NHTSA reopens investigation into massive global airbag recall

The National Highway Traffic Safety Administration has reopened an investigation into airbag defects that were already cited in a massive 2013 recall affecting several automakers and millions of vehicles across the globe.

Toyota appears to be the first company to act on the latest information, recalling 650,000 vehicles a second time to replace any airbag inflators that were merely inspected rather than swapped for a new unit during the initial recall.

The NHTSA investigation suggests the problems with supplier Takata’s airbag inflators may be more widespread than initially thought, increasing the risk of inflator explosion, fire and occupant injuries due to improper propellant.

The agency’s Office of Defects Investigation has tracked at least six recent incidents of bag inflator rupture, all occurring in high-humidity environments such as Florida and Puerto Rico.

In one of the incidents, the driver-side airbag inflator in a 2005 Honda Civic is said to have exploded and sent a one-inch piece of shrapnel into the driver’s eye. The August 2013 accident reportedly led to loss of sight and severe lacerations to the nose, requiring 100 stitches. The vehicle was not included in any of the previous recall campaigns focused on Takata inflators that were known to exhibit similar behavior.

In another accident, the passenger airbag inflator in a 2003 Toyota Corolla reportedly exploded and sent shrapnel into the driver’s head. The car allegedly caught on fire and the front windshield was shattered, but the airbag did not inflate.

The NHTSA is currently taking a closer look at airbag complaints related to 2002-2006 models produced by Honda, Nissan, Mazda, Chrysler and Toyota. The issue could lead to another recall for over a million vehicles.