Honda Takata Recall includes the 2008 Honda Pilot.

Honda is recalling 1.1 million cars, SUVs, and pickup trucks because they have replacement driver's-side airbag inflators that were manufactured incorrectly. That raises the risk that the airbag could explode with unintended force, rupturing and sending sharp metal fragments into the cabin, the automaker says.

This is not part of the planned rollout of Takata airbag replacements, a Honda representative told CR.

A statement from Honda says the company discovered the issue after a 2004 Honda Odyssey minivan was involved in a single-vehicle crash in January 2018. The van’s driver's-side front airbag deployed and the Takata replacement inflator ruptured, injuring the driver’s arm.

When Honda looked into the crash, it discovered that inflators manufactured at Takata’s facility in Monclova, Mexico, “experienced manufacturing process errors that introduced excessive moisture into the inflator during assembly.” Moisture can speed up the degradation of the chemicals used to inflate the airbag over time. That can lead to the overly powerful deployment of the airbag, and possibly rupturing the inflator, Honda says.

RECENT HONDA RECALLS

According to a chronology of events provided to the National Highway Traffic Safety Administration, these inflators were used as replacements for the original Takata driver’s-side airbag inflators. Honda says it has received only one injury claim related to this issue.

Honda says that it has replacement parts available for affected owners, “all from alternate suppliers,” and will begin conducting free repairs immediately. In addition, owners can get a free rental car for the day of the recall repair, or longer if a replacement part is temporarily unavailable, Honda says.

Owners will start getting notifications in early April, the automaker says.

These vehicles were already part of the largest and most complex automotive recall in U.S. history, covering at least 50 million Takata airbag inflators in 37 million vehicles from 19 manufacturers, according to NHTSA.

The devices use ammonium nitrate to inflate the airbag in the event of a crash. The ammonium nitrate can become unstable over time, particularly when exposed to high temperatures and humidity, leading to inflators that explode with an unexpectedly violent force.

At least 15 drivers and passengers in the U.S. have died and more than 250 people have been injured because of the airbag inflators, NHTSA says.

The Details

Vehicles involved: 1.1 million cars, SUVs, and pickup trucks, including:

The problem: In the manufacturing process, the inflators—labeled PSDI-5D—were exposed to too much moisture, raising the possibility that they could rupture, shooting sharp metal fragments into the cabin.

The fix: Honda says it has replacement parts available for affected owners, and will begin notifying them in early April. It also says that replacement vehicles will be made available if needed.

How to contact the manufacturer: Owners can check to see whether their vehicle needs a replacement airbag by checking recalls.acura.com and recalls.honda.com, or they can call 888-234-2138.

NHTSA campaign number: 19V182

Check to see whether your vehicle has an open recall: NHTSA’s website will tell you whether your vehicle has any open recalls that need to be addressed.

If you plug your car’s 17-digit vehicle identification number (VIN) into NHTSA’s website and this recall doesn’t appear, it means your vehicle doesn’t currently have any open recalls. Because automakers issue recalls often, and for many older vehicles, we recommend checking back regularly to see whether your vehicle has had a recall issued. 

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Honda Takata Recall includes the 2011 Acura TL.