Tag Archives: air bag safety

Safety Alert:  2025–2026 Ford Bronco Sport & Maverick Passenger Airbag Issue

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If you own or are considering purchasing a 2025–2026 Ford Bronco Sport or Ford Maverick, there is an important safety defect you need to be aware of.  Ford Motor Company has issued recall #26C19 (NHTSA campaign number: 26V-201) due to a defect that could impact how the front passenger airbag functions.

What’s the Problem?

The issue centers around the Occupant Classification Sensor (OCS) system and the component responsible for determining whether a passenger (adult, child, or none) is sitting in the front seat.

In affected vehicles:

  • A faulty OCS bladder port may break.
  • This can cause the system to incorrectly detect passengers.
  • As a result, the passenger airbag may be disabled when it should deploy.

This creates a non-compliance with Federal Motor Vehicle Safety Standard 208, which governs occupant crash protection.

Why This Matters

In a crash scenario:

  • The front passenger airbag may not deploy.
  • This significantly increases the risk of injury.

Even though only a small number of cases have been confirmed so far, airbags are critical safety systems and failure to deploy properly is a serious concern.

What Causes the Issue?

Ford’s investigation points to:

  • A mechanical separation in the OCS system (pressure hose disconnecting from a fitting)
  • This leads to a dielectric fluid leak, disrupting sensor accuracy

The issue appears to be:

  • Limited to a specific production window.
  • Linked to a tier-2 supplier component.
  • Unique to Bronco Sport and Maverick due to design interaction between parts.

Importantly:

  • The problem was not detected during factory testing.
  • It likely occurs after assembly, affecting only certain vehicles.

Warning Signs to Watch For

Drivers may notice:

  • SRS (airbag) warning light illuminated.
  • A dashboard message indicating a restraint system issue.
  • “Passenger Airbag OFF” displayed unexpectedly.

If you see these warnings, it’s important to have your vehicle inspected promptly.

What Ford Has Reported

  • 6 confirmed cases (as of March 16, 2026)
  • Includes 5 warranty claims + 1 factory detection
  • No reported injuries or accidents linked to the issue

While the number is small, recalls are issued proactively to prevent future risk.  If you own one of these vehicles, Ford Motor Company will have dealers replace the passenger seat Occupant Classification Sensor at no cost. Owners are expected to receive initial notification letters starting April 13, 2026, with the final repair solution anticipated to be fully available by November 2026. In the meantime, you should watch your mail for recall notices, keep an eye on your dashboard for any warning lights or messages, contact your local Ford dealer to confirm whether your vehicle is affected, and schedule the repair as soon as parts become available.

Final Thoughts

Even though this issue currently affects a limited number of vehicles, it involves a core safety system. Ford’s recall is a precautionary step to ensure drivers and passengers remain protected.  If you’re driving a Bronco Sport or Maverick from this model year range, staying informed and taking action when notified.

2025 Ford Ranger Airbag Deployment Problem Raises Safety Concerns

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Ford Motor Company has issued a recall for certain 2025 Ford Ranger trucks due to a potential problem with the passenger airbag system. According to the automaker, a manufacturing error could prevent the airbag from deploying properly in the event of a collision, creating an increased risk of injury for passengers.

While the issue affects only a limited number of vehicles, Ford is taking immediate action to ensure compliance with federal safety standards and to protect customer safety.

The Issue: Faulty Instrument Panel Scoring

The concern originates from the instrument panel (IP) assembly—specifically the laser scoring process used on the underside of the IP topper. The scoring defines the precise way the airbag deploys through the dashboard surface.

Ford discovered that the supplier, Yanfeng (YF), had unintentionally altered the laser scoring parameters during production. This seemingly small change resulted in a deviation from the approved design, affecting the scoring pattern in certain 2025 Ford Ranger vehicles.

This flaw may cause the passenger airbag to deploy more slowly or not fully deploy at all, especially during cold-temperature conditions or low-output deployments. During internal safety testing, Ford observed that in some cases, the airbag cushion failed to completely exit the panel surface, creating a potential hazard and violating Federal Motor Vehicle Safety Standards (FMVSS) 208, which govern occupant crash protection performance.

