10 Biggest Recalls That Rocked The Auto Industry

Within the automotive industry, a recall is the last thing that any manufacturer wants to be faced with. Especially on a large scale, a recall can end up costing a company billions of dollars, becoming an almighty challenge to overcome. The reason for a recall can vary drastically, with only minor issues having the ability to affect millions of everyday cars. While these recalls can sometimes cost huge amounts to correct, the issues that cause a great risk to customer safety are what can damage a brand’s image as well as severely affect profits.

Each year, the industry sees quite a few recall cases. In 2023, there were more than 320 different recalls in the U.S., potentially affecting up to 32 million vehicles on the road. While these numbers may seem high, throughout automotive history, single recall cases have eclipsed 2023’s numbers by themselves. Here’s a look at 10 of the biggest recalls that made waves throughout the automotive industry, and ones that brands would most likely want to forget and keep in the past.

In order to give you the most up-to-date and accurate information possible, the data used to compile this article was sourced from various manufacturer websites and other authoritative sources, including The New York Times, CBS, CNBC, MotorTrend, and the NHTSA. The entries on this list are ordered from lowest to highest, and are based on the total number of units recalled.

10 The Ford Pinto Controversy

1.5 Million Units Recalled In 1978

The first and perhaps the most controversial recall to feature on this list came in 1978, with the Ford Pinto needing to have 1.5 million models recalled in 1978. The Ford Pinto had to be recalled due to the fuel filler neck presenting a great risk of separation in a rear-end collision, which would release fuel into the passenger seats and be ignited. The worst element about this issue is that Ford was aware of it, but decided it would cost too much money to alter the design.

• Models Affected: 1971-1976 Ford Pinto
• Number Of Units Affected: 1.5 Million
• Corrective Action Taken: Ford placed a polyethylene shield between the fuel tank and the common causes of a puncture, lengthened the filler tube, and improved the tank filler seal in the event of a collision.

The recall wasn’t the only challenge that the Ford Motor Company would have to face, as lawsuits regarding the Pinto’s reason for recalling quickly followed. Ford has to pay a landmark $125 million in punitive damages, a testament to how serious this case was for the company. Sadly, 27 deaths were reported to be linked to this issue by the NHTSA.

9 Volkswagen’s Faulty Windshield Wipers

3.7 Million Units Recalled In 1972

One of the earliest cases of a major recall in semi-recent automotive history came with German automaker Volkswagen, with a minor issue leading to a significant safety risk. In the late1960s, the VW Beetle became one of the most popular cars in the U.S., with its most successful year coming in 1968 with 423,008 models sold.

• Models Affected: 1949-1969 Volkswagen Beetles and Volkswagen T2s
• Number Of Units Affected: 3.7 Million
• Corrective Action Taken: Volkswagen decided that customers should pay for the windshield wiper repairs themselves.

However, as the car’s cost-effective practicality attracted more and more customers, reports of their car’s windshield wipers started to become common, leading to the NHTSA requesting Volkswagen to investigate this issue. In response, the German manufacturer issued a recall for all models affected. If owners decided to replace the parts necessary, they actually had to pay for the parts themselves.

8 Fiat Chrysler’s Cruise Control Malfunction

4.8 Million Units Recalled In 2018

One of the most frightening reasons for a large-scale recall in the 21st century affected the majority of Chrysler’s most popular models. At the time, Fiat was the parent company of Chrysler, until 2021 when Fiat merged with the PSA Group to form Stellantis. In total, 4.8 million vehicles had to be recalled due to the same issue, that being potentially deadly faults with the company’s cruise control system.

• Models Affected: 2014-2019 Ram pickup trucks, 2015-2017 Chrysler 200, 2014-2018 Chrysler 300, 2017-2018 Chrysler Pacifica Minivan
• Number Of Units Affected: 4.8 Million
• Corrective Action Taken: Fiat Chrysler fixed the software glitch causing the cruise control malfunction.

The reason for the recall was due to reports of drivers not being able to turn their cruise control mode off, causing their cars to either maintain speed if they didn’t break extremely hard, or speed up unexpectedly. As well as Chrysler models, Dodge, Jeep, and Ram were also affected by the recall.

