Since the induction of the National Traffic and Motor Vehicle Safety Act in 1966, more than 390 million vehicles have been recalled in the United States. The same is true for more than 66 million pieces of motor vehicle equipment. Recalls occur when a vehicle or one of its components fails to comply with a Federal Motor Vehicle Safety Standard or there’s a safety-related defect. Between 2015 and 2016 alone, about 51.26 million vehicles made by major manufacturers were recalled nationwide. The reasons for safety problems in vehicles are numerous, ranging from poor communication along the supply chain to the use of poor-quality component. While unfortunate, recalls give auto manufacturers an opportunity to improve upon their products and the processes used to make them.

Timeline of the Biggest Auto Recalls in U.S. History

Ford (1966 to 1980)

In what could have been the biggest recall in history, Ford only issued a partial recall for its park-to-reverse automatic transmission defect. The American auto manufacturing giant built 21 million vehicles with defective gearboxes.

The automatic transmission defect caused cars that seemed to be in the “park” gear to slip into reverse. After years of complaints and more than 6,000 accidents, the government officially recognized the defect. After the threat of a forced recall, Department of Transportation (DOT) officials settled with Ford. Instead of replacing gearbox parts, the solution was to issue millions of warning stickers that instructed vehicle operators to place the car in “park,” fully engage the parking brake, and turn off the ignition.

General Motors (1965 to 1971)

In 1971, General Motors (GM) issued the largest recall of the time for 6.7 million vehicles because of engine mount problems. When the engine mount malfunctioned, it caused the engine to move and flip up. It also made accelerators jam open and remove the power brake house, resulting in disabled transmissions. In some vehicles, drivers lost control because of the unexpected throttle increases.

During the voluntary recall, GM inspected each engine mount and installed restraint cables—a solution that cost less than $5 per vehicle.

Ford Pinto (1971 to 1976)

One of the most infamous auto recalls involved the Ford Pinto, which some argue was designed to fail. In the early 1970s, drivers reported explosions that occurred in low-speed collisions. At the heart of the issue was a lack of reinforcements between the bolts in the rear differential and fuel tank. The design flaws made the tank vulnerable to being pierced by the bolts and catch fire.

In 1978, Ford issued a recall for 1.5 million vehicles, including similar Mercury Bobcats.

Toyota, including Lexus Models (2004 to 2010)

When 12 Toyota and Lexus models suddenly accelerated and gas pedals stuck to the floor, the auto manufacturer initially suggested driver error was to blame. Toyota then issued a recall for all-weather floor mats, which representatives said trapped the accelerator pedal. The solution was to anchor floor mats so there was at least 1 centimeter of clearance between the floor and fully-depressed accelerator pedals.

When the reports of runaway vehicles continued, Toyota replaced the pedals. In certain models, they also installed brake override software that engages when a driver presses both pedals.

The recall affected about 9 million vehicles.

Takata Air Bag Inflators (2001 to 2017)

In the largest auto recall in U.S. history, 19 auto manufacturers recalled more than 37 million vehicles to replace Takata airbags with faulty inflators. The airbag manufacturer used an ammonium nitrate-based propellant without a chemical drying agent to create a small explosion that inflates the bags in a collision. The chemical, however, deteriorates when exposed to high humidity levels and heat, causing it to burn faster. As a result, the metal canisters designed to contain the explosion blew apart and sent shrapnel flying into vehicles. The U.S. DOT plans to continue recalling additional airbags through December 2019.

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Posted under Falk Gearboxes, Machinery Maintenance on Wednesday, May 9th, 2018