Timeline of Events

The airbag concern was identified and escalated through Ford’s quality and safety review process over the course of several weeks:

  • September 10, 2025: Supplier Yanfeng notifies Ford of an unintended change to the laser scoring process.
  • September 18, 2025: Ford’s Critical Concern Review Group (CCRG) launches a detailed investigation into the issue.
  • September 9, 2025: The supplier revises the laser scoring process to match the original specifications and validates the fix.
  • October 3, 2025: Ford’s Field Review Committee reviews the findings, confirms non-compliance with FMVSS 208, and authorizes a field action.

Although Ford is not aware of any crashes, injuries, or customer complaints linked to the problem, the company has decided to act out of caution and replace affected components.

What Ford Owners Need to Know

Owners of affected 2025 Ford Ranger trucks will be contacted directly by Ford. Here’s what you should know about the recall:

  • Recall Number: 25C54
  • NHTSA Campaign ID: 25V-678
  • Remedy: Ford dealers will replace the instrument panel assembly.
  • Notification Schedule:
    • Interim owner letters were mailed on October 24, 2025, to inform customers of the issue.
    • Final remedy letters will be mailed once replacement parts are available and the repair process begins.

Fiat Spider Airbag Could Deploy With Excessive Force

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Chrysler (FCA US, LLC) has identified a software error in the airbag control module of certain 2017-2020 Fiat/Abarth 124 Spider vehicles. This issue can cause the airbags to deploy with excessive force during a crash, which poses a safety risk. As a result, these vehicles do not comply with the Federal Motor Vehicle Safety Standards (FMVSS) for occupant crash protection, specifically FMVSS No. 208, which governs crash protection and performance requirements for automotive airbags.

The problem came to light in July 2024, when Mazda Motor Corporation, a partner in the development of these vehicles, notified Stellantis Europe S.p.A. about a potential issue with the airbag control module. Mazda discovered this error during the development of new airbag sensors for upcoming vehicle models. As part of the research and testing process for these sensors, engineers identified a misconfiguration in the calibration tool used to program airbag control modules.

This discovery prompted Mazda to take a closer look at the settings of airbag control modules in previous models, including the 2016-2023 MX-5 Miata. During extensive simulation tests, Mazda engineers uncovered a potential flaw in the collision detection sensitivity of the airbag system. This flaw could cause airbags in these models to deploy improperly, failing to meet the safety standards designed to protect passengers from serious injury. The main concern is that the system might trigger the deployment of the dual-stage front airbag rather than the single-stage deployment that is appropriate for certain types of collisions. This misconfiguration increases the risk of neck injuries during a frontal crash.

FMVSS No. 208 requires that vehicles meet specific performance standards related to neck injury prevention during a 26 km/h frontal impact. The dual-stage airbag deployment in the affected Fiat/Abarth 124 Spider vehicles increases the force of the airbag during deployment, potentially leading to a higher risk of neck injuries, which would prevent the vehicles from meeting these safety requirements.

The issue is not related to a defective part, but rather a design oversight in the programming of the airbag control module. The voltage specifications for the accelerometer, a key component of the system that detects a crash and triggers the airbags, were incorrectly set. This misconfiguration leads to improper airbag deployment, which could result in the failure to meet safety regulations.

To remedy this issue, Chrysler will reprogram the airbag control module in all affected vehicles with the correct specifications. This software update will ensure that the airbags deploy at the appropriate force in the event of a crash, reducing the risk of injury and bringing the vehicles into compliance with federal safety standards.

Chrysler plans to begin notifying vehicle owners about the recall on November 7, 2024. Once notified, owners will be instructed to bring their vehicles to authorized dealerships for the airbag control module to be reprogrammed at no cost. In the meantime, Chrysler has assigned the recall number A3B to this issue, and the National Highway Traffic Safety Administration (NHTSA) has assigned it the campaign number 24V-694.

Mazda MX-5 Miata Air Bag Control Module Safety Concern

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Mazda will soon be reaching out to the owners of specific 2016-2023 Mazda MX-5 Miata vehicles due to a software issue affecting the airbag control module. This problem, first identified in April 2023, stems from a calibration error that may result in the front airbags deploying with excessive force during a crash. As a consequence, these vehicles fail to meet the Federal Motor Vehicle Safety Standards (FMVSS) for Occupant Crash Protection, potentially endangering the safety of both drivers and passengers.

