PASSENGER AIR BAG LID FAILURE

THIS INVESTIGATION INVOLVES THE VOLKSWAGEN (VW) PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) LID UTILIZED IN MY 1998-2002 VW PASSAT. THE PSIR LID MAY DETACH FROM THE INSTRUMENT PANEL DURING AIR BAG DEPLOYMENT. THE OFFICE OF DEFECTS INVESTIGATION (ODI) OF THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) OPENED THE PRELIMINARY EVALUATION ON MAY 23, 2003 TO DETERMINE WHETHER ALLEGED PSIR LID DETACHMENT PRESENTS AN UNREASONABLE SAFETY RISK TO PASSENGERS IN THE VEHICLE. ODI¿S INVESTIGATION REVEALS THAT DETACHMENT OF THE PSIR LID DURING AIR BAG DEPLOYMENT MAY OCCUR FOR TWO REASONS: 1) THE SHAPE OF THE PSIR LID, AND THE LENGTH OF THE ATTACHING TETHER, MAY SNAG THE AIR BAG DURING DEPLOYMENT APPLYING ADDITIONAL PRESSURE ON BOLTS THAT FASTEN THE LID TO THE INSTRUMENT PANEL (IP); AND/OR 2) THE ORIGINAL PSIR LID DESIGN (SUBJECT VEHICLES) UTILIZED SIX GRADE 4.8 MM CARBON STEEL TACK WELD BOLTS WHICH MAY NOT BE AS STRONG AS THE NEW DESIGN PSIR LID CONSISTING OF SIX GRADE 8.8 MM CARBON STEEL PRESS BOLTS THAT ARE HEAT TREATED. ODI CONCLUDES THAT DETACHMENT OF THE PSIR LID IS A DEFECT BECAUSE THE LID SHOULD REMAIN ATTACHED TO THE IP AFTER DEPLOYMENT OF THE AIRBAG. HOWEVER, AFTER ANALYZING VW¿S RESPONSES, AND TEST DATA COLLECTED BY VW AND FAURECIA, THE PSIR LID SUPPLIER, ODI BELIEVES THAT FURTHER INVESTIGATION WOULD NOT LIKELY IDENTIFY A SAFETY-RELATED DEFECT TREND BECAUSE A DETACHED PSIR LID AND PARTS DO NOT PROJECT TOWARDS A PASSENGER DURING DEPLOYMENT OF THE AIRBAG. THE TEST DATA SHOWS THAT THE AIRBAG PUSHES A DETACHED PSIR LID UPWARDS INTO THE WINDSHIELD DURING DEPLOYMENT, AND AWAY FROM THE PASSENGER COMPARTMENT. IT IS HIGHLY UNLIKELY THAT A PASSENGER WOULD CONTACT THE PSIR LID OR ASSOCIATED PARTS DURING AIR BAG DEPLOYMENT. THEREFORE THIS ENGINEERING ANALYSIS (EA 03-020) IS CLOSED. THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. FOR A DETAILED DISCUSSION OF THE PSIR LID AND TESTING, SEE THE ATTAC