May 18, 2015 

DEFECT INFORMATION REPORT 

TK HOLDINGS INC. 

PSPI PASSENGER AIR BAG INFLATORS 

I. Manufacturer's name: 

TK Holdings Inc. ("Taka ta"). 

2. Items of equipment potentially affected: 

All PSPI air bag inflators installed as original equipment in frontal passenger air bag 

modules in spec ific vehicle models sold in the United States , as follows: 

Model Year 2003 Honda Accord vehicles 

Model Years 2001-2006 Honda Civic vehicles 

The above represents all Model Years of the I isted vehicle makes and mod els that contain 

PSPI inflators. 

This Report contemplates the potential for a national recall, subject to the determinations 

ofNHTSA and consultations with the vehicle manufacturer , as described in section 7 

below. The recall contemplated in this Report would be in addition to the previous 

recalls and safety campaigns involving these inflators, including reca ll number s 13V- l 32, 

14V-349 , 14V-353, and 14V-700. Takata previously filed Defect Information Reports 

13E-O 17 and 14£-073 relating to the subject inflators. 

The inflators covered by this detem1ination were installed as original equipment in 

vehicles manufactured by the following vehicle manufacturer: 

American Honda Motor Co. 

1919 Torrance Blvd. 

Torrance , CA 90501-2746 

Phone: (310) 783-2000 

3. Total number of items of equipment potentially affected: 

The total number of subject inflators potentially affected on a national basis in the vehicle 

models identified above is approximately 3 .3 milli on. Of that number , Takata estimates 

that approximately 2.1 million are subject to previous recalls and safety campaigns. 
TK HOLDINGS INC. 

May 18, 2015 

4. Approxim ate percentage of items of equipment estimated to actually cont ain the 

defect: 

The number of field incidents know n to Takata involving ruptur es of the subject infl ators 

in the Un ited States is three (3), all of which involved inflators that we re subjec t to 

previous reca lls. For comparison purp ose s, Takata estimates that there have been 

approxi mate ly 94,875 total field deployments of the subject inflators in the United States. 

That estimate is based on the numb er of subj ect infl ators described in sec tion 3, an 

estimate of the ave rage age of the subject inflators in the field (11. 5 yea rs), and an 

estimate that an average of 0.25 percent of passe nger air bags deploy in the field eac h 

year. In additi on, as desc ribed below, since September 2014 , Takata has condu cted 

ballistic testing of a selected population of subjec t inflators return ed by Ho nda, includin g 

a disprop ortion ate number of subject infl ators return ed from areas of hi gh absolute 

humidit y; that ballistic testing to date has result ed in twenty (20) ruptur es (approx imately 

0.5 l percent) of the subject infl ators tested. 

5. Description of the defect: 

As a result of the deve lopments and circumstances desc ribed below and in section 4 

above , Takata has determined that a defect related to motor vehicl e safety may arise in 

some of th e subj ect infl ators. 

The propellant wafe rs in some of the subj ect inflators may experience an alteration ove r 

time, which could potentially lead to ove r-agg ressive combu stion in the eve nt of an air 

bag deplo yment. Depending on the circum stances, this pot enti al conditi on could crea te 

exce ssive internal pressure when the air bag is deployed, which could result in the body 

of the inflator rupturin g upon deployment. Based upon Takata's investigation to date, the 

potential for such ruptures may occur in some of the subj ect inflators after seve ral yea rs 

of exposure to persistent conditi ons of high absolute humidit y. In additi on, Takata's test 

results indic ate that even with identic al infl ator designs, the likelihood of a potential 

ruptur e is greater in certain vehicle models, includin g the models identifi ed above, due to 

factors that have not yet been identifi ed. Th e potenti al for ruptur e may also be influ enc ed 

by other factors, includin g manufa cturin g variabilit y. 

In the event of an infl ator ruptur e, metal fr agments could pass through the air bag cushion 

material, which may result in injur y or death to vehicl e occ upants. 

6. Chronological summary of events leading to this determination: 

October or Nove mber 2011 - Takata was notified of a rupture of a PSPI passenge r 

inflator in a model yea r 2001 Honda Civic vehicl e loca ted in Puerto Rico . Taka ta 

promptl y bega n an investigation. 

2010- Prese nt - Beginnin g in 2010 and at diff erent periods therea fter, in co nnection wi th 

its investigation, Takata has consulted with the Fraunh ofe r Institut e for Chemica l 

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May 18, 2015 

Technology ("Fraunhofer ICT") to provide an independent researc h investigation of the 

root cause of the inflat or rupture s. Fraunhofer ICT conducts researc h for governme nt and 

industry and its core competencies include energetic materials and energ etic systems. 

Fraunhofer ICT is considered the leading research organization within the pyrotechnic 

gas generator and airbag system industry. 

August 2012 - Nove mber 20 12 - Takata was inform ed of three additional incident s in the 

United States (two in Puerto Rico and one in Maryland (the Maryland vehicle had 

previously been operated in Florida for eight years)). These incid ents all occurred in 

Honda Civ ic or Toyota Coro lla vehicles. 

