NHTSA Defect Investigations for the 2005 Toyota Tundra

The Office of Defects Investigations (ODI) is an office within the NHTSA which investigates serious safety problems in the design, construction or performance of vehicles. The NHTSA is authorized to order manufacturers to recall and repair vehicles, if the ODI finds a safety issue. NHTSA investigations for the 2005 Toyota Tundra, both ongoing and closed, are listed below:

  1. Air Bag Inflator Rupture NHTSA Engineering Analysis #EA15001

    • Status:
      OPEN
    • Date Opened: February 24, 2015
    • Date Closed: Pending
    • Recall: possible recall

    Component(s): Air Bags
    Air Bags:Frontal

    Summary: The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016 four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016 four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The investigation now includes all manufacturers and vehicles known to be affected at this time.ODI's investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The five ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA15001 »

  2. Air Bag Inflator Rupture NHTSA Preliminary Evaluation #PE14016

    Component(s): Air Bags
    Air Bags:Frontal

    Summary: The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with consistently high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly, ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016, four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016, four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The PE is now closed/upgraded to an Engineering Evaluation (EA15-001) to include all manufacturersand vehicles known to be affected at this time.ODI's EA investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The recalls related to this PE are: 14V343, 14V344, 14V348, 14V351, 14V353, 14V655, 14V700, 14V701, 14V752, 14V763, 14V770, 14V773, 14V787, 14V802 and 14V817.The number of vehicles affected are an estimate since some vehicles may have both the driver and passenger side inflators recalled. The five ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE14016 »

  3. FRAME CORROSION NHTSA Preliminary Evaluation #PE09049

    Component(s): Fuel System, Gasoline
    Fuel System, Gasoline:Storage:Tank Assembly
    Fuel System, Gasoline:Storage:Tank Assembly:Mounting
    Service Brakes, Hydraulic
    Service Brakes, Hydraulic:Foundation Components:Differential Proportional Valve
    Service Brakes, Hydraulic:Foundation Components:Hoses, Lines/Piping, And Fittings
    Structure:Frame And Members
    Tires:Temporary/Emergency Spare Tire

    Summary: 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.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE09049 »

  4. LOWER BALL JOINT FAILURE NHTSA Engineering Analysis #EA06014

    Component(s): Suspension:Front:Control Arm:Lower Ball Joint

    Summary: 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.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA06014 »

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