Porsche 911 Investigations

6 ODI actions on file.

• EAEA21002OPENOpened 9/17/2021
  Desiccated Air Bag Inflator Rupture
  AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

  From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

• PEPE13009CLOSEDOpened 4/26/2013
  Rapid coolant loss
  ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS

  On April 26, 2013, the Office of Defects Investigation (ODI) opened PE13-009 to investigate 10 complaints alleging incidents of sudden coolant loss while traveling on public roadways in certain model year (MY) 2001 through 2007 Porsche 911 vehicles.The complaints alleged that pipe ends joined by epoxy to certain cooling system components may fail suddenly and separate, resulting in large volumes of coolant leakage.The investigation was opened to assess evidence of a design or manufacturing defect in the coolant pipe fittings and any related safety consequences. In response to ODI?s Information Request letter, Porsche identified a manufacturing quality issue with the supplier?s application of adhesive to coolant pipe fittings that resulted in elevated failure rates in approximately 6,800 early production 997 generation vehicles (MY 2007 and early MY 2008).ODI?s analysis of field data showed that the age-adjusted failure rate for these vehicles was approximately six times greater than MY 2001 through 2005 996 generation vehicles and MY 2008 through 2011 997 generation vehicles built after a process improvement for adhesive application was implemented by the supplier.Most of the leak complaints reviewed by ODI did not appear to involve complete separation of the fittings and many were detected when the vehicle was parked.There were no crashes or injuries reported to be related to the alleged defect in any of the subject vehicles.ODI identified two allegations that coolant leakage resulted in loss of control incidents, but neither involved vehicles affected by the assembly process quality issue.A third loss of control allegation involving a vehicle built during the period affected by the supplier process concern is not counted since ODI was unable to contact the owner to confirm the incident.See the full closing resume in the document file for PE13-009 for additional information about the subject cooling system and ODI?s analysis of field data related to the alleged defect. A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.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.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.

• PEPE01031CLOSEDOpened 8/30/2001
  WIRING HARNESS
  ELECTRICAL SYSTEM
• RQRQ98017RECALLOpened 10/6/1998
  INADVERTENT DRIVER'S SID AIR BAG
  AIR BAGS:FRONTAL

  THE DRIVER'S SIDE AIR BAG REPORTEDLY CAN DEPLOY INADVERTENTLY WHILE BEING DRIVEN.

• EAEA96002CLOSEDOpened 3/29/1996
  ALLEGED WHEEL FAILURE
  WHEELS

  ALLEGED WHEEL FAILURES WHEN RUNNING OVER NORMAL ROAD HAZARD.

• DPDP95006CLOSEDOpened 10/6/1995
  ALLEGED DEFECTIVE WHEELS
  WHEELS

  ALLEGED DEFECTIVE WHEELS