The 2006 Avalon airbag system shows a pattern of field problems across multiple failure modes. Owners report complete non-deployment in actual collisions at highway speeds—one driver struck another vehicle at 60 mph with major front-end damage and no airbag inflation; another experienced a broadside hit at 50 mph on the driver side with no side airbag deployment; a third struck a deer at 40 mph with no deployment. In a 25 mph frontal impact, airbags that did deploy released metal fragments alongside gases, causing a driver to sustain a dislocated vertebra, facial injuries, chest trauma, permanent hearing loss, and requiring spinal surgery.
A separate but widespread complaint is progressive cracking of the dashboard over airbag covers, particularly the passenger side, expanding from small fissures to multi-inch splits with heat exposure. Owners describe the cracked material becoming sticky and worry about debris ejection if airbags deploy. One owner paid $2,000 out-of-pocket to replace the entire dashboard after dealer refusal. Multiple owners report the airbag warning lamp staying lit continuously; dealers charge diagnostic fees and cite no recall coverage.
One owner's wife sustained fractures to both feet, severe contusions, and a third-degree chemical burn when the knee bolster airbag deployed in an accident. Toyota issued recall 15V043000 for airbags, but owners report parts unavailability caused long delays and some missed recall deadlines entirely.
Failure modes owners describe
Airbag non-deployment in collisions
Driver or passenger-side airbags failed to deploy during frontal and broadside collisions at speeds ranging from 40–60 mph, resulting in occupant injuries.
When: Multiple incidents between 12,000–121,000 miles; collision events at 25–60 mph
Symptoms owners cite: Airbags did not inflate during frontal impacts; Side airbags did not inflate during broadside collision; No deployment upon hitting another vehicle or obstruction
Repairs/costs cited: Vehicle destruction; no repair documented. One owner notes a recall 133 cars in 3/2006 but was not notified.
Recalls/TSBs owners mention: Recall 15V043000 (airbags) mentioned; part availability delayed beyond reasonable timeframe. No response documented for non-deployment complaints.
Dashboard cracking over airbag cover
Passenger-side and front dashboard panels crack progressively over the airbag deployment zones, raising concerns about debris ejection during deployment.
When: Cracking observed in 2010 and subsequent years; one complaint mentions progression from 1 inch to 2 inches in length
Symptoms owners cite: Visible cracks in dashboard over airbag cover; Cracks expand over time with heat exposure; Dashboard becomes sticky to touch; Passenger-side cover bowing outward
Repairs/costs cited: One owner replaced entire dashboard at personal cost of $2,000. Dealers advised cracking is acceptable and will not diminish airbag integrity; repairs denied under warranty.
Recalls/TSBs owners mention: No recall issued for dashboard cracking. Dealers state out of warranty; Toyota corporate declined reimbursement.
Airbag warning lamp constantly illuminated
SRS airbag warning light remains on continuously without apparent trigger, preventing driver from confirming system status.
When: Observed at 161,000 miles on original owner vehicle; another at unspecified mileage
Symptoms owners cite: Airbag warning light on continuously; Light will not clear; No diagnostic trouble codes accessible to owner
Repairs/costs cited: Dealer charges $75 diagnostic fee. One owner suspected Takata manufacture given humid climate (Eastern Kansas).
Knee bolster airbag injury on deployment
Knee-level airbag deployed in accident and inflicted severe injuries to occupant, including foot fractures and chemical burn.
When: Accident-triggered deployment; mileage not specified
Symptoms owners cite: Knee bolster airbag deployed during collision; Occupant sustained fractures to both feet; Severe contusions on both feet; Third-degree chemical burn on left leg
Repairs/costs cited: Owner requested knee airbag removal post-injury.
Passenger-side airbag deployment with metal fragments and gases
Frontal airbag deployed with excessive force, releasing metal fragments and hot gases that injured the occupant beyond normal deployment trauma.
When: 20,000 miles; 25 mph frontal impact
Symptoms owners cite: Frontal driver and feet airbags deployed with gases and metal fragments; Driver sustained dislocated vertebrae, facial injuries, chest injuries from seat belt, shin injuries from feet airbags; Permanent hearing loss in driver; Required surgery for spinal damage
Repairs/costs cited: Vehicle destroyed. Fire Department present at scene.
Recalls/TSBs owners mention: Dealer notified (Sheehy Toyota, Stafford, VA) but manufacturer not made aware.
Synthesized from 23 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.