2006 Toyota Tundra 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.

THIS INVESTIGATION WAS OPENED BASED ON 20 REPORTS OF MODEL YEAR (MY) 2000 AND 2001 VEHICLES EXPERIENCING SEVERE CORROSION OF THE FRAME, RESULTING IN EITHER UNDER-BODY MOUNTED SPARE TIRE SEPARATION OR REAR BRAKE FAILURE.THE FAILURE REPORT COUNTS SHOWN ABOVE ARE FOR MY 2000 AND 2001 VEHICLES ONLY.BY LETTER OF NOVEMBER 16, 2009 TOYOTA HAS NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (09V-444) OF APPROXIMATELY 110,000 MODEL YEAR (MY) 2000 THROUGH 2003 TUNDRA VEHICLES.THE AFFECTED RECALLED VEHICLES WERE SOLD OR ARE CURRENTLY REGISTERED IN THE DISTRICT OF COLUMBIA AND THE STATES OF CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV.TOYOTA ALLEGES HIGH AMOUNTS OF ROAD SALTS ARE USED IN THESE AREAS AND EXCESSIVE CORROSION OF THE REAR CROSS-MEMBER (TO WHICH THE SPARE TIRE IS MOUNTED) CAN OCCUR AND CAUSE THE SPARE TIRE TO SEPARATE FROM THE VEHICLE AND CAN ALSO LEAD TO REAR BRAKE FAILURE.TOYOTA STATED: TOYOTA HAS TENTATIVELY CONCLUDED THAT THE ROOT CAUSE IS A COMBINATION OF FACTORS, INCLUDING USAGE IN AREAS WHERE ROAD SALT IS APPLIED, INADEQUATE VEHICLE MAINTENANCE (I.E., NOT FOLLOWING THE RECOMMENDATIONS IN THE OWNER'S MANUAL), THE DESIGN OF THE REAR CROSS-MEMBER, AND MANUFACTURING ISSUES.THE DESIGN OF THE REAR CROSS-MEMBER IS SUCH THAT IT IS OPEN ON THE TOP SIDE AND SUSCEPTIBLE TO ACCUMULATION OF DIRT, WATER AND ROAD SALT.MANUFACTURING ISSUES OF THE REAR CROSS-MEMBER RELATED TO THE COATING PROCESS ALSO AFFECT ITS CORROSION RESISTANCE.TOYOTA ALSO STATES THAT OWNERS OF MY 2000 THROUGH 2003 VEHICLES IN STATES NOT COVERED BY THE RECALL WILL BE NOTIFIED ON HOW TO OBTAIN THE SAME INSPECTION AND REPAIR AS THE RECALLED VEHICLES, FREE OF CHARGE.FURTHER TOYOTA STATES: PLEASE NOTE THAT WHILE TOYOTA HAS NOT DETERMINED A DEFECT EXISTS IN 2004 THROUGH 2006 MY TUNDRA VEHICLES, TOYOTA PLANS ON INITIATING A FIELD ACTION IN THE NEAR FUTURE TO PREVENT FUTURE CORROSION ON THOSE VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE AFFECTED REGION AT NO COST TO THE OWNER.BY LETTER OF JANUARY 8, 2010 TOYOTA HAS NOTIFIED THE AGENCY THAT IT AMENDED ITS DEFECT INFORMATION REPORT FOR SAFETY RECALL 09V-444 TO INCLUDE THE FUEL TANK MOUNTING SYSTEM (I.E., FUEL TANK SUPPORT STRAPS AND FUEL TANK MOUNTING CROSS-MEMBERS) IN THE SAFETY RECALL.TOYOTA STATES: TOYOTA HAS NOT DECIDED THAT THE FUEL TANK MOUNTING SYSTEM IN THOSE VEHICLES CONTAINS A SAFETY-RELATED DEFECT WITHIN THE MEANING OF FEDERAL MOTOR VEHICLE SAFETY LAW.RATHER, TOYOTA IS TAKING THIS ACTION AT ODI'S REQUEST AND TO AVOID FUTURE DISAGREEMENT WITH ODI WITH RESPECT TO THIS ISSUE.MY 2007 AND NEWER TUNDRA VEHICLES ARE NOT INCLUDED IN ANY OF TOYOTA'S ACTIONS AS THE REAR CROSS-MEMBER IN THOSE VEHICLES HAVE BEEN REDESIGNED SO THAT IT IS OPEN ON THE BOTTOM.THE ACTIONS TAKEN BY TOYOTA ARE SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.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 IN THE SUBJECT VEHICLES.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

IN A LETTER DATED JANUARY 18, 2007, TOYOTA NOTIFIED NHTSA OF A SAFETY DEFECT IN MODEL YEAR (MY) 2004 THROUGH 2006 TOYOTA TUNDRA AND MY 2004 THROUGH 2007 TOYOTA SEQUOIA VEHICLES PRODUCED BETWEEN SEPTEMBER 15, 2003 AND NOVEMBER 17, 2006 (NHTSA RECALL NO. 07V-013). ACCORDING TO TOYOTA, ?IN THE FRONT SUSPENSION LOWER BALL JOINT ON THE SUBJECT VEHICLES, DUE TO POSSIBLE IMPROPER FINISHING OF THE BALL JOINT, SUCH AS THE ASPECT OF THE BALL STUD SURFACE, SOME BALL JOINTS MAY EXPERIENCE AN INCIDENTAL DETERIORATION OF THE INTERNAL LUBRICATION. THIS MAY CAUSE THE BALL JOINT TO WEAR AND LOOSEN PREMATURELY, WHICH COULD RESULT IN INCREASED STEERING EFFORT, REDUCED VEHICLE SELF-CENTERING, AND NOISE IN THE FRONT SUSPENSION. IN EXTREME CASES, IF THE VEHICLE IS CONTINUOUSLY OPERATED IN THIS CONDITION, THE LOWER BALL JOINT MAY SEPARATE FROM THE KNUCKLE AND COULD CAUSE LOSS OF VEHICLE CONTROL.?TOYOTA WILL INSTRUCT OWNERS TO RETURN THEIR VEHICLES TO ANY TOYOTA DEALER FOR REPLACEMENT OF THE FRONT SUSPENSION LOWER BALL JOINTS. THIS ENGINEERING ANALYSIS HAS BEEN CLOSED, AS TOYOTA IS RECALLING THE AFFECTED VEHICLES.ODI WILL MONITOR THE EFFECTIVENESS OF THE REMEDY AND TAKE FURTHER ACTION IF WARRANTED.