2004 Toyota Corolla

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.

I received a "do not drive" recall for my vehicle in the mail because of defective air bags. The recall letter claimed that there have been twenty-eight confirmed deaths in relation to this recall. I entered Priority Toyota of Chesapeake, VA to address the issue. That was on Monday, April 6th, 2026. Even though there was a "do not drive" order on the recall, Priority Toyota of Chesapeake refused to give me a loaner vehicle. It is now Monday, April 13th, and Priority Toyota of Chesapeake has claimed that they are still waiting on an email to begin repairing the vehicle, which I need for transport. This is a formal complaint that Priority Toyota of Chesapeake, VA has failed to repair the recalls to the vehicle in a timely manner.

NHTSA ID

11730961

Incident

Apr 6, 2026

I am attempting to complete a manufacturer-issued safety recall involving my vehicle’s airbag system, which includes a “Do Not Drive” advisory due to the risk of airbag inflator failure. Despite multiple good-faith attempts, I have encountered repeated barriers at the dealership level that have prevented timely completion of the repair. I scheduled a service appointment with Culver City Toyota and clearly indicated I required a rental vehicle to leave my car. My confirmation stated “Arrangement: Rental Vehicle,” and the appointment was scheduled accordingly. When I arrived, I was told no rentals were available and that they are first-come, first-served. I was turned away and told to return another day. When I returned, I was able to leave my vehicle, but was asked how long I would need the rental without being given a repair timeline. Only after asking was I told the repair would take approximately two days. This was not communicated in advance, and given the prior lack of rental availability, it is unclear how I would have been expected to proceed without transportation. This has occurred across multiple attempts: lack of rental availability and requests to leave my vehicle for extended periods without transportation have made it difficult or impossible to complete the recall. As a result, I have been placed in the position of continuing to operate a vehicle with a known safety defect under a “Do Not Drive” advisory due to the inability to access timely and practical repair. I am concerned that dealership-level processes are creating barriers that delay or prevent consumers from completing urgent safety recalls. As of today, I have left my car at this dealership for the recall repair, however the inconsistent communication and handling of this process have created uncertainty about whether the repair will be completed in a timely and reliable manner. Seeing reviews online, I'm not the only one who's had this issue and the GM is non responsive.

NHTSA ID

11727004

Incident

Mar 23, 2026

This complaint concerns two separate incidents, both involving defective interior door handles. First, in 2023, the driver side driver door handle broke abruptly when the driver attempted to exit the vehicle. As a result, the driver, [XXX] , was trapped in the vehicle and required someone else to let him out from the outside. This was repaired privately at substantial cost to the owner. Then, the exact same thing happened to the passenger side front seat interior door handle in January 2025. The handle mechanism seems to be made of cheap plastic and seems to have broken, preventing the passenger from exiting the vehicle at all and leaving them effectively trapped in the front seat. This has been a major issue recently when transporting family members to the hospital, as time was lost when they tried to get out of the driver side passenger door and found that the door handle mechanism was inoperable. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11665704

Incident

Jan 1, 2025

I got in an accident with a car who ran a stop sign when I didn't have one. I was going approximately 15-20mph and my entire front end collided with their passenger side. My air bags did not go off at all.

NHTSA ID

11558245

Incident

Nov 18, 2023

I have repaired all the safety recalls on my 2004 Toyota Corolla S. However, I just had another warning signal for the seatbelt/airbag today. Since this has been a recall previously, can I have the dealer look at the car and repair again? I wouldn't think the airbags/seatbelt warning would come back so fast after being repaired for the recall. Please advise. Thank you.

NHTSA ID

11478711

Incident

Aug 9, 2022

We received the enclosed NHTSA notice about a vehicle repair that is need for a recall. However we no longer own this vehicle. We sold the vehicle in 2018 or 2019 and transferred the pink slip to the new owner. We have no way to contact him and he is responsible for the vehicle now. So we are just notifying you that we cannot take any action on this.

NHTSA ID

11469390

Incident

Jun 15, 2022

The contact's mother owned a 2004 Toyota Corolla. The contact's mother received notification of NHTSA Campaign Number: 19V741000 (Air Bags) and would like to be removed from the recall distribution list as the vehicle was totaled. The local dealer and manufacturer were not contacted.

NHTSA ID

11464882

Incident

May 16, 2022

Hello, In January 3, 2022. I took the vehicle to the Toyota Hamer dealer about one issue of the air bag recall in the Toyota Corolla with the VIN: [XXX] there after around 4:pm on the Sunday the vehicle it was released with unsolved problems by the dealer and now I am requesting that it be properly repaired due to chronic and faulty problems. That the vehicle has. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ID

11447260

Incident

Jan 3, 2022

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. In areas known for high frequency and/or concentration of acid rain, frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.

Toyota vehicles are currently protected with RapgardTM protective film designed to protect the horizontal painted surfaces. This material protects from acid rain, environmental fallout, and rail contamination. Follow the Removal Procedure in this bulletin to remove the RapgardTM protective film within 90 days from initial application.

Vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks, train wheels, exposure to heavy machinery facilities, grinding, welding, etc. This type of contamination can be identified by the presence of small, red or brown particles on the paint surface. These particles are often difficult to see on dark color paints but can be easily felt when brushing a hand across horizontal body surfaces such as the hood, roof, or deck lid. Follow the Repair Procedure in this bulletin to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust during rail transportation or extended storage near industrial areas.

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.