Toyota will be contacting the owners of certain 2021-2022 Sequoia and 2021 Tundra trucks because of a problem affecting the power steering gear assembly. Owner notification letters are expected to be sent out on January 22, 2022.

In late September 2021, Toyota observed an increase in field reports and warranty claims affecting the power steering in certain 2021-2022 Sequoia and 2021 Tundra trucks. A high percentage of these vehicles experienced power steering fluid leaks, all from the area of the power steering gear assembly. Manufacturing records showed that these reports mainly involved vehicles produced during the months of August and September 2021. Toyota began recovering additional parts involved in these reports and sent them to the supplier for inspection.

These inspections found that the circlip holding the oil seal and end stopper in position at the end of the power steering rack housing was disengaged from the groove machined in the rack housing and that the oil seal and the end stopper were moved from the correct position. Further investigation of the returned parts revealed that the groove where the circlip is installed was improperly machined leading to an incorrect groove shape.

Based on these findings, the supplier investigated their production process and identified that one of the four pieces of equipment used to machine the groove in the rack housing was not creating a groove of the correct shape. The tool was inspected, it was found that certain teeth on the cutting tool, which creates the groove in the rack housing, were damaged. Based on these results Toyota has decided to conduct a safety recall campaign.

Owners of the affected vehicles will be notified to return to their Toyota dealer to have the power steering gear assembly inspected and replaced if necessary. Toyota’s numbers for this recall are 21TB10 and 21TA10, and the NHTSA campaign number is 21V-920.

Chrysler (FCA US, LLC) will be contacting owners of certain Chrysler, Alfa Romeo, and RAM vehicles for a problem affecting the fuel system. In total, approximately 236 000 vehicles are being recalled.

2020-2021 Alfa Romeo Stelvio and Alfa Romeo Giulia vehicles fuel line sensor housing may crack and leak fuel. NHTSA Campaign Number: 21V-878

The problem was traced to September 11, 2020, when defective fuel sensors were introduced into vehicle production, and ended on May 25, 2021, when the fuel sensors from the suspect batches were no longer used. The suspect population was determined using part traceability and vehicle production records.

According to the defect report, a leak in the fuel line sensor may cause fuel starvation of the engine and in rare circumstances, if the leaked fuel comes in contact with an ignition source, a fire could occur. A vehicle fire can result in an increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage. Fuel starvation could also result in an unexpected loss of motive power.

2019 Fiat 124 Spider fuel pump failure may cause an engine stall. NHTSA Campaign Number: 21V-879

The suspect period began on April 6, 2018, when the defective fuel delivery module (FDMs) were introduced into vehicle production, and ended on October 18, 2018, when FDMs with improved molding of the impellers were implemented in vehicle production.

Some 2019 Fiat 124 Spider vehicles may have been manufactured with a fuel delivery module (FDM) with impellers that could deform. An FDM with a deformed impeller may interfere with other fuel pump components which can inhibit the operation of the fuel pump potentially causing fuel starvation. : Fuel starvation may result in an unexpected loss of motive power.

2019-2020 RAM 2500, 3500, 4500, and 5500 diesel trucks fuel pump failure may cause an engine stall.
NHTSA Campaign Number: 21V-880

The suspect period began on October 11, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production.

According to the defect report, the high-pressure fuel pump could fail and introduce debris into the fuel system. Fuel starvation and an unexpected loss of motive power could result without prior warning. Vehicle occupants may notice an illuminated Malfunction Indicator Lamp, a fuel leak or smell, abnormal engine noises, or a change in drive quality.

During a configuration review at the supplier for an unrelated manufacturing issue, FCA US LLC Product Engineering became aware of an error with an airbag squib driver circuit that identified three internal faults not mapped to a diagnostic trouble code (DTC). An investigation was opened and it was discovered that some 2021 Jeep Grand Cherokee, 2022 Jeep Wagoneer, and 2022 Jeep Grand Wagoneer vehicles may not set a DTC, and the airbag warning indicator may not illuminate.

