July 21, 2022 NHTSA CAMPAIGN NUMBER: 22V526000
Passenger Air Bag May Deploy Incorrectly/FMVSS 208
A passenger air bag that does not deploy as intended increases the risk of injury.
NHTSA Campaign Number: 22V526
Manufacturer Tesla, Inc.
Components AIR BAGS
Potential Number of Units Affected 5
Summary
Tesla, Inc. (Tesla) is recalling certain 2022 Model S vehicles. The front bumper carrier structure may alter the vehicle’s crash detection, causing the front passenger air bag to deploy incorrectly during certain low speed crashes. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, “Occupant Crash Protection.”
Remedy
Tesla Service will replace the front bumper carrier structure, free of charge. Owner notification letters were mailed September 19, 2022. Owners may contact Tesla customer service at 1-877-798-3752. Tesla’s number for this recall is SB-22-10-006.
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.
Check if your Tesla has a Recall
SB-22-10-006
July 25, 2022
Replace Ankle Catcher Assembly
Condition
Certain Model S vehicles are equipped with a front bumper carrier structure (ankle catcher assembly) that may change the front passenger airbag deployment behavior, which may not meet regulatory requirements in certain lowspeed
crash scenarios.
Correction
Replace the ankle catcher assembly.
Parts Required
| Part Number | Description | Quantity |
| 1649987-00-B | ANKLE CATCHER, MS | 1 |
Shop Supplies
Loctite 222 threadlocker
Procedure
Replace the ankle catcher assembly (refer to Service Manual procedure 10011202).
Chronology :
– On April 15 and April 16, 2022, for production validation purposes, the new ankle catcher was installed in production on a small number of vehicles manufactured for sale in the U.S.
– From June 3, 2022, to July 5, 2022, as part of the preparation for introducing the new ankle catcher, Tesla conducted CAE simulation assessments to confirm that the new ankle catcher did not have any adverse impact on vehicle crash and airbag performance.
– On July 5, 2022, Tesla learned that CAE simulation results were inconclusive for the 16-mph full frontal load case, and therefore, Tesla began preparations to run physical testing to validate the ankle catcher.
– On July 14, 2022, Tesla conducted a 16-mph full frontal impact test on a representative production vehicle with the new ankle catcher. Tesla carefully reviewed the results from the compliance test and identified a potential non-conformance. On the same day, Tesla learned that a small number of vehicles with the new ankle catcher were delivered to customers, and Tesla determined to issue a voluntary recall.
– As of July 21, 2022, Tesla is not aware of any warranty claims, field reports crashes, injuries, or deaths related to this condition.
1 Affected Product
Vehicle
| MAKE | MODEL | YEAR |
| TESLA | MODEL S | 2022 |
5 Associated Documents
Recall Acknowledgement
RCAK-22V526-3422.pdf 781.554KB
Non-Compliance Notice 573 Report
RCLRPT-22V526-1603.PDF 214.231KB
Remedy Instructions and TSB
RCRIT-22V526-5596.pdf 71.565KB
Owner Notification Letter(Part 577)
RCONL-22V526-5776.pdf 71.138KB
Recall Quarterly Report #1, 2022-3
RCLQRT-22V526-7241.PDF 211.14KB
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SEOCONTENT-START
SB-22-10-006 Page 1 of 1 For feedback on the accuracy of this document, email ServiceBulletinFeedback@tesla.com Tesla, Inc. Service Bulletin Replace Ankle Catcher Assembly SB-22-10-006 July 25, 2022 Classification Section/Group Mobile Service Configuration Recall Bulletin 10 – Body Can Perform (where permitted) All Model Year Model Country/Region Build Location 2021 – 2022 Model S United States Fremont The model(s) and model year(s) listed are a general approximation of the affected VIN list. Refer to the VIN/Bulletin Tracker or Customer/Vehicle profile to determine applicability of this bulletin for a particular vehicle. Recall Bulletins are mandatory service procedures that, unless they can be completed via a firmware update that a customer installs through the normal course of ownership, must be carried out by Tesla-certified Service Centers. Recall work performed by uncertified technicians could lead to unsafe conditions or voided warranty provisions. Condition Certain Model S vehicles are equipped with a front bumper carrier structure (ankle catcher assembly) that may change the front passenger airbag deployment behavior, which may not meet regulatory requirements in certain lowspeed crash scenarios. Correction Replace the ankle catcher assembly. Correction Description Correction Time Replace Ankle Catcher Assembly S012210006 0.45 Part Number Description Quantity Parts Required 1649987-00-B ANKLE CATCHER, MS 1 This part number was current at the time of publication. Use only the revision listed or later, unless otherwise specified in the Parts Catalog. Shop Supplies Loctite 222 threadlocker Procedure Replace the ankle catcher assembly (refer to Service Manual procedure 10011202).
