2015 Hyundai Sonata Hybrid
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
Vehicles › Hyundai › Sonata Hybrid › 2015
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
These records cover every 2015 Hyundai Sonata Hybrid. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
4 recalls name the 2015 Hyundai Sonata Hybrid. Newest first.
Hyundai Motor America (Hyundai) is recalling certain 2011-2015 Elantra, Genesis Coupe, Sonata Hybrid, 2012-2015 Accent, Azera, Veloster, 2013-2015 Elantra Coupe, Santa Fe, 2014-2015 Equus, 2010-2012 Veracruz, 2010-2013 Tucson, 2015 Tucson Fuel Cell, and 2013 Santa Fe Sport vehicles. The Anti-Lock Brake System (ABS) module may leak brake fluid internally…
An engine compartment fire while parked or driving can increase the risk of injury.
Owners are advised to park outside and away from structures until the recall repair is complete. Dealers will replace the ABS fuse, free of charge. Owner notification letters were mailed April 10, 2024 through October 11, 2024. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 251.
Hyundai Motor America (Hyundai) is recalling certain 2011-2014 Sonata and 2011-2015 Sonata Hybrid vehicles previously repaired under recall campaign 17V-152. The seat belt linkages for both front seat belts may detach from the seat belt anchor pretensioners.
If the seat belt linkage detaches from the seat belt anchorage, it can not properly restrain the occupant in the event of a crash, increasing the risk of injury.
Hyundai will notify owners, and dealers will again verify the connection between the seat belt linkage and the pretensioner and additionally install a warning label to prevent future seat belt linkage detachment, free of charge. The recall began November 6, 2017. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 169.
Hyundai Motor America (Hyundai) is recalling certain 2011-2014 Sonata and 2011-2015 Sonata Hybrid vehicles. In the affected vehicles, the seat belt linkages for both front seat belts may detach from the seat belt anchor pretensioners.
In the event of a crash, if the seat belts detach from the anchor pretensioners, it can increase the risk of injury.
Hyundai will notify owners and dealers will inspect the connection between the seat belt linkages and the seat belt anchor pretensioners, repairing them as necessary, free of charge. The recall is expected to begin April 7, 2017. Owner's may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for the recall is 160.
Hyundai Motor America (Hyundai) is recalling certain model year 2015-2016 Sonata Hybrid vehicles manufactured December 8, 2014, to August 18, 2015, and Hyundai Sonata vehicles manufactured May 28, 2014, to March 18, 2016, equipped with the panoramic sunroof option. Due to a bonding issue with the sunroof wind deflector, the sunroof panel on the affected…
If the sunroof detaches from the vehicle it could become a road hazard, increasing the risk of a crash.
Hyundai will notify owners, and dealers will repair the wind deflector anchor plate, free of charge. The recall began December 2016. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 152.
Recently got the engine rebuilt (2024) and then it broke down on me yesterday with the engine light flashing and a warning sign stating pull over don’t drive
The contact owns a 2015 Hyundai Sonata. The contact stated that while driving approximately 65 MPH, the vehicle failed to properly accelerate. Later, while attempting to accelerate from a yield sign, the vehicle suddenly stalled. The vehicle was later towed to the local dealer to be diagnosed, and it was determined that the engine bearings had failed and the engine needed to be replaced. The manufacturer was notified of the failure. The failure mileage was 97,000.
The contact's sister-in-law owned a 2015 Hyundai Sonata Hybrid. The contact stated that while the vehicle owner was driving 55 MPH, the owner noticed smoke coming from under the hood. The owner parked and exited the vehicle, and while attempting to inspect the vehicle, the owner noticed flames coming from underneath the hood, and the fire extended to the cabin of the vehicle. The Fire Department extinguished the fire and informed the owner that the fire had gone through the firewall and entered the interior of the vehicle. The front seats of the vehicle were completely burned. The vehicle was towed to a local tow yard and was deemed a total loss. The vehicle was under liability insurance. A Police report was filed. The contact sustained back pain from riding in the police officers vehicle. Additionally, the contact stated that the dealer had repaired the vehicle for ABS failure two weeks prior to the incident. The dealer was notified of the fire incident but informed the contact that an inspection could not reveal the cause of the fire. The manufacturer was contacted by phone, and a case was filed. The failure mileage was approximately 98,000.
The Hybrid system kept crashing ! Triggering the auto theft and would not connect to fob , told it was immobilzer, and/or shortage in EV battery!!!