The problem started in February 2021, when occupant restraint controllers (ORCs) with an incorrect software version were introduced into vehicle production, through to November 1, 2021, when the suspect ORCs were no longer used in vehicle production. Vehicle and supplier production records were used to determine the vehicles included in the recall population.

According to the defect report, “If specific ORC internal faults are active then a DTC will not be set and the airbag warning indicator may not illuminate. The internal faults will disable deployment of both the driver and passenger airbag squib 3 (related to airbag venting post-deployment) and knee airbags. The airbag warning indicator may not illuminate to notify the driver of possible compromised airbag system functionality. Reduced occupant protection in the event of a crash may result in an increased risk of injury to motor vehicle occupants.”

Owners receiving notices will be asked to return to their FCA dealers to have the occupant restraint controller reprogrammed with the correct software version that maps subject internal faults to a DTC. FCA US, LLC’s number for this recall is Y79 and the NHTSA campaign number is 21V-873.

If you purchased or leased a defective vehicle in California, it has turned out to be a lemon, and you need help to get rid of it, just fill out the above contact form or call us now at 1-888-395-3666 for a free case evaluation.

Mazda is recalling certain 2018-2020 vehicles because the impeller inside the low-pressure fuel pump may crack and deform, potentially causing the fuel pump to fail.

In March 2019 Mazda received the first field report of an engine stall due to an inoperative fuel pump. A study of the pump showed that cracking on the impeller surface made the impeller more likely to deform. Further investigation found that solvent used during the manufacturing process and low-density impellers may be factors causing impeller cracking. During the test, the surface of the impeller cracked as the solvent dried over time. It was confirmed that fuel pumps produced with impellers of lower density exposed to production drying solvent for longer periods of time could experience the impeller cracking at a level that could lead to excessive fuel absorption, and could cause impeller deformation.

The Vehicles Affected Include:
2019 Mazda CX-3
2018-2019 Mazda CX-5
2018-2019 Mazda CX-9
2019-2020 Mazda Mazda2
2018 Mazda Mazda3
2018 Mazda Mazda6
2018-2019 Mazda MX-5

Fuel pump failure may result in engine no start and/or vehicle stall while driving at low speed and, in rare instances, a vehicle stall could occur while driving at higher speeds, increasing the risk of a crash. Drivers may notice this defect by a check engine light, and/or rough engine operation.

Mazda will be contacting owners of affected vehicles with instructions to return to their dealers to have the fuel pump replaced. Mazda’s number for this recall is 5321K and the NHTSA campaign number is 21V-875.

The NHTSA Office of Defects Investigation (ODI) have opened up an investigation into certain 2019-2020 RAM trucks after receiving 22 complaints and 2 field reports alleging incidents of stalling and loss of engine power. The vehicles affected are equipped with 6.7L Cummins turbo diesel engines. According to the investigation report, the complaints found that most stall/loss of motive power incident allegations occurred at speeds above 25 MPH and resulted in permanent disablement of the vehicle.

The Vehicles Affected Include:
2019-2020 Ram 2500
2019-2020 Ram 3500
2019-2020 Ram 4500
2019-2020 Ram 5500

In November 2019, FCA issued Warranty Bulletin D-19-02 to announce to its dealers a Fast Feedback Program wherein they were notified of a campaign to collect, monitor, and correct quality issues on certain 2018-2020 Ram trucks equipped with the 6.7L Cummins engine. As a result of this campaign, high-pressure fuel pumps have been collected and inspected by the manufacturer and pump manufacturer.

ODI is opening this investigation to further assess the scope, frequency, root cause, and potential safety-related consequences of the alleged defect leading to stall/loss of motive power on 2019-2020MY RAM heavy-duty trucks.

A manufacturing defect affecting airbags will have a small number of 2008-2017 Buick Enclave and 2013-2017 Chevrolet Traverse owners returning to their dealerships for repairs.

