Evenflo Lawsuit Alleges Recalled Children’s Car Seats Pose Choking Hazard Due to Headrest Design Defect

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A proposed class action lawsuit alleges that certain Evenflo car seats suffer from a headrest-related design defect that can create a choking hazard for infants and young children.

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The 31-page lawsuit against Evenflo claims that the cover of the foam headrest found on the company’s Gold Revolve360 Slim and Revolve360 Slim car seat models can be easily removed by children, exposing foam underneath that can be pulled off in pieces. Should these chunks be ingested, they could pose a potentially fatal choking hazard, the suit says.

The case states that roughly 324,000 car seats were voluntarily recalled by Evenflo in September 2025 in cooperation with the National Highway Traffic Safety Commission. The recall came after “11 case reports of children with foam pieces from the headrest in their mouths and 12 case reports of children with foam pieces from the headrest, though not ingesting it,” with no injuries reported, the complaint details.

However, the class action lawsuit charges that the Evenflo recall was “wholly inadequate for consumers” given that the remedy—a free kit with an additional tape seal supposedly designed to prevent a child’s access to the headrest foam—provides no real relief and instead leaves consumers with a car seat that remains dangerous to use.

Per the suit, the model numbers associated with the recalled Gold Revolve360 Slim and Revolve360 Slim car seats are 36812449, 36812449AZ, 36812450, 36812450POP, 36812450AZ, 36812451, 36812451AZ, 36812467, 36812467AZ, 36812468, 36812468AZ, 36812469, 36812469AZ, 36812470, 36812470A, 36812470TGT, 36812471, 36812501, 36812501A, and 36812504. The recall applies to units manufactured between December 1, 2022, and December 8, 2024, the filing says.

According to the complaint, Evenflo “was aware, or should have been aware, that the Car Seats’ headrest cover could become unsecured” because of robust industry-standard product testing. The plaintiffs contend that the danger posed by the car seats negates several advertising claims made by Evenflo, including statements such as “safety has never meant more,” and that its products “typically include more advanced safety and comfort features than convertible car seats.”

On top of the recall, Evenflo has urged consumers with the afflicted car seat models to cease using them and contact the company for a free repair kit. This kit includes tape intended to act as an additional seal for the headrests, covering the foam access points.

Head to this page to confirm your model information and receive a free headrest repair kit from Evenflo, with shipping included. The repair kit requires no additional tools and includes instructions for assembly. The company claims that shipping will begin in early November.

This is not the first time Evenflo has been under fire for allegedly defective, unsafe products. In January 2020, a portable crib "napper" was recalled due to a suffocation risk after it was reported that infants could easily roll from their back to stomach or side.

“Every Product suffers from the uniform Defect, which, unknown to consumers but known to Defendant, exists at the point of purchase and poses an unreasonable safety hazard to children,” the case alleges. “As such, Plaintiff and all reasonable consumers are victims of the unfair bargaining power between them and Defendant based on Evenflo’s superior industry knowledge.”

Proposed class members for the Evenflo car seat lawsuit include all consumers in the United States who bought one or more of the products at issue in the U.S. during the applicable statute of limitations period. Check out ClassAction.org’s lawsuit list for the latest open class actions.