Takata is adding a new type of airbag inflator to the US's largest automotive recall.
The company filed documents with the US government adding 2.7 million vehicles to the recall from Ford, Nissan and Mazda, all with a type of inflator that was previously thought to be safe.
Takata inflators can explode with too much force and spew shrapnel into drivers and passengers.
At least 17 people have died and more than 180 injured due to the problem.
The inflators have caused the largest automotive recall in US history, with 42 million vehicles and up to 69 million inflators being called back for repairs.
Takata uses the chemical ammonium nitrate to inflate airbags but it can deteriorate when exposed to high airborne humidity and high temperatures.
Previously, the company believed a drying agent called a desiccant stopped the chemical degrading.
But the National Highway Traffic Safety Administration says tests by Takata show for the first time a type of desiccated inflator "will pose a safety risk if not replaced".
Nissan says the new recall affects just more than 515,000 Versa subcompact hatchback and sedans from the 2007 through 2012 model years.
Mazda says its recall covers about 6000 B-Series trucks from 2007 through 2009.
Ford, which has the most vehicles involved in the latest recall, is reviewing the information and will file a list of models within the five days required by law.
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