In July 2015 the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE15-027) into ARC Automotive Inc. (ARC) air bag inflators after receiving reports about two injury incidents involving a driver air bag inflator rupture. One incident involved a 2002 Chrysler Town & Country that had a dual-stage air bag inflator and the other involved a 2004 Kia Optima with a single-stage inflator. Both air bag inflators were manufactured by ARC.

During the evaluation the ODI gathered information from ARC about which air bag module manufacturers used the subject ARC inflators and requested information from the identified air bag module manufacturers about which vehicle manufacturers used modules with the subject ARC inflators. That process identified additional affected vehicle manufacturers, including General Motors.

According to the defect report, GM will be recalling certain 2008–2017 Buick Enclave and 2013-2017 Chevrolet Traverse vehicles for front driver airbag inflators which may have been installed either as original equipment or as part of a replacement driver airbag module during service. These airbags could contain a manufacturing defect that may result in an inflator rupture during deployment. If the inflator ruptures it could cause metal fragments to pass through the airbag and into the vehicle, potentially causing injury or death to vehicle occupants.

Dealers will inspect and replace the driver’s air bag module as necessary. GM’s number for this recall is N212349040 and the NHTSA campaign number is 21V-782.

General Motors has decided that a defect relating to vehicle safety exists in certain 2021-2022 Chevrolet Silverado 2500/3500 and 2021-2022 GMC Sierra 2500/3500 trucks.

GM first became aware of the problem in September 2021 when two 2021 GMC Sierra 2500 vehicles experienced under hood fires at the assembly plant. Both vehicles were parked outside awaiting shipment and had been exposed to heavy rainfall the day before. Using X-ray and CT scans on the vehicles showed a gap between the bolt head and brake pressure modulator valve (BPMV), indicating that the assembly had not been properly sealed to prevent water intrusion. Both vehicles had been subject to temporary production process changes that involved offline replacement of the electronic brake control module (EBCM), which is a sub-assembly of the BPMV. Analysis of the vehicles also found that the fire started in this area.

According to the defect report, bolts attaching the BPMV may have not been properly tightened, failing to create the seal between two sub-assemblies that is intended to prevent water intrusion. If water becomes trapped in the BPMV, it could result in a short circuit, which could lead to an under hood fire.

Owners of these trucks are advised to park outside and away from other structures until the recall repair is completed. Dealers will correct the problem by replacing the BPMV assembly.. GM’s number for this recall is N212349181 and the NHTSA campaign number is 21V-758.

In September 2019, the NHTSA was asked to initiate an investigation into certain Tesla Model S and Model X vehicles that received a revised battery management software update in one or more over-the-air updates from Tesla, beginning in May 2019. The petitioner based his request on vehicle fires that took place worldwide and over the air software updates Tesla made to the Battery Management System (BMS) of certain Tesla vehicles that resulted in loss of available vehicle mileage range and increased charging duration’s.

The five non-crash fires referenced in the petition include two fires that occurred in China in early 2019 involving vehicles that:

  • Had recently completed Supercharging sessions.
  • Were at a high state-of-charge (SOC) of the HV battery.
  • Were parked with the battery cooling system shutoff.
  • Had histories of high-stress usage for the HV batteries.

The three fires that occurred outside China did not involve the same patterns regarding vehicle state and charging history. The two fires that occurred in the United States include one involving a vehicle with no Supercharging history that was driving when the fire occurred and another in which the origin of the fire was external to the HV battery. The fifth fire, which also originated external to the HV battery, involved a vehicle in Germany that had been parked at a low SOC for an extended period. To date, incidents of fires involving parked vehicles with recent Supercharging and histories of high-stress use have only been observed in China, where high-stress use factors appear to be more common.

Given the absence of any incidents in the United States related to fast charging, and the absence of any such incidents globally since May 2019, the petition has been denied. The denial of this petition does not stop the Agency from taking further action if future findings find that a safety defect exists based on additional information received. NHTSA could initiate a recall if they find a defect in the design, construction, or performance of a motor vehicle that presents an unreasonable risk to safety.