7 Toyota’s Window Switch Drama

6.5 Million Units Recalled In 2015

A much more recent case of a small fault causing potentially huge problems came in 2015, with a brand that’s considered one of the most reliable, Toyota. The typically mechanical aspects that Toyota gained its reliable reputation from, such as engine components, transmission, or suspension, weren’t the cause for the massive 6.5 million-unit recall. Instead, it was due to the window switches having the potential to catch fire.

• Models Affected: 2007-2009 Toyota Camry and Camry Hybrid, 2009-2011 Toyota Corolla, 2008-2011 Toyota Highlander and Highlander Hybrid, 2009-2011 Toyota Matrix, 2006-2011 Toyota RAV4, 2009-2011 Toyota Sequoia, 2009-2011 Toyota Tundra, 2006-2010 Toyota Yaris, 2009-2011 Toyota Scion XD, and 2009-2010 Toyota Scion XD.
• Number Of Units Affected: 6.5 Million
• Corrective Action Taken: Dealers inspected the switch and a lubricant was applied if an abnormality was found.

Toyota became aware of this rather bizarre issue after receiving eleven reports of burn marks on their car’s door, which led to the investigation that subsequently led to the large-scale recall. The Japanese manufacturer concluded that debris would gather within the switches’ contact points, leading to significant overheating and/or short-circuiting.

6 General Motors’ Chevrolet Engine Mounts

6.7 Million Units Recalled In 1971

Going back to the early 1970s, one of the biggest automotive recalls in American history impacted a manufacturer at the forefront of the nation’s industry, General Motors. GM was and still is the parent company for a few different brands in 1971, with Chevrolet and GMC being two of these. With Chevrolet producing an array of different models by 1971, the recall of a massive 6.7 million units affected countless buyers.

• Models Affected: 1965-1969 full-size Chevrolets,1965-1969 Chevy II’s and Novas, 1967-1969 Camaros, and 1965-1970 Chevrolet/GMC trucks
• Number Of Models Affected: 6.7 Million
• Corrective Action Taken: General Motors designed a cable system to attach to the engine and car frame, which kept the engine from raising, even in the event of the engine mount breaking.

The reason for the 1971 General Motors recall was due to some Chevrolet and GMC models having defective engine mounts, which included ’65-’69 full-size Chevrolets, Chevy IIs and Novas, ’67-’69 Camaros, and ’65-’70 Chevrolet/GMC trucks. The issue came with the left side of the mount braking, leading to the V-8 engines’ large amounts of torque lifting the engine, and opening the accelerator linkage.

5 Toyota’s Pedal Entrapment Tragedy

9.0 Million Units Recalled In 2010

Alongside the Ford Pinto case, Toyota’s recall in 2010 is one of the worst cases regarding driver safety, ultimately leading to the worst possible result. In 2010, Toyota issued a recall on almost nine million models due to the removable floor mats occasionally slipping forward, trapping the gas pedal, and leading to unintended acceleration.

• Models Affected: 2005–2010 Toyota Avalon, 2007–2010 Toyota Camry, 2009–2010 Toyota Corolla, 2008–2010 Toyota Highlander, 2009–2010 Toyota Matrix, 2004–2009 Toyota Prius, 2005–2010 Toyota Tacoma, 2007–2010 Toyota Tundra, 2009–2010 Toyota Venza, 2007–2010 Lexus ES 350, 2006–2010 Lexus IS 250, 2009–2010 Pontiac Vibe
• Number Of Models Affected: 9.0 Million
• Corrective Action Taken: Toyota reconfigured the accelerator pedals, replaced the all-weather floor mats with thinner mats, and installed a brake override system to prevent any unwanted acceleration.

Tragically, 89 deaths have been linked to the floor mat entrapment issue. Toyota had to pay a total of $16.4 million due to its delayed response to the issue. Out of all the major recalls in the 21st century so far, Toyota received one of the biggest hits to its reputation for building some of the most reliable cars on the road.

4 Volkswagen’s ‘Dieselgate’ Mass Recall

11 Million Units Recalled In 2016

A story that grabbed all the major headlines in 2016 was Volkswagen’s widespread recall, which quickly gained the nickname ‘Dieselgate’. The reason for the scandal was that VW vehicles that were fitted with either a diesel 1.6-liter or 2.0-liter TDI engines had software installed that evaded the EPA emission standards at the time. Due to the VW Group owning multiple brands such as Audi, it wasn’t just the manufacturers’ cars that were affected.

