Why Some Recalls Become Infamous
Car recalls can happen for all sorts of reasons, but the ones that stick in people’s minds usually share two traits: they’re widespread, and they’re severe. Sometimes the issue is a safety defect that can cause injuries or fires, while other times it’s a problem so costly or complicated that it reshapes how an automaker operates. Below are 20 recalls that earned a reputation for scale, seriousness, or lasting impact.
1. Takata Air Bag Inflators
Takata’s inflator defect became the largest and most complex safety recall in U.S. history, spanning many brands and model years. It’s not that the airbags wouldn’t work; it’s that they worked too well. It was discovered that in many of these vehicles, the airbags would explode when they were deployed. What was meant to be a safety feature caused the deaths of well over 30 people. Over 67 million vehicles have been recalled in the U.S alone.
2. GM Ignition Switch Defect
GM realized that six different small car models were suffering from a faulty ignition switch, which brought on a plethora of issues, such as a loss of power while driving or air bag deployment. Well over 30 million cars have been recalled worldwide, and GM has had to provide compensation for over 100 deaths due to the issue.
3. Toyota Floor Mat Entrapment
Toyota’s floor mat-related recall was triggered by concerns that certain mats could trap the accelerator pedal. In response, Toyota ended up recalling models of their Camry, RAV4, Tacoma, and Lexus models - around 3.8 million in the United States alone.
4. Toyota Sticky Accelerator Pedals
Separate from the floor mat incident, Toyota also recalled vehicles over accelerator pedals that could become mechanically stuck or slow to return. The risk wasn’t subtle: unintended acceleration can remove a driver’s ability to control speed in normal traffic conditions. The recall documentation lists about 2.3 million vehicles potentially involved.
5. Firestone ATX/Wilderness Tires
This tire recall became notorious due to its association with crashes, injuries, and fatalities. NHTSA’s engineering analysis describes the defect determination and the start of the replacement effort in August 2000. Contemporary reporting around the campaign commonly cited more than 6.5 million tires recalled in the U.S.
6. Volkswagen Diesel Defeat Device
Volkswagen’s diesel emissions scandal, known as “Dieselgate,” didn’t just cause a recall; it triggered years of buybacks, repairs, and regulatory settlements. The underlying issue involved emissions controls that performed differently during testing than in real-world driving, violating many Clean Air Act rules and regulations.
7. GM Rear Suspension Campaign
If you’re looking for pure scale, this one is hard to top: an early-1980s GM campaign involving 55.8 million vehicles tied to failing rear suspensions. The sheer volume made it a defining moment in the public’s awareness of recalls. Luckily, no deaths were reported due to this error.
8. GM Motor Mount Failure
This 1971 GM recall involved 6.7 million vehicles, all of which were at risk for acceleration and brake failure due to a faulty motor mount. This massive issue was discovered in 1965-69 Chevrolet cars and Novas, as well as in 1967-69 Camaro autos, and a few of the smaller trucks from that period as well.
9. Firestone 500 Radial Tires
This recall is often referenced as a turning point for tire safety. In 1978, Firestone 500 recalled over 7 million tires after discovering that some of their models were causing blowouts and tread separation. Well over 250 people died due to this error.
10. Ford Cruise Control Fires
Ford’s speed control deactivation switch issue became infamous because it involved fire risk, even when vehicles were parked. Over 4.5 million-vehicles were recalled due to these cruise control settings.
11. Ford Pinto Fuel Tank
The Pinto recall remains one of the most discussed safety cases in automotive history. Ford agreed to recall 1.5 million Pintos and 30,000 Mercury Bobcats to address fuel system design concerns tied to rear impacts and fire risk. The reputational damage from this episode has lasted for decades.
dave_7 from Lethbridge, Canada on Wikimedia
12. Ford Ignition Switch Fires
Ford’s 1996 ignition switch recall was vast and unsettling, with roughly 7.9 million Ford, Lincoln, and Mercury vehicles in the U.S. for an ignition switch defect. The long and short of the issue was that the engines weren’t actually turning off, which could lead to further engine troubles or fires.
13. FCA Uconnect Cybersecurity
This was a landmark moment because it treated a software security vulnerability like the safety issue it can become. Reports noted that this issue affected around 1.4 million vehicles, tied to Uconnect systems with specific vulnerabilities. A recall for cybersecurity also forced the broader industry to take connected-car threat models more seriously.
14. Jeep Liberty Fuel Tank
This early 2000s recall saw over 1.50 million vehicles recalled, due to an increased risk of fuel tank leaks should someone get into a rear-end collision. This error caused well over 50 deaths, simply due to the fuel tank placement.
15. FCA Shifter Rollaway Risk
This recall addressed “monostable” shifters that could leave drivers believing the vehicle was in Park when it wasn’t. The Part 573 report lists 811,146 potentially involved vehicles and explains the injury risk if a driver exits while the vehicle can still move. FCA’s remedy centered on software updates designed to add safeguards.
16. Chevy Bolt Battery Fires
Battery recalls are uniquely disruptive because the remedy can be complex and the interim guidance can affect daily life. Currently, all 2017-2022 Chevy Bolt EVs and 2022 EUVs are being recalled due to fire risks from defective battery modules.
17. Hyundai/Kia ABS Fire Risk
This recall drew attention because regulators and manufacturers warned owners to park outside due to fire risk. A reported 3.3 million vehicles were affected in the U.S., linked to potential electrical shorts tied to the anti-lock brake control module area.
Hyundai Motor Group on Unsplash
18. Ford Door Latch Failure
Door latches that can fail aren’t just annoying; they’re dangerous at highway speeds. It was discovered that many Ford models had a faulty pawl spring tab that could break quite easily, which caused doors to open without warning.
19. Tesla Autopilot Controls
Tesla has recalled over 2 million vehicles from 2012 to 2023, due to ongoing issues with the driver monitoring systems. Reports say that the current monitoring for driver attentiveness was less than adequate.
20. Hyundai/Kia Theta II Engines
Engine-related defects can be financially brutal and safety-critical at the same time. Over 4 million Sonatas, Santa Fe Sports, Tuscsons, and Kia Optimas, Sorentos, and Sportages have been recalled due to potential issues with engine seizure, stalling, and fire risks.
