Millions of drivers whose cars have been recalled to replace air bags that explode and spray deadly shards of metal may not be fully protected unless they have the potentially dangerous inflaters replaced twice, a federal regulator told Congress on Thursday.
Rosekind said Thursday that the inflaters being installed in recalled vehicles may themselves become defective but that the evidence suggests they will perform to design for several years.
“At this point we’re only seeing ruptures at 7
years,” Rosekind said. “A certain number that are being replaced have at least a 7
-year time span available for that safety to protect people in the vehicle.”
The news that some recalled vehicles may need to have their air-bag inflaters replaced twice adds a fresh layer of complexity to the issue. The air bags were manufactured by the world’s largest maker of air bags, a Japanese firm named Takata, and installed by a majority of automakers. Unlike most air-bag makers, Takata uses ammonium nitrate to trigger a small explosion that inflates the air bag when the vehicle strikes something.
But in some vehicles — particularly those that were several years old and kept in regions with high humidity — the ammonium nitrate burns too fast, causing the chemical’s container to explode and spray drivers and passengers with metal shrapnel.
Many Takata replacement air bags still use the ammonium nitrate that is suspected to cause the explosive malfunctions, and Rosekind said Thursday that testing has proved that the chemical deteriorates over time.
Many air-bag inflaters have been replaced since the recalls began in 2014, and dealers should have notified drivers about whether their new inflaters were triggered by ammonium nitrate and whether they should be replaced a second time when inflaters without the chemical become available, Rosekind said.
“If the dealer tells you that it’s an interim remedy, then you would know that you’ll be recalled again for a second fix,” Rosekind said. “You don’t want people to get that first [replacement] and think they’re done.”
With replacement air bags on back order, many dealers have been telling drivers who have received recall notices that it may take weeks or months before their inflaters can be replaced.
Getting drivers to comply with recall notices is a challenge, said Mitch Bainwol, president of the Alliance of Automobile Manufacturers, a trade group that represents 12 major foreign and domestic automakers.
“We do mail and email until we’re blue in the face,” Bainwol told the House subcommittee. “It’s tough. We need help.”
NHTSA is launching a pilot program in which automakers work with state motor-vehicle administrations to include recall information in renewal notices for licenses and auto registration. Six states will take part in the pilot program.
“As much as is currently being done, it’s not enough,” Rosekind said, enumerating 19 new strategies developed to draw the attention of drivers to recall notices.
Huma Hanif, 17, died March 31 when an air bag malfunctioned after her car hit another vehicle at an intersection in suburban Houston. The auto dealer and Honda said they had sent six air-bag recall notices to Hanif’s family, but family members said they had not received the notices.
On Wednesday, NHTSA gave Takata until the end of 2019 to prove that their new process for ensuring the safety of inflaters triggered by ammonium nitrate is effective. The company is using a drying agent called desiccant to keep the chemical from deteriorating when exposed to heat and humidity. If Takata fails to provide that proof, it could lead to a recall of an additional 85 million cars.
Rep. Janice Schakowsky (D-Ill.) asked Rosekind whether potentially defective air bags were being installed in newly manufactured cars.
“It would be illegal to sell a known defect in a new car,” Rosekind said.
An earlier version of this story stated that Takata has until the end of 2018 to prove that their new process for ensuring safety of inflaters is effective. The company has until the end of 2019.
