Apparently, the quality control programs in place at the air bag supplier were not good enough to catch these defects during the air bag inflator manufacturing process.

One interesting aspect of this air bag safety recall is that Subaru first received notification about this problem back on October 1, 2009, about 9 months before announcing this recall.  Apparently, internal grease within the steering wheel roll connector (sometimes called a clockspring) can chemically degrade the internal flat ribbon which is used to carry electrical current to several steering wheel-mounted devices, including the driver air bag.

The safety recall is expected to begin on or before July 1, 2010. 10V-283. Subaru has internally designated this recall with the number WVR-28.

Honda’s supplier informed Honda on March 24, 2010 of the fact that the dashboard covers were not properly scored during manufacturing. Then, about two weeks later, Honda determined that this was a safety defect and notified the government by letter dated April 9, 2010. The improperly manufactured dashboards (instrument panels) did not receive laser cuts on the underside of the cover at the passenger side air bag. Without those laser cuts, both the timing of the passenger air bag deployment and its force level are affected. The problem was so serious that Honda issued a “Stop Order” to its dealerships prohibiting from selling any of those vehicles until they are inspected and, if necessary, repaired. Honda then told its dealerships that if they violate this, they will be required to indemnify Honda for any damages it has to pay to someone injured as a result of the failure to inspect and repair.

The front crash sensors may crack under certain environmental conditions and allow water to enter into the sensor. This can cause the sensor to become inoperative and illuminate the airbag warning light. The crash sensor was supplied by Robert Bosch Corporation in Farmington Hills, Michigan. This recall demonstrates yet another problem Chrysler had with its up-front crash sensors, continuing a pattern from prior defective air bag sensors.

These sensors were added to enhance the performance of the airbag system in certain frontal crashes. If the front crash sensors become inoperative, the driver is immediately alerted by illumination of the airbag warning light and the vehicle should be promptly serviced. Until the vehicle is repaired, the airbags may not provide the enhanced protection in the event of a crash. Chrysler will replace the front airbag sensors with a new design. This service will be performed free of charge. The safety improvement campaign will begin during June 2010. Chrysler’s campaign number is J38. 10V-008.

The supplier who manufactured the part was Masonico LLC in Fraser, Michigan. A quality control (continuing conformance test) at Masonico on November 11, 2009 revealed an improper deployment of the passenger air bag. The very next day, additional testing revealed that the passenger air bag was not deploying properly during both cold-temperature and ambient-temperature. That caused the assembly plant (Chrysler’s Jefferson North Assembly Plant) to stop production. Although it was determined that defective parts may have been installed in vehicles that were built as early as October 22, 2009, their failure to detect the defective parts for nearly three weeks raises serious questions about the effectiveness of their quality control program.

Changes to certain welds and the way the air bag door was scored were implemented. The recall fix involves having the instrument panel top cover replaced.