The use of DNA constructs encoding mycobacterial proteins is a promising new approach to vaccination against tuberculosis. A DNA vaccine encoding the hsp60 molecule of Mycobacterium leprae has previously been shown to protect against intravenous infection of mice with Mycobacterium tuberculosis in both the prophylactic and immunotherapeutic modes. It is shown here, however, that this vaccine was not effective in a more realistic aerosol infection model or in a model of latent tuberculosis in the lungs. Moreover, when given in an immunotherapeutic model the immunized mice developed classical Koch reactions characterized by multifocal discrete regions of cellular necrosis throughout the lung granulomas. Similar and equally severe reactions were seen in mice given a vaccine with DNA coding for the Ag85 antigen of M. tuberculosis. This previously unanticipated safety problem indicates that DNA vaccines should be used with caution in individuals who may have already been exposed to tuberculosis.Disease caused by Mycobacterium tuberculosis is the leading cause of death from an infectious disease. Currently, it is estimated that over 2 million people die from tuberculosis yearly and that 8 million people contract the disease (5). Individuals who have been exposed to the bacillus but may have controlled it in the form of a latent infection, and who therefore are at risk of reactivation disease, may number in the hundreds of millions (6).There has been a gradual realization that the existing vaccine against tuberculosis, Mycobacterium bovis BCG, loses its effectiveness in individuals as they pass the teenage years (3, 21), and in certain clinical trials its overall effectiveness has been zero (14). As a result there is now a concerted effort to try to identify more effective vaccines against tuberculosis, using well-characterized animal models for initial screening (16).To date, the most effective vaccine used in mouse studies is a DNA vaccine encoding the 65-kDa heat shock protein of Mycobacterium leprae (hsp60/lep). Mice immunized with this DNA vaccine have shown 2-to 3-log reductions in bacterial load after intravenous challenge with virulent M. tuberculosis, and the vaccine is equally protective if given prophylactically, as an immunotherapeutic vaccine, or in a Cornell type model in which bacteria are eliminated by chemotherapy, leaving only bacilli that are in a latent or dormant form (12).In the study presented here the hsp60/lep vaccine was tested using the more realistic pulmonary infection model in the mouse, in which the animal is exposed to a small challenge dose by aerosol exposure. In this model the hsp60/lep DNA vaccine was ineffective in both the prophylactic and Cornell modes. Moreover, this vaccine, as well as the previous described highly protective Ag85/TB DNA vaccine (1, 8, 25), both induced progressively severe pulmonary necrosis in an immunotherapeutic vaccination model, especially when given to a susceptible mouse strain. While this class of DNA vaccines appears to be completely safe in terms of i...