2004 Pontiac Vibe 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

FOR THE SUBJECT VEHICLES, THERE IS A POSSIBILITY THAT THE RETENTION FORCE OF THE REGULATOR BOLTS WHICH ATTACH THE FRONT SIDE WINDOW GLASS TO THE POWER WINDOW REGULATOR MAY NOT BE SUFFICIENT DUE TO AN INTERFERENCE OF THE RETENTION NUT AND THE BOLT SHOULDER RADIUS.IN THIS CONDITION THE BOLT MAY BECOME LOOSE, CAUSING A LOUD NOISE TO BE GENERATED WHEN THE WINDOW IS RAISED OR LOWERED.IF THE VEHICLE AND THE POWER WINDOW ARE CONTINUOUSLY OPERATED IN THIS CONDITION, THE BOLT MAY COMPLETELY SEPARATE, CAUSING THE GLASS TO BECOME MISALIGNED, AND IN THE WORSE CASE, THE GLASS MAY SHATTER DURING OPERATION OF THE POWER WINDOW.GENERAL MOTORS CORPORATION (GM) AND TOYOTA NORTH AMERICA, INC. (TOYOTA) WILL CONDUCT A SAFETY RECALL ON THE PONTIAC VIBE, TOYOTA COROLLA AND TOYOTA MATRIX VEHICLES TO REPLACE THE REGULATOR BOLT WITH A BOLT AND WASHER.GM WILL RECALL 122,593 MY 2003-2004 PONTIAC VIBE VEHICLES.ODI IS AWARE OF A TOTAL OF 16,045 WARRANTY AND GOODWILL CLAIMS, 274 FIELD AND CONSUMER REPORTS, AND 23 INJURIES FOR THESE VEHICLES.TOYOTA WILL RECALL 415,341 MY 2003-2004 TOYOTA COROLLA VEHICLES. ODI IS AWARE OF A TOTAL OF 6,601 WARRANTY CLAIMS, 150 FIELD AND CONSUMER REPORTS, AND 11 INJURIES FOR THESE VEHICLES.TOYOTA WILL RECALL 124,244 MY 2003-2004 TOYOTA COROLLA MATRIX VEHICLES.ODI IS AWARE OF A TOTAL OF 2,198 WARRANTY CLAIMS, 113 FIELD AND CONSUMER REPORTS, AND 6 INJURIES FOR THESE VEHICLES.ODI IS AWARE OF A TOTAL OF 24,843 WARRANTY CLAIMS, 537 FIELD AND CONSUMER REPORTS, AND 40 INJURIES FOR 662,178 MY 2003-2004 VEHICLES.THE RECALL IS IDENTIFIED BY NHTSA NUMBER 08V-162.

THE SUBJECT VEHICLE IS MANUFACTURED BY NEW UNITED MOTOR MANUFACTURING, INC. (NUMMI) IN FREMONT, CALIFORNIA.NUMMI IS A JOINT VENTURE BETWEEN GENERAL MOTORS AND TOYOTA.TOYOTA IS RESPONSIBLE FOR RESPONDING TO THIS NHTSA INVESTIGATION.TOYOTA REPORTS THAT ITS EVALUATION IS INCOMPLETE AT THIS TIME, HOWEVER; TOYOTA HAS IDENTIFIED TWO ISSUES THAT CAN CONTRIBUTE TO SIDE WINDOW GLASS BREAKING.IN ITS JANUARY 11, 2008 LETTER TO ODI, TOYOTA STATED THAT A MAJORITY OF THE REPORTS INCLUDED IN THIS RESPONSE ARE MOST LIKELY RELATED TO THE LOOSENING OF THE WINDOW REGULATOR BOLTS.THE SECOND ISSUE IS, LESS PREDOMINANTLY, THE INTERFERENCE OF THE SIDE WINDOW GLASS WITH THE DOOR CHECK LINK....ODI HAS RECEIVED 46 CONSUMER COMPLAINTS ALLEGING THAT THE DRIVER AND/OR PASSENGER POWER FRONT WINDOW SHATTERED, AND/OR THE WINDOW MAKES A POPPING/CLICKING NOISE DURING OPERATION.A LOOSENING OF THE WINDOW REGULATOR BOLTS MAY PRODUCT A POPPING NOISE WHILE OPERATING THE WINDOW.THE POWER WINDOW SYSTEM IN THE VIBE IS ALSO USED IN THE TOYOTA COROLLA AND THE TOYOTA COROLLA MATRIX.TOYOTA IDENTIFIED 203 COMPLAINTS FOR MODEL YEAR (MY) 2003-2004 PONTIAC VIBE; AND, 254 COMPLAINTS FOR MY 2003-2004 TOYOTA COROLLA AND TOYOTA COROLLA MATRIX ALLEGING THAT THE SIDE FRONT POWER WINDOW SHATTERED AND/OR MADE A POPPING/CLICKING NOISE DURING OPERATION.TOYOTA IS STILL MONITORING AND EVALUATING THIS ISSUE.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA08-004) TO FURTHER INVESTIGATE THIS ISSUE .