Mazda became aware of the issue during the development of new airbag sensors for future models. During this process, engineers uncovered a misconfiguration in the calibration tool used to set up the airbag control modules. This discovery prompted Mazda to reevaluate and reassess the settings in control modules from earlier vehicle models. Through a series of rigorous simulation tests, Mazda found that the collision detection sensitivity in the 2016-2023 MX-5 Miata models could lead to improper airbag deployments that do not comply with safety standards.

The problem particularly arises during minor collisions, where the airbags may deploy with a force higher than intended. This excessive force poses an increased risk of injury to vehicle occupants, especially in situations where airbag deployment should be less aggressive. Although the issue seems isolated to the MX-5 Miata, Mazda has taken steps to conduct similar tests across other vehicle models to ensure that the problem does not affect a broader range of vehicles.

To resolve this issue, Mazda dealers will perform a software update on the Sophisticated Air Bag Sensor (SAS) control module of the affected vehicles. This update is designed to re-calibrate the airbag deployment system to meet FMVSS 208 standards, ensuring that airbags deploy at appropriate force levels in the event of a collision. Mazda has scheduled owner notification letters to be mailed starting November 17, 2024, alerting owners to the recall and the necessary repairs.

Mazda’s recall number for this issue is 6924I, and the National Highway Traffic Safety Administration (NHTSA) has assigned campaign number 24V-695 to this recall. It is crucial for MX-5 Miata owners to have their vehicles inspected and repaired as soon as possible. Doing so will not only bring the vehicles back into compliance with federal safety regulations but also ensure the continued safety of all passengers in the event of an accident.

Airbag May Not Deploy In Subaru Outback And Legacy Vehicles

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This matter came to light in February 2024 when Subaru initiated an investigation after receiving returned parts from reports indicating airbags failing to deploy as intended. Subaru collaborated with the supplier and submitted an equipment recall (24E-016) to the National Highway Traffic Safety Administration (NHTSA), signalling the commencement of evaluations regarding the safety implications for Subaru vehicles and the potentially impacted population. Subaru made the decision in March to launch a comprehensive safety recall campaign.

Digging into the technicalities of the issue, the defect report highlights a convergence of factors contributing to the capacitor cracking. It suggests that the utilization of alternate component sub-suppliers during short-term natural disaster recovery, combined with certain supplier processing methods, may have led to this vulnerability. Specifically, it’s noted that during a specific production period at a particular supplier, the ODS Sensor Printed Circuit Board (PCB) might have undergone deformation, thereby initiating cracks in the capacitor. Over time, these cracks could permit moisture ingress into the capacitor, ultimately resulting in a short circuit.

The ramifications of this malfunction are significant. When a short circuit occurs, indicators such as the SRS airbag system warning lamp and the front passenger’s frontal airbag OFF indicator illuminate. This signifies a potential failure of the front passenger airbag to deploy in specific crash scenarios, thus elevating the risk of injury to the occupant in the respective seat.

In response to this concern, Subaru has outlined a comprehensive course of action. Owners of the affected vehicles will be contacted and requested to visit authorized dealerships for the replacement of ODS sensors on the front passenger seat. Initial communication regarding the safety risk is anticipated to be dispatched by May 21, 2024, in the form of interim letters. A subsequent letter will follow once the remedy procedure is finalized. To facilitate communication and tracking, Subaru has assigned the recall number WRA-24, with the NHTSA campaign number denoted as 24V-227.

Chevy Traverse And Buick Enclave Driver Airbag Inflator May Explode

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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.

Takata Airbags Ongoing investigation

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The NHTSA Office of Defects Investigation have opened an investigation to whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal air bag inflators manufactured by Takata. This investigation will include information on the Takata production processes, a study 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.

From 2000 through 2017, Takata produced 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.

“Takata 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 are ongoing and to date, none 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. “

NHTSA Action Number: EA21002

Click Here to see the complete list of vehicles involved in this investigation.