Tenneco Automotive recall 22E002

Affected vehicles (5)

Component / system

Defect

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.

Risk / consequence

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

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.

Chronology of events

1. Jul 27, 2021

   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.

2. Aug 2, 2021

   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.

3. Dec 2, 2021

   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.

4. Jan 9, 2022

   January 9, 2022: The Global Warranty Committee approved this safety recall. There are no reports of accidents or injuries related to this condition.

Notification schedule

Dealer notification

FEB 14, 2022 - FEB 18, 2022

Owner notification

MAR 07, 2022 - MAR 11, 2022