2007 Lexus ES350 recalls and problems

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 n…

THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED DP09-001 ON APRIL 8, 2009, TO EVALUATE A DEFECT PETITION REQUESTING ADDITIONAL INVESTIGATION OF POTENTIAL THROTTLE CONTROL SYSTEM DEFECTS UNRELATED TO FLOOR MAT INTERFERENCE WITH ACCELERATOR PEDALS IN MODEL YEAR (MY) 2007 LEXUS ES 350 VEHICLES.THE PETITIONER REFERENCED AN EARLIER ODI INVESTIGATION CONCERNING FLOOR MAT INTERFERENCE WITH ACCELERATOR PEDAL RETURN (PE07-016/EA07-010), WHICH HE STATED WAS TOO NARROW IN SCOPE AS IT DID NOT INCLUDE ALL INCIDENTS OF UNWANTED ACCELERATION AND CONSIDER ALL POTENTIAL CAUSES OF VEHICLE SPEED CONTROL CONCERNS.THE PETITION ALSO REQUESTED AN INVESTIGATION OF MY 2002-2003 LEXUS ES300 FOR THOSE 'LONGER DURATION INCIDENTS INVOLVING UNCONTROLLABLE ACCELERATION WHERE BRAKE PEDAL APPLICATION ALLEGEDLY HAD NO EFFECT' THAT WERE DETERMINED NOT TO BE WITHIN THE SCOPE OF INVESTIGATION PE04-021. AS BACKGROUND, THE PETITIONER OWNS A MY 2007 LEXUS ES350 THAT ALLEGEDLY EXPERIENCED AN UNWANTED AND UNCONTROLLED ACCELERATION EVENT (ODI COMPLAINT NUMBER 10261660).TOYOTA CONCLUDED THAT THE INCIDENT WAS CAUSED BY AN UNSECURED FLOOR MAT. TO ASSESS THE PETITIONER'S REQUEST, ODI INTERVIEWED THE PETITIONER, INSPECTED HIS VEHICLE, REVIEWED INFORMATION SUBMITTED BY TOYOTA, REVIEWED OWNER COMPLAINTS ALLEGING INCIDENTS OF UNWANTED ACCELERATION IN THE SUBJECT VEHICLES AND MATERIAL RELATED TO THE INVESTIGATIONS CITED BY THE PETITIONER.ODI IDENTIFIED 64 COMPLAINTS ALLEGING INCIDENTS OF UNWANTED ACCELERATION IN MY 2007 LEXUS…

THE DRIVER SIDE FLOOR MAT WILL NOT INTERFERE WITH THE THROTTLE PEDAL IF PROPERLY SECURED USING THE RETAINING HOOKS PROVIDED BY TOYOTA.HOWEVER, IF THE ALL WEATHER MAT IS UNSECURED AND MOVES FORWARD FROM ITS INTENDED POSITION IT CAN ENTRAP THE THROTTLE PEDAL AT THE FULLY OPEN POSITION AFTER IT HAS BEEN DEPRESSED.THIS CAN HAPPEN REGARDLESS OF WHETHER OR NOT ANOTHER MAT (CARPET) IS UNDERNEATH.WHEN THIS OCCURS, SOME OPERATORS REACT BY APPLYING THE BRAKE PEDAL MULTIPLE TIMES, DEPLETING THE BRAKING SYSTEM'S (VACUUM BASED) POWER ASSIST.STOPPING THE VEHICLE WITH UNASSISTED BRAKING WHILE THE THROTTLE IS FULLY OPEN REQUIRES SIGNIFICANT PEDAL FORCE, WHICH SOME OPERATORS DID NOT, OR WERE UNABLE TO, APPLY FOR THE REQUIRED DURATION.CONTINUED DRIVING IN THIS CONDITION RESULTS IN OVERHEATED BRAKES, WHICH FURTHER DIMINISHES THE BRAKING EFFECTIVENESS.SOME OPERATORS ATTEMPTED TO TURN THE VEHICLE OFF BY DEPRESSING THE ENGINE CONTROL BUTTON, HOWEVER THEY WERE UNAWARE THE BUTTON HAD TO BE DEPRESSED FOR THREE SECONDS TO STOP THE ENGINE WHEN THE VEHICLE IS IN MOTION; THIS FUNCTIONALITY WAS NOT EXPLAINED ADEQUATELY IN THE OWNER'S MANUAL.IN ODI INTERVIEWS, OWNER'S REPORTED THEY WERE UNAWARE THE ALL WEATHER MAT HAD THE POTENTIAL TO INTERFERE WITH THE THROTTLE PEDAL, ADVISING THAT THIS WAS NEVER PROPERLY EXPLAINED GIVEN THE SIGNIFICANT HAZARD IT REPRESENTED.OWNERS REPORTED SEVERAL EXPLANATIONS FOR WHY THE MAT WAS UNSECURED, INCLUDING THAT THE VEHICLE WAS DELIVERED IN THIS CONDITION (MOST COMMON REASON), …

COMPLAINANTS INTERVIEWED BY ODI STATED THAT THEY APPLIED THE THROTTLE PEDAL TO ACCELERATE THE VEHICLE THEN EXPERIENCED UNWANTED ACCELERATION AFTER RELEASE.SUBSEQUENT (AND SOMETIMES REPEATED) APPLICATIONS OF THE BRAKE PEDAL REDUCED ACCELERATION BUT DID NOT STOP THE VEHICLE.IN SOME INCIDENTS DRIVERS TRAVELED SIGNIFICANT DISTANCES (MILES) AT HIGH VEHICLE SPEEDS (GREATER THAN 90 MPH) BEFORE THE VEHICLE STOPPED (ODI NOTES THAT MULTIPLE BRAKE APPLICATIONS WITH THE THROTTLE IN AN OPEN POSITION CAN DEPLETE THE BRAKE SYSTEM'S POWER (VACUUM) ASSIST RESERVE RESULTING IN DIMINISHED BRAKING).THE SUBJECT VEHICLES HAVE AN ENGINE CONTROL BUTTON INSTEAD OF A TRADITIONAL IGNITION KEY. SOME DRIVERS REPORTED THAT THEIR ATTEMPTS TO TURN THE ENGINE OFF BY PRESSING THE CONTROL BUTTON WERE UNSUCCESSFUL.IN THESE CASES IT APPEARS THE DRIVERS WERE UNAWARE THAT THE BUTTON'S FUNCTIONALITY CHANGES WHEN THE VEHICLE IS IN MOTION REQUIRING THAT IT BE DEPRESSED FOR 3 SECONDS (INSTEAD OF MOMENTARILY) TO STOP THE ENGINE.ODI HAS OBSERVED THAT AN UNSECURED LEXUS ACCESSORY ALL WEATHER FLOOR MAT CAN TRAP THE THROTTLE PEDAL IN AN OPEN POSITION RESULTING IN SIGNIFICANT UNWANTED ACCELERATION.UNSECURED FLOOR MATS HAVE BEEN FOUND IN THE MAJORITY OF INCIDENT VEHICLES.IN ADDITION, ODI HAS INSPECTED TWO INCIDENT VEHICLES DOCUMENTING BRAKE DAMAGE DUE TO OVERHEATING. IN THE FIVE ODI CRASH INCIDENTS THE OPERATORS ALLEGE THEY EXPERIENCED UNWANTED ACCELERATION AND WERE UNABLE TO STOP THE VEHICLE TO AVOID THE COLLISION.FOUR OF T…