April 20 13 - Based on its investigat ion, Takata submitted a defect information report 

("DIR "), identified by NHTSA as l 3E-O 17, which covered certain passenger inflators 

containing propellant wafers manufactured at Takata's Moses Lake, Washington plant 

durin g the period from April 13, 2000 through September 11, 2002 , and certain air bag 

inflators manufactured at Takata 's Monclova, Mexico plant during the period from 

October 4, 2001 throu gh October 31, 2002. Promptly thereafter, the five manufacturer s 

of vehicles in which tho se inflators had been installed submitted corresponding DI Rs and 

recalled those vehicles: 13V-130 (Mazda); 13V-132 (Honda) ; 13V-133 (Toyota); 13V136 (Nissan); and 13V-172 (BMW) . 

June 2014 - Takata notified the vehicle manufacturers that some of its traceabilit y 

records were incompl ete (i.e. , Takata could not identify with absolute certainty the 

prop ellant lots from which the propellant wafers in a specific inflator were taken) , and 

that it was possible for propellant wafers to hav e been stored at its Monclova plant for up 

to three months before being used in an inflator. Based on those findings , and to assure 

that all potentiall y affected inflators were covered , Takata recommended that all PSPI, 

PSPI-L , and SPI inflator s built through the end of 2002 should be recalled. Based on that 

recommendation, the five vehicle manufacturer s identified above decided to expand their 

20 13 reca lls: 14V-312 (Toyota); 14V-349 (Honda); 14V-361 (Nissan); 14V-362 

(Mazda); and 14V-428 (BMW). In addition , based on the expanded date range for the 

covered inflators , Fuji Heav y Industries (Subaru) submitt ed a similar DIR covering a 

relatively sma ll number of vehicles (14V-399). Subaru was not affected by the original 

date range in 13£-017. 

June 11, 2014 - Takata sent a letter to NHTSA stating that, consistent with the fact that 

Takata 's highe st priorit y is safety, and in light of the Company's desire to address 

potential safety concerns promptly and thorou ghly, Takata wou ld support NHTSA 's 

request for regional field actions to replac e PSPI, PSPI-L , and SPI passeng er inflator s 

manufactured between the start of production in Apri l 2000 and July 31, 2004 that were 

installed in vehicles sold in or registered in Puerto Rico , Florida , Hawaii , and the U.S. 

Virgin Islands, based on the high levels of absolute humidity in tho se areas. (Those 

region al field actions also covered certain driver inflator s.) The l O vehicle manufacturers 

that had installed the se passenger inflators in their vehicles promptl y agreed to conduct 

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May 18, 2015 

the reque sted regional field actions and to send the replaced inflators to Takata for 

testing. 

June 11, 20 14 - Based on six field ruptur es of Takata inflators (three driver inflat ors and 

three passenger inflators ), N HTSA ope ned a defec t investigation, PE 14-016. On Marc h 

2, 20 15, that investigation was upgraded to EA 15-00 1. 

April 2014 - April 20 15 - Taka ta was inform ed of seve n additi onal incid ents in which 

passenger inflators not cove red by the prior recalls had ruptur ed. Four of these involved 

PSPI-L inflators installed in Toyota Coro lla vehicles. Three of these incid ents occ urred 

in Puerto Rico and the remainin g incident occurred in Texas. 

October - Decemb er 20 14 -A t the reque st ofN HTSA, Toyota , Honda, and Nissa n 

submitt ed DIRs covering vehicles with the passenger inflators covered by the regional 

field actions identifi ed above that had been sold in or registere d in a wider geogra phi cal 

area, includin g Puerto Rico, Hawaii , the U.S. Virgin Islands, Guam , Saipan, American 

Samoa, Florida and adjacent counties in southern Geo rgia, as we ll as the coastal areas of 

Alabama, Louisiana , Mississippi and Texas. On Nove mber 17, 2014, Taka ta submitt ed 

DIR 14E-073. Subsequently, in December 20 14, severa l other vehicle manufactur ers 

submitt ed DIRs with respec t to regiona l recalls cover ing vehicl es with the identified 

inflators that had been sold in or registered in those areas. 

September 20 14 - May 20 15 - As part of its continuin g investigation, Takata has 

conducted exte nsive testing of inflators returned by the vehicle manufacturers. This 

testing has includ ed (but has not been limited to) ballistic tests, live dissec tions, 

propellant analysis for moisture , chemical analysis, air and helium leak testing, and CT 

scanning. As of May 1, 2015 , Takata has ballistically tested 3,932 Honda PSPI inflators. 

Of those inflators, 20 ruptured during this testing, yielding a rupture rate of 0.51 percent. 

All of these test ruptur es involved inflators returned from the high absolute humidit y 

States listed in the first stage of the remedy program described in section 7 below. 

