2002 Honda Accord Recalls

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.

ODI HAS RECEIVED 16 COMPLAINTS ALLEGING FAILURES OF THE IGNITION PARK-SHIFT INTERLOCK THAT ALLOWED THE IGNITION KEY TO BE REMOVED FROM THE IGNITION SWITCH WITHOUT THE TRANSMISSION BEING SHIFTED TO PARK IN MODEL YEAR (MY) 2002 AND 2003 HONDA ACCORD VEHICLES WITH AUTOMATIC TRANSMISSIONS.ELEVEN OF THE COMPLAINTS ALLEGE THAT THE FAILURE OF THE INTERLOCK RESULTED IN A ROLLAWAY CRASH.ONE OWNER ALLEGED THAT SHE WAS ALMOST INTO HER HOUSE WHEN SHE NOTICED THE CAR ROLLING OUT OF THE GARAGE AND DOWN THE DRIVEWAY AND THAT WHEN SHE TRIED TO STOP THE CAR IT ALMOST RAN OVER HER, BEFORE CRASHING INTO A CABLE BOX AT THE END OF THE DRIVEWAY.ANOTHER OWNER ALLEGED THAT THE VEHICLE ROLLED OUT OF THE DRIVEWAY AND STRUCK A TREE ACROSS THE STREET.THERE HAVE BEEN 28 COMPLAINTS MADE TO HONDA REGARDING IGNITION PARK-SHIFT INTERLOCK FAILURES IN THE SUBJECT VEHICLES, 10 OF WHICH ALLEGE ROLLAWAY CRASHES. IN OCTOBER 2003, AMERICAN HONDA MOTOR COMPANY INITIATED RECALL 03V-423 TO CORRECT AN IGNITION PARK-SHIFT INTERLOCK DEFECT IN CERTAIN MY 1999 HONDA ODYSSEY, MY 1997-99 ACURA CL, MY 1999 ACURA TL, AND MY 1998-99 HONDA ACCORD VEHICLES.IN JANUARY 2005, HONDA INITIATED ANOTHER RECALL TO ADDRESS DEFECTIVE IGNITION PARK-SHIFT INTERLOCKS (RECALL 05V-025), THIS TIME COVERING MY 1997-2001 HONDA PRELUDE, MY 1999-2000 ACURA TL, AND CERTAIN MY 1999-2002 HONDA ACCORD VEHICLES.NOT ALL MY 2002 HONDA ACCORDS WERE COVERED UNDER RECALL 05V-025.THE REMAINING MY 2002 AND ALL MY 2003 ACCORD VEHICLES ARE COVERED IN THE SCOPE OF THIS RECALL QUERY. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS(EA09-001) TO CONTINUE TO ASSESS THE SCOPE AND FREQUENCY OF THE ALLEGED DEFECT.

THE ABOVE FAILURE REPORT COUNTS ARE FOR MODEL YEAR (MY) 1999 - 2001 HONDA ACCORD MODELS THAT WERE NOT WITHIN THE SCOPE OF A RELATED HONDA RECALL ACTION (NHTSA 03V423); THESE VEHICLES WERE INVESTIGATED BY ODI UNDER DEFECT PETITION (DP) 04-006.COMPLAINT INFORMATION FOR OTHER MODELS AND MODEL YEARS WAS NOT OBTAINED BY ODI.THE NOTED POPULATION INDICATES THE NUMBER OF VEHICLES (INCLUDING THE MY 2002 ACCORD PLUS THE PRELUDE AND TL MODELS) THAT ARE WITHIN THE SCOPE OF HONDA?S NEW RECALL (NHTSA 05V-025, HONDA P68, P69); 402,525 OF THESE WERE INVESTIGATED IN DP04-006.SEEPART 573 DOCUMENTS RELATED TO 05V-025 FOR FURTHER DETAIL ON OTHER MODELS AND MYS.ODI NOTES THAT, ACCORDING TO HONDA?S ANALYSIS, INTERLOCK SYSTEM WARRANTY RATES FOR THE TL AND PRELUDE MODELS INVOLVED IN 05V-025 ARE SIMILAR TO THOSE OF THE ACCORD MODELS.INFORMATION PROVIDED BY HONDA DURING DP04-006 INDICATES THAT CERTAIN VEHICLES CONTAINING INTERLOCK SYSTEMS MADE BY ITS JAPANESE LOCK MANUFACTURING FACILITY MAY CONTAIN DEFECTIVE INTERNAL COMPONENTS.IN COMBINATION WITH CERTAIN WEAR AND USAGE FACTORS, THIS MAY LEAD TO A CONDITION THAT PREVENTS THE SYSTEM FROM BLOCKING REMOVAL OF THE IGNITION KEY WHEN THE VEHICLE IS NOT IN PARK.IF THE DRIVER LEAVES THE TRANSMISSION IN A NON-PARK POSITION AND FAILS TO SET THE HAND BRAKE WHEN PARKING, THE VEHICLE MAY ROLL AWAY AND CRASH.INTERLOCK SYSTEMS MANUFACTURED BY HONDA?S U.S. LOCK MANUFACTURER DO NOT APPEAR TO CONTAIN THIS DEFECT AND ARE THEREFORE NOT INCLUDED IN THE RECALL ACTION. IN A LETTER DATED JANUARY 27, 2005, HONDA ADVISED THAT IT WILL CONDUCT A SAFETY RECALL TO EITHER UPGRADE (FOR OPERATIVE SYSTEMS) OR REPAIR (FOR INOPERATIVE SYSTEMS) SUBJECT INTERLOCK SYSTEMS WITH NEW DESIGN LEVEL COMPONENTS THAT DO NOT CONTAIN THE DEFECT.