• Models Affected: 2009-2015 VW Jetta, 2013-2015 VW Beetle, 2010-2015 Audi A3, 2010-2015 VW Golf, 2012, VW Passat, 2009-2016VW Touareg, 2013-2016 Porsche Cayenne, 2014-2016 Audi A6, 2014-2016 Audi A7, 2014-2016 Audi A8/A8 L, 2014-2016 Audi Q5, 2009-2016 Audi Q7
• Number Of Models Affected: 11 Million
• Corrective Action Taken: Volkswagen installed a minor hardware modification to the air intake systems of all cars, as well as a new software update.

This was one of the largest recalls in automotive history, costing Volkswagen a staggering $35 billion in total, taking into account financial settlements, buyback costs, and penalties. The scandal was brought to a close in the U.K. in 2022, with the brand having to pay an extra £200 million.

3 Ford’s Ignition Switch Dangers

22.7 Million Units Recalled In 1996

Ford’s recall in 1996 was the largest recall ever made by an automotive manufacturer. The reason for the recall wasn’t quite as severe as other reasons in this list, but it still led to at least 28 injuries between 1984 and 1993.

• Models Affected: 1988-1993 Ford Vehicles, Mercury Vehicles and Lincoln Vehicles
• Number Of Models Affected: 22.7 Million
• Corrective Action Taken: Ford fixed all the recalled vehicle’s ignition switches to prevent any potential short-circuits.

The recall was due to the ignition switches being prone to short-circuiting. Unfortunately for Ford, the same switch was used in the majority of their best-selling models, including the Mustang, and Explorer. Things went from bad to worse for the Detroit-based company, as the case was actually split into two different recalls. The first led to 8.7 million vehicles being recalled, but then an additional 14 million units also had to be fixed, costing Ford $435 million in total.

2 General Motor’s Ignition Switch Turbulence

30 Million Units Recalled Between 2006 And 2014

General Motors has seen its fair share of recalls throughout its history, but none affected the company as heavily as the recall of 30 million cars in 2014. The models that the problem was most prominent in were the Chevrolet Cobalt and the Saturn Ion, with their faulty ignition switch disabling systems such as brake assist and airbags.

• Models Affected: 2003-2007 Saturn Ion, 2005-2010 Chevrolet Cobalt, 2006,2011 Chevrolet HHR, 2007-2010 Pontiac G5, 2006-2010 Pontiac Solstice, 2007-2010 Saturn Sky
• Number Of Models Affected: 30 Million
• Corrective Action Taken: GM replaced all the recalled vehicle’s ignition switches to prevent them from affecting any other systems of the cars.

The 2014 recall was one of the most turbulent periods of GM’s history, as the ignition switch was linked to 124 deaths. Taking into account repair costs, fines, and compensation, GM ended up spending a total of $4.1 billion throughout 2014.

1 The Largest Recall Of All Time: Takata’s Airbags

67 Million Units Recalled So Far

So far, the largest automotive recall in history hasn’t come from a car manufacturer, but instead from a car parts maker, specifically airbags. Takata was one of the biggest suppliers of airbags in the world, supplying airbags to 19 different automakers, bringing the total to 34 brands. However, supplying so many brands was the reason for the eventual demise of the company.

• Models Affected: 2000–2015 models from manufacturers including Acura, BMW, Cadillac, Chevrolet, Chrysler, Dodge, Ford, Honda, Jeep, Lincoln, Mazda, Mercury, Nissan, and Ram.
• Number Of Models Affected: 67 Million
• Corrective Action Taken: NHSTA prioritized the vehicles that were fitted with Takata airbags to be replaced.

The issue with Takata’s airbags is the worst-case scenario, with the bags exploding when deployed. In the U.S. alone, there have been 400 injuries and 26 deaths as a result of the metal shards coming from the airbags after exploding, with the shards being a result of the specific construction of the bags.

So far, 67 million vehicles have been recalled worldwide by the end of 2022, with 11 million units still needing to be recalled. In 2017, Takata eventually filed for bankruptcy, with the $1 billion criminal penalty tipping the already-struggling brand over the edge.