some support brackets to the subframe to get the car to move. After doing some research, I found multiple forums, websites, videos, and repair TSBs about this issue. The failure occurred because of an engineering failure of the placement of the HVAC evaporator drain hose. The hose drips the draining moisture right onto the right side of the subframe. Over time, this trapped moisture leads to corrosion and rust formation on the subframe. The corrosive effect weakens the structural integrity of the subframe, which caused the subframe to break under normal driving conditions. A mechanic has inspected and patch repaired the subframe. I am willing to have the car inspected if requested. There were no symptoms before the failure, it happened all of the sudden. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11607061

Incident

Aug 7, 2024

I complained to Joe Morgan Honda that my driver's seat broke from the frame causing it to be a rocking chair and Joe Morgan Honda confirmed that the car needs an entirely new seat because the frame had snapped. Joe Morgan Honda said they don't make the seat anymore and it was important that I not get a seat from a vehicle that had been wrecked, because so no seat in a scrapped vehicle could be found. I complained to the better business bureau to the Honda Corporation at 1919 Torrance, CA and the Better Business Bureau said they refused to answer the safety complaint Silicon Valley Complaint #[XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11590816

Incident

Apr 26, 2024

Service Bulletin - This bulletin is a notification of a class action settlement relating to airbag inflators. American Honda is offering a Customer Support Program (Warranty Extension) to cover any manufacturing defects in the replacement driver's airbag inflator only.

Service bulletin - This bulletin has been cancelled because the collection is now complete. If you did the collection in this Service Bulletin on or before October 26, 2018 (RO date), use the Warranty Claim Information provided below.

Service bulletin - This bulletin is a notification of a class action settlement relating to airbag inflators. American Honda is offering a Customer Support Program (Warranty Extension) to cover any manufacturing defects to the replacement driver's airbag inflator only.

EMAIL TEMPLATE TO REMIND OWNERS OF THE TAKATA RECALL AND TO SCHEDULE AN APPOINTMENT AT THEIR EARLIEST CONVENIENCE.

POSTERS SENT TO HAWAIIAN INDEPENDENT REPAIR FACILITIES, AUTOMOTIVE PART STORES, CAR WASHES, AND GAS STATIONS TO REMIND OWNERS OF THE TAKATA RECALL AND TO SCHEDULE AN APPOINTMENT AT THEIR EARLIEST CONVENIENCE.

FLYER CIRCULATED TO THE RESIDENTS OF HAWAII TO REMIND OWNERS OF THE TAKATA RECALL AND TO SCHEDULE AN APPOINTMENT AT THEIR EARLIEST CONVENIENCE.