Although the Company' s testing and investigation is ongo ing, with the aid of the 

independent resea rch performed by Fraunhofer JCT, Takata has reached some 

prelimin ary conclusions. It appea rs that the inflater ruptur es have a multi- factor root 

cause that includ es the slow-ac ting effects of a persistent and long-term exposure to 

climat es with high temperatures and high absolute humidit y. Expos ure ove r a period of 

severa l years to persistent leve ls of high abso lute humidit y outside the inflat er, combined 

with the effects of thermal cycling, may lead to moisture intru sion in some inflators by 

means of diffusio n or perm eation. Fraunhofer JCT has identified the possibility in these 

climates for moisture intru sion into the inflater over time and a pro cess by which the 

moisture may slowly incr ease the poro sity of the propellant within the inflater. 

Fraunhofer ICT's analysis also indicates that the design of the inflater and the grain 

(shape) of the prop ellant can affec t the likeliho od that the porosity change will occur, as 

can manufacturing variabilit y. The results of the Fraunhofer lCT research to date are 

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May 18, 2015 

consistent with the geographic location and age of the infl ators that have ruptured in the 

field and in Takata's testing. 

Takata 's testing indicate s that vehic le and model design differences are associated with 

difference s in outcomes. Significantly , Takata's test results indicate that the like lihood of 

a potential rupture is greater in the vehicle model s identified in this report , due to as-yet 

unidentified factor s. 

ln addition , the ana lysis to date suggest s that the potential for this long -term phenomenon 

to occur was not within the scope of the testing specifications pre scribed by the veh icle 

manufacturer s for the va lidation and production of the subject inflator s as origina l 

equipment. 

May 2015 - Based upon the result s of its investigation and the preliminary conclusions 

identified above , as we ll as NHTSA 's insistence that action be taken to mitigate the risk 

posed to safety by these inflators, Takata decided to submit this Report. 

7. Description of the remedy program: 

Consistent with the Consent Order issued by NHTSA on or about May 18, 2015 (the 

"Consent Order "), Takata sha ll cooperate with NHTSA in all future regulatory action s 

and proceedings pursuant to NHTSA 's authority under the Nationa l Traffic and Motor 

Vehicle Safety Act , or any regulations thereund er, including 49 U.S .C. § 30120(c)(3), 

regarding the organ izat ion and prioriti zation of replacement air bag inflators. 

Pursuant to the Consent Order , Takata wi ll continue to test the subject inflater type in all 

makes , models , and model yea rs of vehicles that are covered by a safety campaign or 

otherwise made ava ilable or obtained by Takata for testing , and Takata wi\\ report those 

results to NHTSA. 

Consistent with paragraphs 4 and 9 of the Consent Order , ,this Report recommend s and 

contemplates that the remedy program for the subject inflators is to use a phased 

customer notification and remedy approach. Under that approach , Takata plans to work 

with the manufacturer of the vehicles in which the subject inflators were installed 

(Honda) to implement an appropriate recall to replace the subject inflators first in high 

absolute humidity States, with any further expansion of the remedy program to proceed 

by geographic zone s, contingent on subseq uent orders that may be issued by NHTSA 

based on the results of further testing and engineering ana lysis of the subject inflators and 

following consultation with Takata and the affected vehicle manufacturers , as follows: 

• The initial recall contemplated by this Report and the Consent Order wou ld 

include the veh icle models listed in section 2 that were sold in or ever regi stered 

in any part of Florida , Puerto Rico , the U.S. Virgin Islands, Hawaii , the Outlying 

U.S. Territories, Texas, Louisiana , Georg ia, South Caro lina, Alabama , and 

Mississippi ; 

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TK HOLDINGS INC. 

May 18, 2015 

• Pursuant to the Conse nt Order, if ordered by NHTSA based on the results of 

further testing and eng ineering analysis of the subject inflators and following 

consu ltation with Takata and the affected vehicle manufacturer , the recall 

contemplated by this Report and the Consent Order wou ld expa nd to include the 

vehicle models listed in section 2 that were so ld in or ever registered in any part 

of California, Oklahoma , Nort h Caro lina, Virginia, Arkansas, Kentucky, 

Ten nessee , Illin ois, Delaware , Maryland, and Missouri; 

• Pursuant to the Consent Order, if orde red by NHTSA based on the results of 

further testing and engineeri ng analysis of the subject inflators and following 

consultation with Takata and the affected vehicle manufacturer , the recall 

contemplated by this Report and the Consent Order wou ld expand to includ e the 

vehicle models listed in section 2 that were sold in or ever registered in any part 

of Ohio, Indiana , New Jersey , West Virginia , the District of Columbi a, Kansas , 

Pennsylvania, Washington, Massachusetts, Connec ticut , Michigan , New York , 

Rhode Island, Oregon, Iowa, and Nebraska; and 

• Pursuant to the Consent Order , if ordered by NHTSA based on the results of 

further testing and engineering analysis of the subject inflators and following 

consultation with Takata and the affected veh icle manufacturer, the recall 

contemp lated by this Report and the consent Orde r would expand to include the 

vehicle models listed in sectio n 2 that were sold in or ever registered in any of the 

remaining States. 

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