Recall: Front passenger air bag may be deactivated by classification system error (ASA2). 2022-23 Taycans. April 8, 2025

[Tooney]

https://static.nhtsa.gov/odi/rcl/2025/RCLRPT-25V221-8446.PDF

Chronology:
In March 2024, the topic was first reviewed under Porsche's product safety process.
Crimp analyses were carried out until the end of June 2024. However, initial attempts to
replicate the malfunction were unsuccessful as all returned parts appeared to be in
good condition, possibly due to micro-movements during removal and transportation. At
this point, analysis could not be undertaken due to limited number of field cases and the
need to wait for a vehicle with the specific active fault to be identified in the field. Once
such a vehicle was found, specialists flew to the USA to carry out a thorough analysis of
the vehicle and the fault.
By mid-August 2024, a parallel analysis of additional field cases was completed, which
showed that the limited number of observed faults were intermittent, and at least some
of the faults were resolved by handling or using the seat. The root cause analysis
suggested that the problem was due to errors in the crimping process. Coordination
within the brand group took place in September and October 2024. In addition, an
ongoing analysis of the fail-safe mechanism was carried out to determine whether
airbag deactivation could actually occur (or just the warning message).
Further assessment of the estimated failure rate, including discussions with the supplier,
took place in November 2024. Continued coordination within the brand group continued
through February 2025. By the end of February 2025, the technical differences between
certain seat occupancy detection system versions, various manufacturing processes &
possible error mechanisms depending on them and the related production years were
analyzed in comparison to other years under consideration of the number of claims in
specific time periods. As a result, a potential clean date was identified to determine the
actual potentially affected population and comparisons were made of the failure
mechanisms within the brand group.
In March 2025, the results of the analysis were completed and on April 2, 2025,
Porsche’s Product safety and compliance committee decided that a safety defect exists
and to recall the affected vehicles, out of abundance of caution.
https://static.nhtsa.gov/odi/rcl/2025/RMISC-25V221-5251.pdf

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[W1NGE]

https://static.nhtsa.gov/odi/rcl/2025/RCLRPT-25V221-8446.PDF

Chronology:
In March 2024, the topic was first reviewed under Porsche's product safety process.
Crimp analyses were carried out until the end of June 2024. However, initial attempts to
replicate the malfunction were unsuccessful as all returned parts appeared to be in
good condition, possibly due to micro-movements during removal and transportation. At
this point, analysis could not be undertaken due to limited number of field cases and the
need to wait for a vehicle with the specific active fault to be identified in the field. Once
such a vehicle was found, specialists flew to the USA to carry out a thorough analysis of
the vehicle and the fault.
By mid-August 2024, a parallel analysis of additional field cases was completed, which
showed that the limited number of observed faults were intermittent, and at least some
of the faults were resolved by handling or using the seat. The root cause analysis
suggested that the problem was due to errors in the crimping process. Coordination
within the brand group took place in September and October 2024. In addition, an
ongoing analysis of the fail-safe mechanism was carried out to determine whether
airbag deactivation could actually occur (or just the warning message).
Further assessment of the estimated failure rate, including discussions with the supplier,
took place in November 2024. Continued coordination within the brand group continued
through February 2025. By the end of February 2025, the technical differences between
certain seat occupancy detection system versions, various manufacturing processes &
possible error mechanisms depending on them and the related production years were
analyzed in comparison to other years under consideration of the number of claims in
specific time periods. As a result, a potential clean date was identified to determine the
actual potentially affected population and comparisons were made of the failure
mechanisms within the brand group.
In March 2025, the results of the analysis were completed and on April 2, 2025,
Porsche’s Product safety and compliance committee decided that a safety defect exists
and to recall the affected vehicles, out of abundance of caution.
https://static.nhtsa.gov/odi/rcl/2025/RMISC-25V221-5251.pdf

When did the Taycan become a "hybrid electric" as per powertrain declaration?

 

[Tooney]

PCNA wrote the 573 Report. Ask them.

 

[hifi239]

When did the Taycan become a "hybrid electric" as per powertrain declaration?

It's Porsche acknowledging that when the electric propulsion fails, a gasoline-powered vehicle provides mobility.

 

[Freeewilly]

I have this error on and off for about 3 months , finally made an appointment and currently been repaired at the service center.

 

[outie]

I also have this error for a few months. I just took my car in last week (right before this recall is published).

The dealer just got back to me that they have to take out the seat to inspect if there's water stain on the sensor to determine whether it's covered under the warranty. In the event that there's water stain, I'd be on the hook to replace it for $2.6k. That's just BS. I just showed them this recall notice and my VIN does fall within the range of affected vehicles.

 

[whitex]

I found it interesting that not a single Taycan of the 9,735 vehicles model year 2022-2023, had put enough miles on the odometer to no longer qualify for the Porsche New Car Limited Warranty. No heavy road-trippers driving 2022 or 2023 Taycans, I personally avoided some road trips worrying about the heater recall, then brake lines recall.

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