Category Archives: Lemon Alert

Toyota Tundra Headlight Electrical Connector Could Overheat

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Toyota will be asking owners of certain 2018-2021 Tundra trucks, to return to their dealership for a problem affecting the electrical circuits controlling the headlights in their vehicle.

The problem began in early April 2020 when Toyota received a field report alleging the headlamp connector on a subject vehicle overheated and caught fire. Since then, there have been 18 Toyota Field Technical Reports (12 alleging an inoperative headlamp and/or damage to the headlamp connector (e.g., connectors melting), but no apparent flame, and 6 alleging a flame at the headlamp assembly). There has also been 47 warranty claims (44 alleging an inoperative headlamp and/or damage to the headlamp connector (e.g., connectors melting), but no apparent flame, and 3 alleging a flame at the headlamp assembly).

According to the defect report, the subject vehicles are equipped with halogen headlamp electrical circuits that were designed incorrectly to allow the circuits for both the high and low beam bulb filaments to be energized simultaneously when the high beams are switched on. If the high beams are subjected to repeated extended use (e.g., continuously switched “on” in a commercial setting when the vehicle is idling or driving at low speed for extended periods of time and not allowing air flow to cool the headlamp connector), excess heat could lead to degradation of the bulb insulation and eventually the bulb connector. This can cause an open headlamp circuit, leading to an inoperative headlamp that can be noticed by the driver and repaired. However, if an open circuit does not occur, there is a possibility that the connector could continue to overheat, resulting in an increased risk of a fire.

Owners receiving notices will be asked to return to their dealers to have the engine wire harness assembly and headlight assembly inspected and replaced as necessary. Toyota’s numbers for this recall are 21TB06 and 21TA06 and the NHTSA campaign number is 21V-688.

Tesla Autopilot / Traffic Aware Cruise Control Investigation Into Crashes

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The Office of Defects Investigation of the National Highway Traffic Safety Administration (NHTSA) have opened an investigation (PE21-020) into crashes involving first responder scenes and vehicles manufactured by Tesla. The vehicles involved were operating in either Autopilot or Traffic Aware Cruise Control prior to the accident.

The Vehicles Affected Include:
2017-2021 Tesla Model 3
2014-2021 Tesla Model S
2015-2021 Tesla Model X
2019-2021 Tesla Model Y

Since January 2018, the NHTSA has identified twelve crashes in which Tesla models of various configurations, encountered first responder scenes and preceded to crash into one or more vehicles involved with those scenes. Most incidents took place after dark and included traffic control measures such as first responder vehicle lights, flares, an illuminated arrow board and road cones. The involved vehicles were all engaged in either Autopilot or Traffic Aware Cruise Control during the approach to the crashes.

Autopilot is an Advanced Driver Assistance System (ADAS) in which the vehicle maintains its speed and lane centring. With the ADAS active, the driver still holds primary responsibility for Object and Event Detection and Response (OEDR), e.g., identification of obstacles in the roadway or adverse maneuvers by other vehicles during the Dynamic Driving Task (DDT).

The NHTSA have opened a Preliminary Evaluation of the SAE Level 2 ADAS system (Autopilot) in the Tesla 3, S, X, and Y models. The investigation will evaluate the methods used to monitor, assist, and enforce the driver’s engagement with the dynamic driving task during Autopilot operation. The investigation will also assess the OEDR by vehicles when engaged in Autopilot mode and ODD in which the Autopilot mode is functional. The investigation will also include examination of the contributing circumstances for the confirmed crashes listed below and other similar crashes.

2021 Subaru Impreza Suspension Problem Could Lead To Loss Of Vehicle Control

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Subaru of America have decided that a defect could exist in the suspension of certain 2021 Subaru Impreza vehicles. Owners are advised to NOT drive their vehicle until the repair can be completed.

