NHTSA owner reports · September 18, 2026 snapshot.
Equipment complaints
14 reportsClear category filter89,000 miles · Jun 2, 2014
Electrical SystemEquipmentSteering
TL * THE CONTACT OWNS A 2004 SATURN ION. THE CONTACT STATED THAT THE VEHICLE WOULD MAKE A LOUD NOISE WHENEVER SHE MADE A TURN. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE RACK AND PINION NEEDED TO BE REPLACED. IN ADDITION, THE CONTACT STATED THAT THE WINDSHIELD WIPER MALFUNCTIONED. THE MAN…
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TL * THE CONTACT OWNS A 2004 SATURN ION. THE CONTACT STATED THAT THE VEHICLE WOULD MAKE A LOUD NOISE WHENEVER SHE MADE A TURN. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE RACK AND PINION NEEDED TO BE REPLACED. IN ADDITION, THE CONTACT STATED THAT THE WINDSHIELD WIPER MALFUNCTIONED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 89,000 AND THE CURRENT MILEAGE WAS 89,447. UPDATED 08/19/14*LJ THE CONSUMER STATED SHORTLY AFTER PICKING THE VEHICLE UP FROM THE DEALER, THEY KEY BECAME STUCK IN THE IGNITION AND THE VEHICLE WOULD NOT TURN OFF ALL OF THE ELECTRICAL SWITCHES STARTED GOING HAYWIRE , ALONG WITH DIFFERENT WARNING SIGNS.. THE CONSUMER RETURNED TO THE DEALER, WHERE AN INSPECTION REVEALED THE SOLENOID WAS DAMAGED. A MONTH PRIOR, THE IGNITION SWITCH WAS REPLACED. ALSO, WHEN THE CONSUMERS SON ATTEMPTED TO USE THE JACK, TO CHANGE THE TIRE, THE JACK BENT AND THE VEHICLE ALMOST COLLAPSED ON HER SON'S FOOT. UPDATED 11/19/14 UPDATED 8/30/2017*CN
NHTSA ODI #10595499
110,000 miles · Jun 20, 2012
Equipment
BELOW A CERTAIN TEMPERATURE IF THE CAR IS NOT WARM OR THE IGNITION IS NOT WARM WHEN TRYING TO START THE VEHICLE; THE ANTI THEFT SYSTEM TURNS ON. ONCE THE ANTI THEFT SYSTEM IS ON I CANNOT START THE VEHICLE FOR AT LEAST 15 MINUTES. USUALLY MAKING ME LATE FOR SOMETHING. I HAVE HAD THIS REPLACED AND WOULD LIKE COMPENSATION IF POSSIB…
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BELOW A CERTAIN TEMPERATURE IF THE CAR IS NOT WARM OR THE IGNITION IS NOT WARM WHEN TRYING TO START THE VEHICLE; THE ANTI THEFT SYSTEM TURNS ON. ONCE THE ANTI THEFT SYSTEM IS ON I CANNOT START THE VEHICLE FOR AT LEAST 15 MINUTES. USUALLY MAKING ME LATE FOR SOMETHING. I HAVE HAD THIS REPLACED AND WOULD LIKE COMPENSATION IF POSSIBLE. *JS
NHTSA ODI #10462371
Mileage unknown · Jul 5, 2011
Electrical SystemEquipment
I HAVE A 2004 SATURN ION. I BOUGHT IN THE WINTER OF 2007. IT IMMEDIATELY PRESENTED WITH THE PROBLEM OF NOT STARTING IN REALLY COLD WEATHER. I TOOK IT TO THE DEALERSHIP IT WAS BOUGHT FROM AND THEY TOLD ME THEY COULDN'T FIND A PROBLEM. I HAVE BEEN TOLD BY ANOTHER MECHANIC THAT HE COULDN'T FIND THE PROBLEM EITHER. I SOMETIMES …
