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US expands probe into ZF-TRW airbag failure-to-deploy to 12.3 million vehicles

DETROIT — U.S. auto safety regulators have expanded an investigation into malfunctioning airbag controls to include 12.3 million vehicles because the bags may not inflate in a crash. The problem could be responsible for as many as eight deaths. Vehicles made by Toyota, Honda, Kia, Hyundai, Mitsubishi and Fiat Chrysler from the 2010 through 2019 model years are included in the probe, which was revealed Tuesday in documents posted by the National Highway Traffic Safety Administration. It involves airbag control units made by ZF-TRW that were installed in the vehicles. The control units can fail in a crash, possibly because of unwanted electrical signals produced by the crash itself that can disable an air bag control circuit housed in the passenger compartment, according to NHTSA documents. The electrical signals can damage the control circuit, the documents say. ZF, a German auto parts maker which acquired TRW Automotive in 2015, said in a statement that it's committed to safety and is cooperating with NHTSA and automakers in the investigation. The case is another in a long list of problems with auto industry airbags, including faulty and potentially deadly Takata airbag inflators. At least 24 people have been killed worldwide and more than 200 injured by the inflators, which can explode with too much force and hurl dangerous shrapnel into the passenger cabin. The inflators touched off the largest series of automotive recalls in U.S. history involving with as many as 70 million inflators to be recalled by the end of next year. About 100 million inflators are to be recalled worldwide. On April 19, NHTSA upgraded the ZF-TRW probe from a preliminary evaluation to an engineering analysis, which is a step closer toward seeking recalls. So far, only Hyundai and Kia and Fiat Chrysler have issued recalls in the case. Four deaths that may have been caused by the problem were reported in Hyundai-Kia vehicles and three in Fiat Chrysler automobiles. NHTSA opened an investigation in March of 2017 involving the TRW parts in Hyundais and Kias. The upgrade came after investigators found two recent serious crashes involving 2018 and 2019 Toyota Corollas in which the airbags did not inflate. One person was killed. Jason Levine, executive director of the Center for Auto Safety, a nonprofit consumer group, said the ZF-TRW case shows the auto industry thus far has learned very little from Takata.

A new Toyota MR2? We want to believe

In the wake of a busy Geneva auto show, the rumor mill is churning, and the latest grist involves one of the most beloved Toyota sports cars of all time. EVO reports that Tetsuya Tada, the chief of the Scion FR-S/Toyota 86 project and a hard-liner about sportscar priorities (light and nimble, but with modest horsepower), wants a third vehicle for Toyota's nascent sporty lineup. Currently, we know there's a Supra-like vehicle in the works, being co-developed with BMW, and the 86 is sticking around. Tada said he'd like a third sportscar to compliment the two we know about, and that he wants it soon. A quick bit of history: Toyota's classic sporty lineup had three components. The most visible was the Supra, whose power and prestige grew as the car evolved from a cushy personal tourer to a high-horsepower, high-technology icon. The Celica was its Clark Kent, more mild mannered but also more accessible and affordable. The third was the MR2, a mid-engined go-kart that lasted for three distinct generations. Each had its charms, and all have their fans. When Tada says that he wants three sportscars in the lineup, we already know about the Supra successor, and the 86 is already filling the Celica's role, so the blank is easy to fill. It doesn't sound like Tada spoke the word "MR2" to EVO, or hinted that the car would be mid-engined, but Tada doesn't seem to say anything without purpose. Whatever the layout, this third car – if it comes to fruition – will probably play a role similar to the MR2 in relation to its stablemates. To translate: it'll likely be even lighter and more nimble, and probably less powerful, than the 86. The closest real-world analogue to the pure MR2 ideal is the Honda S660, a mid-engined Kei roadster that's on sale in Japan right now. It's light, small, and powered by a 0.66-liter inline-three. Toyota could decide to directly compete with the S660, borrow an engine from its small-car specialist subsidiary Daihatsu, and produce a mid-engined MR2. Another possibility, even simpler from Toyota's perspective, would be to adapt the existing Daihatsu Copen roadster. Sure, it's front-engine and front-wheel drive, but it's a small, light roadster. And even better, it sells abroad with a larger 1.3-liter engine. Restyle it slightly, perhaps to resemble the S-FR concept of a couple years ago, and it's an off-the-shelf solution. The S-FR itself is a third possibility.

Toyota mulling more Tundra, Tacoma capacity in TX

Toyota may be expanding its pickup truck production at its San Antonio, TX factory following calls from dealers for more Tacoma and Tundra models, according to a new report from Automotive News.
The San Antonio plant is currently able to produce 250,000 trucks on two shifts with overtime, while a secondary facility in Tijuana, Mexico can build an extra 50,000 Tacomas. Despite this capacity, and the fact that Tundra is a slow seller relative to the full-size trucks from Ford, Ram and Chevrolet/GMC (not to mention the Tacoma being part of a segment with diminishing sales), Toyota franchisees apparently can't get enough of the trucks.
"Dealers are telling us they could sell more Tacomas and Tundras," said Bill Fay, the general manager of the Toyota Division. "We are evaluating our footprint and capacity." According to AN, Toyota has moved over 248,000 trucks through November.