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NHTSA probes faulty airbag inflators in 49 million vehicles amid possible recall looming

The National Highway Traffic Safety Administration (NHTSA) is currently investigating defective airbag inflators in approximately 49 million cars from 13 manufacturers. These inflators have been linked to at least seven injuries and two deaths in the United States and Canada since 2009. The issue stems from the inflators‘ tendency to explode and hurl shrapnel into drivers and passengers, posing a serious safety risk.

NHTSA reported that seven inflators have ruptured in the U.S. field, showing signs of insufficient welds or excessive pressure in the canister designed to contain the explosion. Additionally, 23 inflators have ruptured during testing, with causes similar to those that failed in real-world conditions. Four inflators have also ruptured outside the U.S., resulting in at least one fatality. This alarming trend has prompted NHTSA to take action to address the issue.

The agency has highlighted that while most inflators may not rupture upon deployment, the evidence suggests that all ARC-designed inflators are at risk due to the same friction welding process. Despite this, multiple automakers have argued that NHTSA has not definitively established a safety defect, as no ruptures have been reported in millions of inflators within their vehicles. This disagreement has led to a standoff between regulators and manufacturers.

NHTSA maintains that the only way to determine which inflators will fail is during a crash, which poses an unacceptable risk under federal motor vehicle safety laws. The agency plans to take public comments for 30 days before deciding whether to pursue a massive recall. If necessary, NHTSA may pursue legal action against ARC if the company refuses to comply with a recall.

Regulators had previously requested ARC to recall the inflators in May 2023, but the company declined, leading to the current standoff. A public hearing held last October indicated NHTSA’s readiness to seek a recall due to a manufacturing flaw causing metal shrapnel to project through a car’s interior during airbag deployment. The core issue lies in the metal inflator canister within the airbag device, with welding byproducts potentially clogging a vent and causing pressure to build until the canister explodes.

Injuries from such incidents can be severe, posing an unreasonable risk of serious injury or death. However, ARC and many automakers oppose a recall, citing the infrequency of the problem and disputing NHTSA’s defect determination. For example, Fiat Chrysler Automobiles (FCA) noted no inflator ruptures in its vehicles, aligning with NHTSA’s defect theory despite having 4.9 million older cars with ARC inflators.

Vehicles from BMW, Ford, General Motors, Hyundai, Jaguar-Land Rover, Kia, Maserati, Mercedes-Benz, Porsche, Tesla, Toyota, and Volkswagen also contain ARC or Delphi-made inflators. Delphi manufactured about 11 million inflators under license from ARC, though a complete list of affected vehicles has not been released. The ongoing investigation and potential recall highlight the importance of addressing safety concerns in automotive components to protect drivers and passengers on the road.

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