2013 McLaren MP4-12C

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 contact owns a 2013 McLaren MP4-12C. The contact stated that mold was developing in the lens covering the headlights, causing the headlights to be foggy. The contact stated that the failure was affecting his vision of the roadway while driving and was causing a glare for oncoming drivers. The vehicle was taken to the dealer, where it was diagnosed that the headlight housings needed to be replaced. The manufacturer was notified of the failure and covered the replacement of the headlights housing; however, the failure persisted, and the headlight housings were replaced with the same model of headlight housings. The vehicle was not repaired. The failure mileage was approximately 4,900.

NHTSA ID

11509758

Incident

Feb 1, 2018

Mileage

4,900 mi

THE HEADLIGHT LENSES ON BOTH SIDES ARE GROWING A MOLD AND FOGGING. THE FOGGING IS GRADUALLY WORSENING, AND, AT SOME POINT, WILL COMPROMISE THE LIGHT EMITTED AND RESULT IN GLARE. IT IS A WELL-KNOWN ISSUE IN THESE CARS, AND SHOULD BE ADDRESSED UNDER WARRANTY, BUT MCLAREN REFUSES TO REPLACE THE LENSES FOR ANYONE WHO HAS TRIED TO GET THIS DONE BY THEIR DEALERS, MYSELF INCLUDED. IT IS CLEAR THAT THIS IS IN VIOLATION OF YOUR REGULATIONS S5.1.2 (B) AND (C): HTTPS://WWW.GPO.GOV/FDSYS/PKG/CFR-2004-TITLE49-VOL5/XML/CFR-2004-TITLE49-VOL5-SEC571-108.XML IT IS ESTIMATED THAT, OF THE 3400 MP4-12C CARS IN THE US ALONE, ABOUT 40% OF THEM HAVE THE PROBLEM. I CAN NOT VOUCH FOR THIS NUMBER, BUT ON A MCLAREN FORUM, THIS PROBLEM HAS BEEN NOTED BY MANY OWNERS AND THEIR DEALERSHIPS WERE UNABLE TO GET MCLAREN TO AUTHORIZE REPLACEMENT OR REPAIR. IT IS ALSO NOTED THAT KOENIGSEGG CARS HAD A SIMILAR PROBLEM, AND THAT NHTSA DID TAKE ACTION. PHOTOS ARE ATTACHED, BUT IT IS DIFFICULT TO SHOW HOW BAD IT REALLY IS WITH THE PHOTOS. APPROXIMATELY 30% OF THE LENS SURFACE IS INVOLVED ON THE RIGHT, AND 20% ON THE LEFT SIDE, AND IT IS PROGRESSING. THE HEADLIGHT DESIGN FAILED TO MEET THE STANDARD THAT IT WOULD NOT HAVE SUCH ISSUES WHEN EXPOSED TO THE ENVIRONMENT. MY CAR HAS HAD NO ACCIDENTS OR ANY SPECIFIC INJURY TO THE HEADLIGHTS.

NHTSA ID

11067214

Incident

Oct 12, 2017

Mileage

4,200 mi

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