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13101 Tesla Road Austin, TX 78725 IMPORTANT SAFETY RECALL
(if applicable; if not, remove this line) <City, State, ZIP> This notice applies to your vehicle, NHTSA Recall No: 22V-526 Dear Tesla Owner, This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Tesla, Inc. has decided that certain model year (“MY”) 2022 Model S vehicles fail to conform to Federal Motor Vehicle Safety Standard (“FMVSS”) No. 208 “Occupant crash protection.” Our records show that you are the owner of a vehicle affected by this action. REASON FOR THIS RECALL On affected vehicles, the front bumper carrier structure may alter the vehicle’s crash detection, which may cause the front passenger air to not meet the front passenger airbag performance requirements under FMVSS 208 during certain low speed crashes. A passenger air bag deployment that does not comply with FMVSS 208 may increase the risk of injury in a crash. WHAT TESLA WILL DO At no charge to you, Tesla Service will replace the front bumper carrier structure with a replacement part that will achieve compliance with the passenger airbag performance requirements under FMVSS 208 for certain low-speed crash events. WHAT YOU SHOULD DO Please schedule a service appointment through your Tesla mobile app. Alternatively, if you wish to contact your nearest Tesla Service Center or require technical assistance, please visit www.tesla.com/findus or call 1-877-79- TESLA (1-877-798-3752). For awareness, the replacement will take approximately 30 minutes. The repair and the inspection may be completed by Tesla Mobile Service where available. If you believe that Tesla has failed or is unable to remedy this defect without charge or within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue SE, Washington, DC 20590, by calling 1-888-327-4236 (TTY: 1-800-424-9153), or by visiting www.safercar.gov. Federal law requires any lessor who receives a notification of a noncompliance or safety-related defect determination pertaining to any leased motor vehicle to send the notice to the lessee within 10 days. If you no longer own the vehicle, update vehicle ownership in your Tesla Account. For more details adding or removing vehicles from your Tesla Account, visit www.tesla.com/support/account-support#add-remove-products. Thank you for being a Tesla customer. We are committed to ensuring that your vehicle provides the highest possible level of safety. TESLA, INC.**************************************************************************************************************OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-526 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Tesla, Inc. Submission Date : JUL 21, 2022 NHTSA Recall No. : 22V-526 Manufacturer Recall No. : SB-22-10-006 Manufacturer Information : Manufacturer Name : Tesla, Inc. Address : 1 Tesla Road Austin TX 78725 Company phone : 6506815000 Population : Number of potentially involved : 5 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2022-2022 Tesla Model S Vehicle Type : Body Style : Power Train : NR Descriptive Information : The subject population includes five (5) model year 2022 Model S vehicles manufactured with a new “ankle catcher” (i.e., front bumper carrier structure) for the U.S. market. Affected vehicles were identified based on vehicle manufacturing records. Production Dates : APR 15, 2022 – APR 16, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Noncompliance : Description of the Noncompliance : Certain Tesla model year 2022 Model S vehicles equipped with a new ankle catcher structure for the U.S. market may not meet the frontal passenger airbag performance requirements for unbelted and out of position occupants under Federal Motor Vehicle Safety Standard (FMVSS) 208, Section 23. The new ankle catcher structure may alter the vehicle crash pulse in certain crash test scenarios, such that the deployment of the passenger airbag may not meet Tesla’s airbag configuration used for certification under FMVSS 208 S23. FMVSS 1 : 208 – Occupant crash protection FMVSS 2 : NR Description of the Safety Risk : In the case of certain low-speed crash events, where the passenger is unbelted and out of position, a passenger airbag that does not meet the performance requirements of FMVSS 208 may increase the risk of injury. Description of the Cause : NR Identification of Any Warning that can Occur : None Part 573 Safety Recall Report 22V-526 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Involved Components : Component Name 1 : Ankle Catcher, MS Component Description : Front bumper carrier structure Component Part Number : 1683760-00-A Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : – On April 15 and April 16, 2022, for production validation purposes, the new ankle catcher was installed in production on a small number of vehicles manufactured for sale in the U.S. – From June 3, 2022, to July 5, 2022, as part of the preparation for introducing the new ankle catcher, Tesla conducted CAE simulation assessments to confirm that the new ankle catcher did not have any adverse impact on vehicle crash and airbag performance. – On July 5, 2022, Tesla learned that CAE simulation results were inconclusive for the 16-mph full frontal load case, and therefore, Tesla began preparations to run physical testing to validate the ankle catcher. – On July 14, 2022, Tesla conducted a 16-mph full frontal impact test on a representative production vehicle with the new ankle catcher. Tesla carefully reviewed the results from the compliance test and identified a potential non-conformance. On the same day, Tesla learned that a small number of vehicles with the new ankle catcher were delivered to customers, and Tesla determined to issue a voluntary recall. – As of July 21, 2022, Tesla is not aware of any warranty claims, field reports crashes, injuries, or deaths related to this condition. Part 573 Safety Recall Report 22V-526 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : At no cost to the customer, Tesla will replace the ankle catcher in affected vehicles with a replacement part that will achieve compliance with the passenger airbag performance requirements under FMVSS 208 for certain low-speed crash events. Tesla does not plan to include a statement in the Part 577 owner notification about pre-notice reimbursement because all involved vehicles remain covered under the new vehicle warranty. How Remedy Component Differs from Recalled Component : The remedy component is a validated product that has been tested and validated to achieve the passenger airbag performance requirements under FMVSS 208 whereas the recalled one is a trial component in the process of being validated. Identify How/When Recall Condition was Corrected in Production : The recalled component was installed in vehicles for production validation purposes and measures were taken to prevent further consumption of it in production until validation is completed. Recall Schedule : Description of Recall Schedule : All Tesla stores and service centers will be notified about this recall on or shortly after July 25, 2022. Owner notification letters will be mailed in accordance with 49 C.F.R. § 577.7. Planned Dealer Notification Date : JUL 25, 2022 – JUL 25, 2022 Planned Owner Notification Date : SEP 19, 2022 – SEP 19, 2022 * NR – Not ReportedSEOCONTENT-END
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