22E002 – Inadequate Hardness of Ball Joint Housing – MOOG K80521, K80522, NAPA NCP2601633, NCP2601634, ACDelco 45D2344, & 45D2345

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January 14, 2022 NHTSA CAMPAIGN NUMBER: 22E002000

Inadequate Hardness of Ball Joint Housing

A ball joint failure may cause a loss of control, increasing the risk of a crash.

 

NHTSA Campaign Number: 22E002

Manufacturer Tenneco Automotive

Components SUSPENSION

Potential Number of Units Affected 6,478

 

Summary

Tenneco Automotive (DRiV) is recalling certain aftermarket ball joints for 2004-2007 Toyota Sequoia and 2004-2006 Toyota Tundra vehicles, MOOG part number K80521, K80522, NAPA part number NCP2601633, NCP2601634, ACDelco part number 45D2344, and 45D2345. The ball joint housing may have inadequate hardness, causing premature failure.

 

Remedy

DRiV will work with distributors to return unsold parts. Dealers will inspect and replace the ball joint as necessary, free of charge. Owner notification letters were mailed on March 17, 2022. Owners may contact DRiV customer service at 1-877-489-6659 or at RECALL.SUPPORT@DRIV.COM.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 


Chronology :

July 27, 2021: DRiV’s labor claim team received a report of a field failure of a lower ball joint. No accident or injury was reported.

August 2, 2021 – September 2, 2021: DRiV analyzed the returned (failed) part and three additional parts (one used part from the field and two new parts from inventory), including internal laboratory tests for stud surface hardness, core hardness and case depth; and for housing surface hardness, core hardness and case depth. DRiV shared the test results with the supplier and tried to engage the supplier to jointly investigate the issue. Parts were placed on internal quality hold on September 2.

September 2 – November 30, 2021: Supplier and DRiV undertook parallel investigations. DRiV’s investigation included third-party laboratory testing of 40 samples from various lot codes, focusing on housing surface hardness, core hardness and case depth. A Product Notice was issued to customers (11/22/2021), a copy of which was submitted to NHTSA in accordance with 49 CFR 579.5. Supplier tested additional samples with conflicting results.

December 2, 2021 – December 31, 2021: DRiV undertook additional testing, using three independent labs, of 240 sample parts from various production codes. These tests indicated that some parts manufactured during the production date range identified herein had inadequate induction hardening (although the supplier does not agree with these findings). The issue was escalated to DRiV’s Global Warranty Committee.

January 9, 2022: The Global Warranty Committee approved this safety recall.

There are no reports of accidents or injuries related to this condition.

 


10 Affected Products

Equipments

BRAND PART NO. PRODUCTION DATES
ACDELCO TOYOTA LOWER BALL JOINT
MOOG TOYOTA LOWER BALL JOINT
NAPA TOYOTA LOWER BALL JOINT

 


Vehicles

MAKE MODEL YEAR
TOYOTA SEQUOIA 2004-2007
TOYOTA TUNDRA 2004-2006

 


16 Associated Documents

Recall Acknowledgement

RCAK-22E002-6029.pdf 712.468KB

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Defect Notice 573 Report

RCLRPT-22E002-3200.PDF 219.646KB

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Recall 573 Report – 2/11/2022

RCLRPT-22E002-8504.PDF 219.734KB

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Recall 573 Report – 3/9/2022

RCLRPT-22E002-8048.PDF 219.757KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22E002-1780.pdf 173.327KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22E002-6366.pdf 164.188KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22E002-7432.pdf 167.473KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22E002-1660.pdf 135.428KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22E002-1411.pdf 141.245KB

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Recall Quarterly Report #1, 2022-1

RCLQRT-22E002-2206.PDF 211.129KB

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Recall Quarterly Report #2, 2022-2

RCLQRT-22E002-3048.PDF 211.233KB

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Recall Quarterly Report #3, 2022-3

RCLQRT-22E002-6815.PDF 211.326KB

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Recall Quarterly Report #4, 2022-4

RCLQRT-22E002-8852.PDF 211.433KB

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Recall Quarterly Report #5, 2023-1

RCLQRT-22E002-7279.PDF 211.55KB

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Recall Quarterly Report #6, 2023-2

RCLQRT-22E002-2722.PDF 211.642KB

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Recall Quarterly Report #7, 2023-3

RCLQRT-22E002-1985.PDF 211.854KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22E002&docType=RCL

 


 

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