In June 2021 Subaru opened an investigation into the 2021 Impreza, after receiving a field report of a partially separated lower control arm. In August a second field report was issued with a similar condition as the previous report. The vehicle production dates were two (2) days apart and the LOT number stamped on the control arm were the same. As a result of the joint investigation with the supplier, 75 left front lower control arms containing a specific LOT number were identified as potentially containing an improper weld. An improper weld in this location could lead to a partial separation of the lower control arm from the cross member. If this partial separation occurs, the tire could contact the wheel well structure and the driver could lose control of the vehicle.

Description of the Cause: Equipment on the control arm assembly line was damaged, resulting in contact between the part ejector rod and the welding torch. This interference caused the welding torch to be unable to trace the proper welding path and resulted in an incomplete weld at the joint.

For all of the potentially affected vehicles, Subaru dealers will inspect the LOT number stamped on the left front lower control arm. If the control arm contains a specific LOT number, the part will be replaced. Until the inspection/remedy is completed, customers will be instructed not to drive their vehicle and to make arrangements with their Subaru dealer to have the vehicle inspected. Subaru’s number for this recall is WRI-21 and the NHTSA campaign number is 21V-675.

2021 Ford F-150 Super Cab Seatbelts Routed Incorrectly

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In May 2021, Ford’s Critical Concern Review Group (CCRG) was informed of a warranty report affecting the seatbelts in a 2021 Ford F-150 Super Cab truck. According to the report, the front passenger outboard seatbelt webbing was routed through only the rubber trim sleeve, and not properly routed through both the sleeve and anchor eyelet. A misrouted seatbelt may not adequately restrain an occupant during a crash and could increase the risk of injury.

In July, another potentially related warranty report was identified during Ford’s ongoing monitoring process. The dealer forwarded photos of the suspect assembly showing that the seatbelt was routed through the anchor’s rubber sleeve cover but not through the anchor attachment, similar to the prior report. Ford is not aware of any reports of accident or injury related to this condition, but have approved a field action for vehicles produced between January 1, 2021 and May 27, 2021.

Owners will be notified by mail with instructions on how to perform a preliminary self-assessment of the vehicle’s seatbelts. Performing this procedure does not replace the need for an inspection by a Ford technician.

If the customer is uncomfortable with the self-assessment procedure or uncertain of the results, they will be instructed to not drive their vehicle and make arrangements with their Ford or Lincoln dealer to have vehicle towed for inspection.

If the customer does not detect a suspect seatbelt, they will still be instructed to take their vehicle to a Ford or Lincoln dealer to be inspected.

If the customer detects a suspect front passenger seatbelt, they will be instructed to not use the seating position and to take their vehicle to a Ford or Lincoln dealer to be inspected.

If the customer detects a suspect driver seatbelt, they will be instructed to not drive their vehicle and make arrangements with their Ford or Lincoln dealer to have vehicle towed for inspection.

The dealer will inspect the front row outboard seatbelts to verify the belt is routed correctly through the anchor’s metal eyelet and anchored to the pretensioner assembly. Should the inspection fail, the dealer will replace the affected seatbelt retractor and pretensioner assembly. Ford’s number for this recall is 21C20 an d the NHTSA campaign number is 21V-653.

Chevy Bolt Battery Fire Recall Expansion

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This is an expansion of NHTSA Recall 20V-701 and 21V-560.

General Motors has decided that a defect which relates to motor vehicle safety exists in 2020-2022 Chevrolet Bolt EVs and 2022 Chevrolet Bolt EUVs. The high voltage batteries in these vehicles may pose a fire risk when charged to full, or very close to full, capacity.

Defective battery modules will be replaced, but until then, GM advises owners to Activate either the Hill Top Reserve (2017 and 2018 models) or Target Charge Level (2019 models) feature in their vehicle to limit the charge level to 90%, charge their vehicle more frequently, avoid depleting the battery to 70 miles range remaining, park outside after charging, and do not charge the vehicle indoors overnight.

