Nissan’s newly updated Sentra has been receiving attention for offering a surprisingly upscale feel for its class. However, the previous-generation version is making headlines for a far stranger reason. Nearly 41,800 units are being recalled due to a defect involving the windshield, which may contain air bubbles that interfere with outward visibility. The problem affects certain 2025 Sentra models, and federal regulators determined that the flaw violates safety rules governing automotive glass, specifically those that dictate the clarity and structural integrity of “glazing materials.”
According to official recall documents, the defect stems from a manufacturing problem involving one of Nissan’s suppliers. In affected windshields, air pockets can form inside the laminated glass, compromising a driver’s forward view. Regulations explicitly forbid bubbles or imperfections that appear more than 13 millimeters (0.5 inches) away from the outer edge of the windshield, making even small defects a legal violation. The issue first came to light in August, when quality inspectors at Nissan’s Aguas II production facility in Mexico noticed abnormalities in a routine audit. During their review, they found that trapped air had accumulated between the windshield’s two glass layers and the polyvinyl butyral (PVB) material that bonds them together.
Nissan’s subsequent investigation—conducted in partnership with the windshield supplier, Vitro—led to a clearer understanding of what had gone wrong. Engineers discovered that the locator pins used in the windshield molds were not properly aligned during production. This misalignment created uneven pressure during the molding process, especially in the upper portion of the windshield. As a result, the system struggled to remove all air during assembly, leaving pockets that could later appear as visible bubbles.
Fortunately, Nissan believes the problem is relatively limited in scope: the company estimates that only around 2.2% of the vehicles included in the recall actually contain the flawed glass. At this stage, Nissan reports no known crashes, injuries, or warranty claims connected to the defect. Still, because inadequate visibility poses a critical safety risk, the automaker is taking corrective action. Under the recall procedure, authorized dealers will carefully examine the windshield of each affected Sentra. If any air bubbles are detected, the windshield will be replaced at no cost to the owner. The service is expected to take up to 2.5 hours, depending on the extent of the work required.
Owners will begin receiving official recall notices in mid-January, though Nissan points out that many drivers may be able to spot the air bubbles themselves simply by looking closely at their windshield. Until repairs are completed, owners are encouraged to monitor the condition and report any concerns to their dealer.