Component Involved: Hybrid Propulsion System High Voltage Battery / EV Battery Electrical System Power Train Incident Summary: I am reporting a serious and repeated safety defect involving my 2015 Hyundai Sonata Hybrid. This vehicle has experienced three separate incidents where warning messages related to the EV/hybrid battery system appeared, followed by a sudden loss of forward propulsion. During these events, the vehicle would not move properly or lost the ability to accelerate safely. This defect creates a major safety hazard because it can occur while driving, increasing the risk of being rear-ended, stranded in traffic, collision, injury, or property damage. I transport my small children in this vehicle and no longer feel it is safe. Detailed Timeline: Initial Incident: Vehicle displayed warning messages involving the EV/hybrid battery system and lost the ability to move forward properly. Vehicle had to be shut off and restarted. Independent Mechanic Inspection: Vehicle was inspected by an independent mechanic who advised the hybrid battery system likely needed repair or replacement and recommended service through Hyundai dealership. Dealer Visit #1 – Stew Hansen Hyundai (3/18/2026): Vehicle was taken to authorized Hyundai dealer for diagnosis. Dealer stated they could not duplicate the issue and no repair was made. Second Failure: After release from dealer, same dangerous loss-of-power condition occurred again, resulting in towing and additional inconvenience. Dealer Visit #2 – Stew Hansen Hyundai (4/8/2026): Vehicle returned to dealer for same issue. Dealer performed software update and stated this should correct problem. Dealer advised vehicle had been driven approximately 40 miles and was safe to release. Third Failure (4/12/2026 approx.): Only two days after picking vehicle up on 4/10/2026, same warning messages and propulsion failure occurred again. Safety Concern: This repeated loss of propulsion without warning is extremely dangerous.
Idle and warning to not drive, 2025 very subtle cut off now full warning
We pulled up at Hillgreen circle Cockysville MD To drop my boyfriend off at his apartment. I went to pull in the parking spot.I went to put the car into park and it had no brakes. I was slamming them and pumping them. It excellerated and took off. Jumped the curb,went down the hill and into the apartment building. A red light had came on the dash, right before it took off. Seemed like it was changing to gas or the electric mode,or the other way around. The airbag on the passenger side came out deflated,and filled with smoke going into the car. He was the belted front passenger and his elbow went in to the front window. You can tell by looking at it,the hole and spidered around it. He broke his right elbow. It is available anytime at the moment. It's at Hyundaii in Glen burnie. I need to get it to state farms lot,to get the Kelly blue book value. We look forward to hearing from you
The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated that while driving 5 MPH and making a left turn, the vehicle made an abnormal knocking sound. The contact stated that upon pulling into an apartment complex parking lot, the contact noticed that there was smoke coming out from underneath the hood. There was no warning light illuminated. The contact immediately parked and exited the vehicle. The contact stated that upon opening the hood, the contact noticed a small fire and was able to extinguish the fire with a water bottle. The contact was able to push the vehicle into a parking space with the assistance of her son. There was no injury sustained. No police report was filed. The vehicle was towed to an independent mechanic, where it was diagnosed that a fluid leak from an unknown hose had caused the fire, and there was a hole in the engine block. The contact also stated that there was a puddle of fluid on the ground. The vehicle was not repaired. The contact became aware that the VIN was included in NHTSA Campaign Number: 23V651000(Service Brakes, Hydraulic), which the contact related to the failure. The dealer and the manufacturer were not notified of the failure. The failure mileage was approximately 115,395.
The contact owns a 2015 Hyundai Sonata Hybrid. The contact took the vehicle to the dealer to be repaired under NHTSA Campaign Number: 23V651000 (Service Brakes, Hydraulic) and Manufacturer recalls: 964 (Auxiliary Canister Installation), 966 (Engine Monitoring Module, ECU Software Update), and 994 (Hybrid Safety Fuse). The contact stated that after the repairs were completed while attempting to start the vehicle at the dealer, the vehicle failed to start. The vehicle remained at the dealer who was unable to determine the cause of the failure. The vehicle had not been repaired. The manufacturer was made aware of the failure and confirmed that the vehicle was not covered under warranty for any further repairs. The failure mileage was 170,000.
