Tag Archives: air bag safety problem

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 Issue in 2021 and 2024 Nissan Titan Vehicles

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A recent safety concern has emerged for a small number of 2021 and 2024 Nissan Titan vehicles due to a potential issue with their Air Bag Control Unit (ACU). This problem, if left unaddressed, could increase the risk of injury to occupants in the event of a crash.

In May 2024, Nissan was alerted by their airbag supplier about a production error that involved a missing spacer between the ACU fastener and the base plate. This spacer plays a critical role in ensuring that the ACU is properly secured. Without it, there is a risk that the fastener could interfere with the vehicle’s floor pan, leading to the fastener becoming loose. If this occurs, the airbag may deploy late or not at all, which could significantly increase the risk of injury during a crash.

Upon learning about the problem, Nissan and the supplier conducted a thorough audit. They discovered that 531 affected parts had been shipped to Nissan’s Canton, MS Plant. Fortunately, 528 of these parts were identified and quarantined before they could be installed in vehicles. However, three parts had already been installed in 2024 Nissan Titan vehicles that had been shipped.

In June 2024, the supplier identified additional affected parts included in a service part kit, of which 41 were shipped to Nissan. Nissan was able to quarantine and scrap 37 of these parts, but four had already been installed in 2021 Nissan Titan vehicles during repairs.

On July 19, 2024, after further assessment, Nissan confirmed that the absence of the spacer could indeed cause interference with the floor pan, potentially leading to loose fasteners and compromised airbag deployment.

As a result of these findings, Nissan decided on July 29, 2024, to initiate a Voluntary Safety Recall for the seven affected vehicles—three from the 2024 model year and four from the 2021 model year. While there have been no reports of accidents or injuries related to this issue, Nissan is taking precautionary measures to ensure the safety of its customers.

Nissan will address the issue by replacing the ACU in the affected vehicles. Owners of these vehicles will receive notification letters starting September 19, 2024. The recall number assigned by Nissan is PD120, and the corresponding National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-580.

Although the number of vehicles affected is small, this recall is a critical step to ensure the safety of Nissan Titan drivers and passengers. If you own a 2021 or 2024 Nissan Titan, keep an eye out for the notification letter and get the the necessary repairs.

Hyundai Santa Fe Air Bag Warning Light

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In April 2024, Hyundai became aware of a significant safety issue involving the main floor wiring harness in certain 2024 Hyundai Santa Fe and Santa Fe Hybrid Electric Vehicle (HEV) models. This issue was first identified following reports of an inadvertent rear seat side airbag deployment in a Santa Fe vehicle in South Korea. As a result, Hyundai initiated a preliminary investigation, which was subsequently extended to include the North American market.

The defect centers on the main floor wire harness, which in the affected vehicles is susceptible to damage due to contact with the passenger-side, second-row bench seat’s folding hinge assembly. This contact can result in the wire harness becoming chafed, leading to several potential hazards:

  • Illumination of the Air Bag Warning Light: A damaged wire harness can trigger the air bag warning light on the vehicle’s dashboard, indicating a malfunction.
  • Inadvertent Air Bag Deployment: The damage can cause the airbags to deploy unintentionally, posing a significant risk to vehicle occupants.
  • Failure to Deploy Air Bags During a Crash: Conversely, the damage could also prevent the airbags from deploying in the event of a crash, reducing the effectiveness of this critical safety feature.

Hyundai’s investigation revealed eight unique incidents related to this defect in the U.S. market. These findings prompted the company to take immediate action to address the issue and ensure the safety of its customers.

Hyundai will notify affected vehicle owners via first-class mail, instructing them to bring their vehicles to an authorized Hyundai dealer for inspection and repair. The repair process will involve:

  1. Inspection of the Wire Harness: Dealers will check the condition of the main floor wire harness for any signs of damage.
  2. Securing the Wire Harness: If no damage is found, the harness will be properly secured to prevent future contact with the seat’s folding hinge assembly.
  3. Replacement of Damaged Wire Harness: If damage is detected, the wire harness will be replaced with a new one to ensure the vehicle’s safety systems function correctly.


As a precaution, Hyundai advises vehicle owners to be vigilant for any of the warning symptoms mentioned in the defect report, such as the air bag warning light illuminating. If any of these symptoms are present, owners are urged to immediately go for diagnosis and the necessary repairs.

Owner notification letters are scheduled to be mailed out on September 23, 2024. Hyundai has assigned the internal recall number 265 to this campaign, while the National Highway Traffic Safety Administration (NHTSA) has designated it as campaign number 24V-561.

Airbag Issue Affects Certain 2024 Jeep Grand Cherokee Models

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A recent discovery by FCA Technical Safety and Regulatory Compliance (TSRC) has led to a voluntary safety recall of certain 2024 Jeep Grand Cherokee vehicles. The issue affects a small number of vehicles that may be missing an important part in the front bumper. This missing piece could compromise the proper deployment of the front airbags.

