NHTSA Complaint #10352045 — 2008 SMART FORTWO COUPE

CRAZING AND FAILURE OF MAKROLON (POLYCARBONATE) ROOF ON ALL SMART FOR TWO COUPES FROM 2008 TO PRESENT. POLYCARBONATE (PC) MATERIAL THE TRANSPARENT ROOF PANEL IS MADE FROM DISINTEGRATES FROM UV SUNLIGHT OR HEAT BEYOND ITS 150F RATING EXACERBATED BY SMART'S SUNSHADE INSIDE THE CAR. PC IS NOT RESISTANT TO OZONE AND OTHER CHEMICALS LISTED HERE: HTTP://WWW.SHEFFIELDPLASTICS.COM/WEB_DOCS/MAKROLON%20CHEMICAL%20RESISTANCE.PDF MANY OF WHICH ARE IN THE AIR AND IN CLEANING SUPPLIES. FROM THIS MFG WEB..."EXPOSING MAKROLON SHEET TO REPEATED STEAM CLEANING OR DISH WASHING CAN CREATE HYDRAULIC CRAZING. THE RESULT CAN BE A CLOUDING OF THE SURFACE AND ULTIMATELY A LOSS OF PHYSICAL STRENGTH PROPERTIES." TEMPERATURES MEASURED BETWEEN SUNSHADE AND MAKROLON ROOF PANEL IN SC PARKING LOT FAR EXCEEDS 150F SPEC, CAUSING THE OBSERVED FAILURES. THESE FAILURES WILL, EVENTUALLY, CONSUME THE PLASTIC ROOF WHICH WILL FALL ON OCCUPANTS OR EXPLODE OUTWARDS ONTO FOLLOWING TRAFFIC WHEN, NOT IF, THE PLASTIC FINALLY FAILS, STRUCTURALLY. THE FAILURE IS SLOW AND TAKES A YEAR OR MORE TO MATERIALIZE. AS THIS MODEL IS ONLY 2 YEARS OLD, JUST OUT OF WARRANTY, SMART HAS DONE NOTHING TO RECALL/REPLACE THE DEFECTIVE MATERIAL, STONEWALLING THE CUSTOMERS TO THE PROBLEM. BEFORE SOMEONE GETS HURT, OR THIS PANEL FAILS AND FALLS ON THE CHILDREN OR CAUSES PANIC TO THE DRIVER, THIS ROOF PANEL SHOULD BE RECALLED, EVEN OUT OF WARRANTY BECAUSE IT TAKES MORE THAN THE 2-YEAR WARRANTY PERIOD FOR THE FAILURE TO OCCUR, BY FORCE OF GOVERNMENT IF NECESSARY. SMART REPLACES ONE DEFECTIVE PANEL WITH ANOTHER UNDER WARRANTY, WHICH DOES NOT SOLVE THE PROBLEM OF DEFECTIVE MATERIAL, SO THE PROBLEM REPEATS. A FORCED RECALL TO REPLACE WITH OTHER MATERIAL MORE REALISTIC TO INTENSE UV SUNSHINE IN A HOT PARKING LOT IS WARRANTED BECAUSE OF THE COMPANY'S ATTITUDE TOWARDS PROPER REPLACEMENT WITH A DIFFERENT MATERIAL. THANK YOU FOR YOUR CONSIDERATION IN THIS MATTER. *TR