Seat Belt Pretensioner Inadvertent Deployment

On November 22, 2023, the Office of Defects Investigation (ODI) opened PE23-021 to investigate instances of seat belt pretensioner inadvertent deployment in model year (MY) 2019 Ford Expedition vehicles manufactured by Ford Motor Company. Some complaints allege hearing a loud, explosion-like sound immediately followed by the seatbelt tightening around the occupant’s torso area. The complaints do not allege a crash occurred that may have resulted in the deployment of the pretensioner system. The investigation revealed certain seatbelt pretensioners may develop corroded squib pins where the bridge wire (heating element of pyro-technic device) is welded. Extended corrosion and a partial separation of the weld may cause a high resistance or an open circuit condition to occur, potentially resulting in pretensioner inadvertent deployment. Inadvertent pretensioner deployment will result in the seatbelt being locked in position, no longer able to extend or retract as designed, which may result in injury in the event of a crash. 11 minor injuries were reported due this failure. Most injuries were bruising to the torso area caused by the rapid tightening of the seatbelt during an inadvertent deployment. On February 9, 2024, Ford filed recall 24V099 for certain MY 2018-2020 Ford Expedition and Lincoln Navigator vehicles with production dates between October 1, 2018, and June 30, 2019. The recall remedy provides the replacement of both front seatbelt retractors if found to have a production date code within the suspect production date range. In view of the recall action being taken by Ford, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.