2006 Toyota
COROLLA MATRIXProblems & recalls

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.

On August 26, 2010, Toyota submitted a Defect Information Report to the National Highway Traffic Safety Administration (NHTSA) regarding problems with Engine Control Modules that could result in engine stall while driving in certain model year (MY) 2005 through 2008 Toyota Corolla, Corolla Matrix and Pontiac Vibe vehicles equipped with the 1ZZ-FE engine and two-wheel drive and manufactured between April 19, 2004 and January 2, 2008.Toyota's report indicated that cracks may develop at certain solder point or on varistors on the ECMs.According to Toyota, such cracks generally resulted in engine warning lamp illumination, harsh shifting or engine no-start.In some cases, if the cracking occurs on particular solder points or varistors, the engine could stop while the vehicle is being driven.Toyota will notify owners of subject vehicles that they should return their vehicles to a Toyota or Pontiac dealer.Dealers will be instructed to inspect the production number of the ECM for each vehicle and replace the ECM if necessary.On November 30, 2009, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE09-054) to investigate alleged engine stall while driving in model year (MY) 2006 Toyota Corolla and Corolla Matrix vehicles.In its response to ODI's information request, submitted on March 2, 2010, Toyota indicated that it had identified two possible conditions with ECMs used in MY 2005 through 2007 Toyota Corolla and Matrix vehicles:1) cracks forming between the IC and the board caused by an improperly cured conformal coating applied to the circuit boards after the soldering process is completed; and 2) cracks occurring in a variable resistor (varistor) due to overheating.During the manufacturing process a glass coating is created on the surface of the varistor.Between March and August 2010, Toyota began collecting ECMs from the field to further investigate failure modes that may result in engine stall.Toyota also conducted durability testing on ECMs collected from in-use vehicles to assess whether the problems may be a continuing trend. In addition, they conducted durability testing in order to assess whether this problem was a continuing trend.Toyota found that 4 of 32 collected ECMs malfunctioned after thermal shock testing.Toyota also confirmed that cracking could develop at solder points on the ECM circuit board that could lead to engine stall while driving and that this trend was likely to continue.The manufacturer failure data in this resume is limited to MY 2005 through 2007 Toyota Corolla and Corolla Matrix vehicles.Based on Toyota's recall, this Engineering analysis has been closed.

Recorded closure: Sep 16, 2010

Campaign reference in the source: 10V387000

On November 30, 2009, the Office of Defects Investigation (ODI) opened a preliminary evaluation (PE09-054) to investigate alleged engine stalling, while driving in model year (MY) 2006 Toyota Corolla and Corolla Matrix vehicles .In its response to ODI's information request submitted on March 2, 2010, Toyota indicated that it had identified two possible causes of production defects of the engine control units (ECU) used in the MY 2005 through 2007 Corolla and Matrix vehicles equipped with the 1ZZ-FE engine.Failure mode A1 - BGA ball failure caused by improperly cured conformal coating applied to ECU circuit boards. This can cause cracks to form in the soldered joints of some components. Failure mode A2 - Varistor over heating; a glass coating is created on the surface of the Varistor during its production process.In case of an insufficient coating, a crack can occur in the surface of the glass coating. When ions are charged in the plating electrolytes after the glass coating process, the plating electrolytes can penetrate into the Varistor through the glass crack then an electrical short occurs. With respect to these failures, if the condition arises, it can potentially lead to one or more of the following: MIL on, engine stall or engine no start, harsh shifting.Of the approximately 155,000 warranty and extended warranty claims Toyota has analyzedthe projected 5 year failure rate of the ECU associated with an engine stall is 0.8%. This investigation has been upgraded to an Engineering Analysis (EA10-006) to further assess the scope, frequency and safety risks associated with the identified defects.

Recorded closure: Aug 19, 2010

Campaign reference in the source: 10V387000