The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated while driving at various speeds, a message advising to pull over and to park the vehicle was displayed. The vehicle was taken to the dealer for diagnostic testing several times. The dealer replaced the HECU and the battery inverter assembly; however, the failure persisted. Additionally, the contact stated that while his son was driving at an undisclosed speed, the contact's son noticed that there was white smoke coming from the rear middle seat of the vehicle. An unknown warning light was illuminated. The contact's son pulled to the side of the road and turned off the vehicle. The vehicle failed to restart and was towed to the dealer, where it was diagnosed that the hybrid battery pack had failed, causing the hybrid battery to melt. The dealer determined that the hybrid battery pack needed to be replaced. The vehicle was not repaired. The contact related the failure to Hyundai Campaign Number: 994. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 37,000.
The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated while driving 45 MPH, the vehicle started overheating, and smelled an abnormal electrical burning odor inside the cabin. Several unknown warning lights were illuminated. The contact veered to the side of the road, turned off the vehicle and inspected under the hood. The contact stated that the vehicle failed to restart and was towed to the residence. The contact received notification of NHTSA Campaign Number: 23V651000 (Service Brakes, Hydraulic) which he related to the failure. The dealer was notified of the failure. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was unknown.
The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated that while driving at an undisclosed speed, the message "Turn off the Engine Immediately" was displayed. Several unknown warning lights were illuminated. The vehicle was taken to the dealer, who was unable to duplicate the failure. The vehicle was not repaired. Later, the contact stated that while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The contact was able to pull to the shoulder of the roadway, where the vehicle failed to restart with several unknown warning lights illuminated. The vehicle was towed back to the dealer, who then diagnosed failures with the ABS and transmission. The vehicle was repaired, but the failure reoccurred. The manufacturer was notified of the failure but provided no assistance. The failure mileage was unknown.
The contact owns a 2015 Hyundai Sonata Hybrid. The contact received notification of NHTSA Campaign Number: 23V651000 (Service Brakes, Hydraulic) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The dealer was made aware of the issue. The manufacturer was made aware of the issue and confirmed that parts were not yet available. The contact had not experienced a failure. VIN tool confirms parts not available. A person stated the wrong email address is listed, never filed a complaint.
The contact owns a 2015 Hyundai Sonata Hybrid. The contact received notification of NHTSA Campaign Number: 23V651000 (Service Brakes, Hydraulic) however, the part to do the recall repair was not yet available. The local dealer was made aware of the issue and confirmed that parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.
The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated that while driving at an undisclosed speed, several unknown warning lights were illuminated. The contact stated that while depressing the brake pedal, the brake pedal went to the floorboard. The contact stated that the warning light to turn off the vehicle was illuminated. The contact turned the vehicle off and the vehicle failed to restart. The vehicle was towed to the dealer; however, the dealer refused to service the vehicle. The vehicle was then towed to the residence. The vehicle was towed to another Hyundai dealer where the vehicle was diagnosed with a failed transmission and battery. The contact was informed that the transmission and battery needed to be replaced. The vehicle was repaired. The contact stated while driving away from the dealer, she heard an unusual knocking sound coming from the engine compartment. The vehicle was taken back to the dealer. The service technician accompanied the contact for a test drive and confirmed the knocking coming from the engine compartment. The contact was informed that the new transmission that was installed was defective, and the transmission needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 74,680.
The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated while stopped in traffic, the vehicle independently jolted with a message indicating a Hybrid System safety failure. Additionally, there was a message to stop driving the vehicle with an alarm sounding. The contact veered to the side of the road. The contact was able to continue driving. The contact received notification of NHTSA Campaign Number: 23V651000 (Service Brakes, Hydraulic) the following day; however, the part to do the recall repair was not yet available. The contact stated that the failure recurred while driving. The contact veered to the side of the road. The vehicle was then taken to an independent mechanic, where it was test-driven; however, the mechanic was unable to duplicate the failure. The local dealer was contacted and informed the contact that the earliest availability was on December 23, 2023. The vehicle was not diagnosed or repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the failure. The failure mileage was approximately 97,500. VIN tool confirms parts not available.
The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated while driving approximately 60 - 65 MPH, the battery warning light illuminated. The charging system failure message was displayed. The vehicle was taken to the local dealer where it was diagnosed and determined that the system needed to be reprogramed. The vehicle was repaired; however, the failure persisted. While driving at an undisclosed speed, the check engine warning light illuminated, and the vehicle stalled. The vehicle was taken to an unknown local dealer, but the vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 75,000.