The affected vehicles fail to comply with the Federal Motor Vehicle Safety Standards (FMVSS) for Occupant Crash Protection. FMVSS No. 208 specifies vehicle crash worthiness requirements and equipment requirements for active and passive restraint systems. In the event of a frontal collision, the missing energy absorbing foam could lead to a non-deployment or improper deployment of the front airbags, potentially increasing the risk of injury or harm to occupants.

According to FCA US, an analysis of vehicle production history revealed that some Jeep Grand Cherokee vehicles may have been built without a front fascia energy absorbing foam. This condition can lead to a non-compliance with FMVSS No. 208, as it compromises the intended load distribution or energy management, potentially jeopardizing proper crash sensing and airbag deployment.

The suspect period for affected vehicles began on December 6, 2023, and ended on December 9, 2023, when vehicle production processes were corrected. During this time, some Jeep Grand Cherokee vehicles may have been manufactured without the crucial foam, which is designed to absorb energy and help protect occupants in the event of a crash.

Dealers will inspect the affected vehicles and install the missing foam as necessary to ensure compliance with safety standards. This recall is intended to minimize any potential risks associated with this airbag issue and maintain the high standards of quality and safety that customers expect from Jeep vehicles.

Owners with affected vehicles will receive owner notification letters providing them with details on the recall and next steps to take. It is essential that vehicle owners take immediate action to address this issue and have their vehicles inspected and repaired as necessary to ensure their safety on the road.

2024 Cadillac XT5 Air Bag Could Tear

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General Motors (GM) has announced a safety recall affecting a small number of its 2024 Cadillac XT5 vehicles. This recall addresses a potential defect with the driver front airbag. This defect may pose a risk to vehicle safety.

The issue was identified when GM’s airbag module supplier observed a tear in the airbag cushion during a routine lot-acceptance test. This incident, which occurred in February 2024, prompted a thorough investigation by GM. The supplier was able to isolate the affected batch and performed additional tests on these airbags across various temperature settings to assess their reliability and safety.

The tests revealed that the airbag cushions could tear during deployment due to a recent design change in the airbag modules. Following these findings, GM’s Safety Field Action Decision Authority (SFADA) made the decision to issue a recall for all vehicles equipped with airbag modules from the affected production lot, manufactured the day before the problematic batch.

It is important for consumers to understand that a tear in the airbag cushion during deployment can significantly impair the airbag’s performance in the event of a crash, thereby increasing the risk of injury to the occupants.

To address this safety concern, GM is taking proactive steps. The company will replace the driver’s front airbag module at no cost to vehicle owners. GM plans to begin notifying affected Cadillac XT5 owners through formal letters, which are scheduled to be sent out on June 17, 2024. The recall has been officially recorded under GM’s number N232439241 and the National Highway Traffic Safety Administration (NHTSA) campaign number 24V-311. GM has confirmed that there have been no field incidents or injuries reported in relation to this defect.

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.

Driver Air Bag Could Deactivate In Ford Trucks

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Ford Motor Company is reaching out to owners of certain 2023 F-150 and Ford Super Duty vehicles, including the F250, F350, F450, F550, and F600 models. There is a concern with the driver’s frontal air bag not deploying during a crash.

The issue came to light in November 2023, when Ford’s main supplier, BCS Automotive Interface Solutions, alerted them about a potential problem. This was linked to airbag clock springs provided by American Furukawa, a sub-supplier to BCS. BCS discovered that some clock spring assemblies in the Steering Column Control Modules (SCCM) they supplied to Ford might have been tainted during production.

The problem lies in the SCCM of the affected vehicles, where the clock spring assembly might have a weak weld between the bus bar and the ribbon cable. This issue traces back to the manufacturing stage, where clock spring bus bars were washed in isopropyl alcohol mixed with glycerin. This mix could weaken the weld between the bus bar and ribbon cable in the clock spring assembly.

This ribbon cable is crucial as it connects to the driver’s airbag. A weak weld can cause the ribbon cable circuits to disconnect, leading to a loss of electrical connection to the driver’s front airbag. This malfunction would trigger the airbag warning light and prevent the airbag from deploying as needed. Ford, alongside BCS, has been investigating this issue. They’re reviewing production and shipping records to identify which Ford vehicles might be equipped with the affected clock springs.

As of December 6, 2023, Ford received 19 warranty reports dating from May 1 to November 10, 2023, which could be linked to this clock spring issue.

Drivers might notice problems like non-functional steering wheel switches (like radio controls), a silent horn, and an illuminated airbag warning lamp.

Affected owners will be contacted to bring their vehicles to Ford dealers for an inspection and, if necessary, a replacement of the air bag clock spring. Initial notifications to owners explaining the safety risk are planned for January 8, 2024. A follow-up notice will be sent once the replacement parts are ready, expected in the second quarter of 2024. This recall is officially listed under the NHTSA campaign number 23V-847.