Tag Archives: manufacturing error

2021-2022 Toyota Sequoia and 2021 Toyota Tundra Power Steering Leak

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Toyota will be contacting the owners of certain 2021-2022 Sequoia and 2021 Tundra trucks because of a problem affecting the power steering gear assembly. Owner notification letters are expected to be sent out on January 22, 2022.

In late September 2021, Toyota observed an increase in field reports and warranty claims affecting the power steering in certain 2021-2022 Sequoia and 2021 Tundra trucks. A high percentage of these vehicles experienced power steering fluid leaks, all from the area of the power steering gear assembly. Manufacturing records showed that these reports mainly involved vehicles produced during the months of August and September 2021. Toyota began recovering additional parts involved in these reports and sent them to the supplier for inspection.

These inspections found that the circlip holding the oil seal and end stopper in position at the end of the power steering rack housing was disengaged from the groove machined in the rack housing and that the oil seal and the end stopper were moved from the correct position. Further investigation of the returned parts revealed that the groove where the circlip is installed was improperly machined leading to an incorrect groove shape.

Based on these findings, the supplier investigated their production process and identified that one of the four pieces of equipment used to machine the groove in the rack housing was not creating a groove of the correct shape. The tool was inspected, it was found that certain teeth on the cutting tool, which creates the groove in the rack housing, were damaged. Based on these results Toyota has decided to conduct a safety recall campaign.

Owners of the affected vehicles will be notified to return to their Toyota dealer to have the power steering gear assembly inspected and replaced if necessary. Toyota’s numbers for this recall are 21TB10 and 21TA10, and the NHTSA campaign number is 21V-920.

Jeep Cherokee And Wagoneer Air Bags Disabled With No Warning

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During a configuration review at the supplier for an unrelated manufacturing issue, FCA US LLC Product Engineering became aware of an error with an airbag squib driver circuit that identified three internal faults not mapped to a diagnostic trouble code (DTC). An investigation was opened and it was discovered that some 2021 Jeep Grand Cherokee, 2022 Jeep Wagoneer, and 2022 Jeep Grand Wagoneer vehicles may not set a DTC, and the airbag warning indicator may not illuminate.

The problem started in February 2021, when occupant restraint controllers (ORCs) with an incorrect software version were introduced into vehicle production, through to November 1, 2021, when the suspect ORCs were no longer used in vehicle production. Vehicle and supplier production records were used to determine the vehicles included in the recall population.

According to the defect report, “If specific ORC internal faults are active then a DTC will not be set and the airbag warning indicator may not illuminate. The internal faults will disable deployment of both the driver and passenger airbag squib 3 (related to airbag venting post-deployment) and knee airbags. The airbag warning indicator may not illuminate to notify the driver of possible compromised airbag system functionality. Reduced occupant protection in the event of a crash may result in an increased risk of injury to motor vehicle occupants.”

Owners receiving notices will be asked to return to their FCA dealers to have the occupant restraint controller reprogrammed with the correct software version that maps subject internal faults to a DTC. FCA US, LLC’s number for this recall is Y79 and the NHTSA campaign number is 21V-873.

If you purchased or leased a defective vehicle in California, it has turned out to be a lemon, and you need help to get rid of it, just fill out the above contact form or call us now at 1-888-395-3666 for a free case evaluation.

Mazda Engine Stall From Fuel Pump Failure

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Mazda is recalling certain 2018-2020 vehicles because the impeller inside the low-pressure fuel pump may crack and deform, potentially causing the fuel pump to fail.

In March 2019 Mazda received the first field report of an engine stall due to an inoperative fuel pump. A study of the pump showed that cracking on the impeller surface made the impeller more likely to deform. Further investigation found that solvent used during the manufacturing process and low-density impellers may be factors causing impeller cracking. During the test, the surface of the impeller cracked as the solvent dried over time. It was confirmed that fuel pumps produced with impellers of lower density exposed to production drying solvent for longer periods of time could experience the impeller cracking at a level that could lead to excessive fuel absorption, and could cause impeller deformation.

The Vehicles Affected Include:
2019 Mazda CX-3
2018-2019 Mazda CX-5
2018-2019 Mazda CX-9
2019-2020 Mazda Mazda2
2018 Mazda Mazda3
2018 Mazda Mazda6
2018-2019 Mazda MX-5

Fuel pump failure may result in engine no start and/or vehicle stall while driving at low speed and, in rare instances, a vehicle stall could occur while driving at higher speeds, increasing the risk of a crash. Drivers may notice this defect by a check engine light, and/or rough engine operation.

Mazda will be contacting owners of affected vehicles with instructions to return to their dealers to have the fuel pump replaced. Mazda’s number for this recall is 5321K and the NHTSA campaign number is 21V-875.

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.

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.

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.