The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated while driving 45 MPH, there was a message that the vehicle was not safe to drive displayed on the instrument panel. The check engine warning light was illuminated. The contact stated that the vehicle began to stall; however, while depressing the accelerator pedal, the vehicle failed to accelerate. The vehicle was not drivable. The contact towed the vehicle to the local dealer, where it was diagnosed with needing both batteries to be replaced. The vehicle was repaired but continued to experience the failure. The contact took the vehicle to a second local dealer: Interstate Hyundai (609 Constitution Dr, West Monroe, LA 71292, (318) 387-2667) where it was diagnosed with needing both Manufacturer Communications 964 & 966 to be completed. The dealer completed manufacturer repairs, but the vehicle continued to experience the failure. The manufacturer had not been informed of the failure. The failure mileage was approximately 95,000.
The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated that the check engine warning light was illuminated. The vehicle was taken to an independent mechanic who replaced the fuel cap and performed other tests on the engine. The check engine warning light disappeared however, two weeks later the warning light returned. The dealer was contacted and a message was left. The manufacturer was not contacted. The failure mileage was 134,298.
The contact owns a 2015 Hyundai Sonata Hybrid. The contact stated while driving 20 mph, the vehicle loss motive power and the check charging system warning light illuminated before the vehicle stalled. The contact was able to coast and move the vehicle to the side of the roadway and waited for several minutes and restarted the vehicle. The contact continued to drive to his destination. The failure recurred several times. The local dealer was contacted and informed of the failure. The contact was informed that since the vehicle was experiencing the failure intermittently, the vehicle could not be diagnosed until the failure occurred and the vehicle was taken in with while the failure was happening. The vehicle was not diagnosed nor repaired. The manufacturer was made aware of the failure. The failure mileage was 29,000.
TL* the contact owns a 2015 hyundai sonata hybrid. The contact stated that while driving at various speeds, with the air conditioner activated and making a turn, the vehicle hesitated and loss power. There was no warning light illuminated. The contact called headquarter hyundai (985 rinehart rd, sanford, fl 32771, (407)292-0000) however, the vehicle was not diagnosed nor repaired. The manufacturer was notified of the failure. The failure mileage was approximately 110,000.
TL* the contact owns a 2015 hyundai sonata hybrid. The contact stated that while driving at 55 mph, the vehicle stalled as the "hybrid system warning, safely stop and do not drive" warning message appeared on the instrument panel. Due to the failure, the vehicle behind her attempted to avoid hitting her; however, the vehicle behind that vehicle collided into his which caused an accident. The contact was then forced to restart the vehicle in the middle of traffic and was able to resume normal driving. The contact then took the vehicle to bud clary auburn hyundai (2807 auburn way n, auburn, wa 98002) where they were unable to duplicate the failure. She also took the vehicle to an independent mechanic who was also unable to duplicate the failure also. The contact stated that the failure had occurred twice since the initial failure. The manufacturer had yet to be notified of the failure. The vehicle had yet to be repaired. The failure mileage was 152,000.
TL* the contact owns a 2015 hyundai sonata hybrid. The contact stated that the vehicle shut down several times without warning while driving various speeds. The contact was uncertain as to what caused the failure, but felt it may be related to tsb number: 06-01-004-1. Keffer hyundai (9010 e independence blvd, matthews, nc 28105, (704) 247-5645) was made aware of the failure and planned to schedule a diagnostic appointment. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was not available.
TL* the contact owns a 2015 hyundai sonata hybrid. While driving various speeds and attempting to brake, the vehicle accelerated. The contact depressed the brake pedal multiple times and was able to stop the vehicle. There was no warning indicator illuminated. In addition, the vehicle intermittently failed to accelerate when the accelerator pedal was depressed. The failures recurred several times. The vehicle was taken to jim click mazda auto mall (877-888-2760, located at 700 w auto mall dr, tucson, az 85705), but the failures could not be diagnosed or duplicated. The manufacturer was not made aware of the failures. The vehicle was not repaired. The failure mileage was not provided.
TL* the contact owns a 2015 hyundai sonata hybrid. While driving 20 mph, the front passenger side coil spring fractured and exited through the front passenger tire. There were no warning indicators illuminated. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and stated that the vehicle was not covered under warranty. Case number: 15697010 was provided and the contact was referred to a dealer. The contact stated that the failure was similar to nhtsa campaign number: 15v629000 (suspension). The failure mileage was 69,000.
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.
NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.
The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing. There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect. During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW. The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications. The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU. In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment. FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle. Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW. These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes. An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time. In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU. This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners. Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW. The risk associated with the ASIC is equally shared among all OEMS involved in the investigation. The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage. There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation. The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU. If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC. Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC. All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled. In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024. With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.