Interim notification letters notifying owners of the safety risk were mailed on August 13, 2021. Owner notification letters were mailed on August 13, 2021. GM’s number for this recall is N212343880 and the latest NHTSA campaign number is 21V-650.

Chevrolet Malibu And Cadillac XT4
Rear Seat Rattle

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In March 2021, a safety report was submitted to GM’s Speak Up for Safety program regarding a warranty claim affecting the seat belt on a low mileage 2021 Cadillac XT4. The customer’s complaints included a rattling noise coming from the passenger side rear seat belt. The rattle could be heard while driving or when attempting to use the seat belt. The dealer determined that the noise was caused by a missing lower fastener in the retractor assembly. A search for similar allegations discovered three additional potentially related claims also involving XT4 vehicles. In each case, the complaint was a rattling noise that was determined to be caused by a loose or missing fastener in a rear seat belt retractor.

An investigation also revealed that 2016-2021 Chevrolet Malibu vehicles were assembled at the same place using the same right-hand rear side assembly process and added these vehicles to the investigation. Data for the entire population of approximately 1.4 million 2019-2021 XT4 and 2016-2021 Malibu vehicles produced at Fairfax found no additional related claims.

Investigator analysis of the repair procedure determined that the procedure could have been the cause of the loose or missing fasteners under a specific set of circumstances that was unlikely to occur, but possible. The investigator retrieved plant manufacturing records to determine whether other vehicles were subject to similar repairs. Those records identified 437 such vehicles out of the total population. Testing was also conducted that determined it was possible for the condition to be present with the absence of warning noises, even though each of the three relevant field reports did describe audible warning signs.

Although no additional related claims were found, GM have decided to conduct a recall.

According to the defect report, GM will be recalling certain 2016-2021 Chevrolet Malibu and 2019-2021 Cadillac XT4 vehicles manufactured at their Fairfax plant. Dealers will inspect the rear seat belt retractors and tighten them as necessary. GM’s number for this recall is N212333380 and the NHTSA campaign number is 21V-649.

2022 Volkswagen Taos Stalls When Coming To A Stop

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In June 2021 Volkswagen started an investigation into certain Taos compact SUVs after reviving field complaints of stalling when coming to a stop. The vehicles affected by this defect are equipped with all wheel drive powertrains.

According to the defect report, some 2022 VW Taos with all wheel drive powertrains and a specific software version installed in the engine control unit, could experience a stalling condition when coming to a stop. Conditions such as high ambient temperatures, high engine loads and a running air conditioner increases the chance of an engine stall. The cause for stalling is currently under investigation.

To correct the problem, Taos owners with affected vehicles will be asked to return to their dealers to have the ECU software updated. Owner notification letters are expected to be mailed October 2021. Volkswagen’s number for this recall is 24HH and the NHTSA campaign number is 21V-615.

2021 Ford F-150 Reduced Brake Performance

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A small number of 2021 Ford F-150 trucks could experience an electronic brake booster leak. The leak could result in brake fluid entering the electronic control unit (ECU), causing longer break pedal travel, higher pedal effort and reduced braking.

In May 2021, Ford’s Critical Concern Review Group reviewed three F-150 truck warranty claims where brake fluid from the electronic brake booster leaked into the ECU. Ford’s review of supplier records found that the supplier had identified 169 2021 model year F-150 brake booster assemblies in December 2020 because they were potentially assembled with a broken clinching tool, used to secure the pressure sensor to the booster housing. Further review of supplier and Ford records determined that 51 of the 169 quarantined parts were inadvertently shipped to Ford’s Dearborn Truck Plant and assembled into vehicles, all of which were shipped to dealers in the U.S.

Engineering analysis found that a brake booster with an incomplete clinch between the pressure sensor and the brake booster housing can cause brake fluid to leak through the pressure sensor into the ECU. This can reduce braking effectiveness of the brake circuits.

Those receiving notifications will be asked to return to their dealerships to have the ECU replaced. Ford’s number for this recall is 21S33 and the NHTSA campaign number is 21V-533.