2009 Toyota Corolla 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 Agency received a petition on September 11, 2014 requesting an investigation into, low-speed surging in the 2006-2010 Toyota Corolla [vehicles] with ETCS-i, in which the brakes fail to stop the vehicle in time to prevent a crash.NHTSA conducted a technical review of the material cited and provided by the petitioner, material Toyota submitted in response to a NHTSA formal request, interviews with complainants and manufacturer representatives, as well as the results of testing of the complaint vehicle.Taking into account the allocation of agency resources, agency priorities, and the likelihood that an additional investigation would result in a finding that a defect related to motor vehicle safety exists, NHTSA has concluded that further investigation of the issues raised by the petition is not warranted.The agency accordingly has denied the petition.The official petition denial, as published in the Federal Register, is available in the document file for this defect petition, as well as copies of reference material related to the denial.Regarding the VOQs associated with the closing of this investigation, the scope as defined by the petitioner is MY 2006 through 2010 Toyota Corollas.Of the 163 VOQs submitted by the petitioner, 149 are within that specific population (11 of the 163 were outside the model and model year scope of investigation as defined by the petitioner and 3 VOQs were submitted by owners from foreign countries) and 6 of the 163 are duplicate submissions.Therefore, there are 143 unique vehicles vins are within the specific population.Of the 143 only 105 fit the alleged defect category as defined by the petitioner.The single complaint and crash noted in the Failure Report above is the petitioner's VOQ.The 143 VOQs are: 10165337, 10166526, 10209540, 10216514, 10256808 (duplicate with 10266580 and 10335955), 10272505, 10293497, 10293688, 10294727, 10297407, 10298012, 10302217, 10302877, 10303106, 10303469, 10303730, 10304192, 10305748, 10305845, 10306012, 10306480, 10307953, 10310973, 10311137, 10311176, 10311185, 10311756, 10312246, 10312272 (duplicate with 10343088), 10312771, 10313972, 10314880, 10315240, 10315442, 10315836, 10315927, 10316192, 10316627, 10316643, 10316800, 10316952, 10317128, 10317598, 10317725, 10317804, 10317894, 10317972, 10317978, 10318562, 10319589, 10320693, 10320720, 10322163, 10322213, 10322333, 10322415, 10324355, 10325755, 10326481, 10327623, 10328492, 10328519, 10329537, 10330026 (duplicate with 10356866), 10330952, 10332679, 10334005 (duplicate with 10340570 and 10547602), 10334028, 10334628, 10334936, 10336649, 10339772, 10339969, 10341515, 10342670, 10342932, 10343174, 10344874, 10345714, 10348120, 10350342, 10351112, 10352668, 10352691, 10353587, 10358767, 10359645, 10360875, 10360905, 10361254, 10363529, 10363685, 10363866, 10364127, 10366100, 10366413, 10369073, 10369494, 10371991, 10376535, 10376721, 10377193, 10379320, 10380210, 10381365, 10381849, 10382018, 10392618, 10396747, 10402827, 10412382, 10433860, 10437011, 10437801, 10450183, 10461118, 10479582, 10482133, 10489344, 10494568, 10496026, 10499932, 10520195, 10521013, 10523677, 10534094, 10537426, 10543949, 10549101, 10551478, 10552563, 10558153, 10562577, 10564980, 10566370, 10572873, 10578871, 10579722, 10587140, 10597296, 10621449, and 10637908 (which is the petitioner's VOQ and not one of the 163 submitted with the petition).The three VOQs that were submitted from foreign countries: 10303105, 10303749, and 10308974. The eleven VOQs that are out of the specified population by model or model year: 10447756, 10453401, 10490200, 10507434, 10521377, 10563214, 10563585, 10575230, 10583796, 10584534,

On February 18, 2010, the Office of Defects Investigation (ODI) opened Preliminary Evaluation PE10-008 to investigate complaints of steering wander or drift in model year (MY) 2009 and 2010 Toyota Corolla and Matrix vehicles.The complaint descriptions indicated dissatisfaction with the on-center steering feel in the subject vehicles. Some drivers (~25%) related the feel to driving in a strong crosswind and others indicated that the effort and attention required to maintain heading increased driver fatigue on long trips.These complaints all relate to the system operating as designed and do not involve failure of any steering system components.The subject vehicles are equipped with an electronic power steering system that was introduced in the MY 2009 vehicles.The power assist, including on-center steering feel, is controlled electronically and is part of the system calibration.Toyota responded to steering feel concerns from some customers by issuing a technical service bulletin (TSB-0140-10 STEERING ON-CENTER FEEL) that released an optional EPS electronic control unit that has a re-calibrated on-center feel.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted by the circumstances.For further details see the attached VRTC and ODI Closing Reports.