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I HAVE A 2004 SATURN ION. I BOUGHT IN THE WINTER OF 2007. IT IMMEDIATELY PRESENTED WITH THE PROBLEM OF NOT STARTING IN REALLY COLD WEATHER. I TOOK IT TO THE DEALERSHIP IT WAS BOUGHT FROM AND THEY TOLD ME THEY COULDN'T FIND A PROBLEM. I HAVE BEEN TOLD BY ANOTHER MECHANIC THAT HE COULDN'T FIND THE PROBLEM EITHER. I SOMETIMES HAVE TO WAIT UP TO 30 MINUTES FOR MY CAR TO START IN FREEZING COLD WEATHER. ABOUT 6 OR 8 MONTHS AGO THE KEY WOULDN'T TURN WHEN IT WAS INSERTED INTO THE IGNITION. I HAVE TO JIGGLE IT BACK AND FORTH, SOMETIMES THE KEY ALMOST COMING OUT TOTALLY BEFORE IT WILL TURN OVER. TODAY IT TOOK 15 MINUTES TO FINALLY GET IT UNLOCKED AND TURNED OVER TO START. *KB
NHTSA ODI #10410533
9,000 miles · Feb 12, 2010
Electrical SystemEquipmentPower Train
AFTER ONLY 9 MONTHS OF OWNING MY ION I HAVE EXPERIENCED PROBLEMS WITH SHIFTING THE CAR IN AND OUT OF GEAR. IT IS A RANDOM OCCURRENCE AND CAN HAPPEN 8 TIMES IN A WEEK THEN NOT AT ALL FOR MONTHS. HOWEVER WHEN IT DOES HAPPEN IT IS A LIFE THREATENING EXPERIENCE AS I AM USUALLY DRIVING ON A MAJOR HIGHWAY. THE CAR WILL BE "LOCKED" INT…
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AFTER ONLY 9 MONTHS OF OWNING MY ION I HAVE EXPERIENCED PROBLEMS WITH SHIFTING THE CAR IN AND OUT OF GEAR. IT IS A RANDOM OCCURRENCE AND CAN HAPPEN 8 TIMES IN A WEEK THEN NOT AT ALL FOR MONTHS. HOWEVER WHEN IT DOES HAPPEN IT IS A LIFE THREATENING EXPERIENCE AS I AM USUALLY DRIVING ON A MAJOR HIGHWAY. THE CAR WILL BE "LOCKED" INTO 4TH FOR EXAMPLE AND WHEN I TRY TO SHIFT TO 5TH I CAN NOT GET IT OUT OF 4TH. I HAVE TAKEN THE CAR TO THE SATURN DEALERSHIP A MINIMUM OF 20 TIMES FOR THIS PROBLEM, ONLY TO BE TOLD THAT THEY COULD NOT DO ANYTHING. I THEN TOOK IT TO A DIFFERENT DEALERSHIP WHERE THE TECH TOOK THE CAR HOME FOR 1 WEEK, EXPERIENCED THE PROBLEM FOR HIMSELF, AND TOLD ME ALL HE COULD DO WAS REPLACE A WIRE AND HOPE IT HELPED BECAUSE SATURN WOULD NOT LET HIM INVESTIGATE ANY MORE OPTIONS. IT DID ABSOLUTELY NOTHING TO HELP MY CAR. AND SINCE THE LAST TIME MY CAR HAS BEEN AT THE SATURN DEALERSHIP MY POWER STEERING NOW GOES IN AND OUT. APPARENTLY THEY BUSTED A SEAL AND FAILED TO MENTION THAT TO ME, SO NOT ONLY DO I HAVE TO WORRY ABOUT NOT BEING ABLE TO SHIFT, BUT ALSO LOSING MY POWER STEERING. THEY ONLY SOLUTION I CAN COME UP WITH IS TO TRY MY BEST TO GET THE CAR TO A SAFE SPOT AND TURN IT OFF AND LET IT SIT. THIS CAR HAS HAD MORE PROBLEMS THAN ANYONE SHOULD HAVE TO DEAL WITH: REVERSE SWITCH GOING OUT, AIRCONDITIONING GOING OUT, POWER WINDOWS NO LONGER WORK, POWER STEERING, AND NOT BEING ABLE TO SHIFT. I HAVE TO DRIVE THIS EVERYDAY WITH MY CHILDREN IN THE CAR WITH ME AT MOST TIMES. THIS SHOULD HAVE ALL BEEN TAKEN CARE UNDER THE ORIG. WARRANTY, AS IT ALL HAPPENED WITHIN THE FIRST 6-12 MONTHS OF OWNING THE CAR. LOL THAT'S WHAT I GET FOR BUYING A GM PRODUCT. *TR
NHTSA ODI #10308874
Mileage unknown · Apr 14, 2009
Electrical SystemEquipmentSteering
I HAVE SO MANY THINGS WRONG WITH MY 2004 SATURN OF COURSE I HAVE THE COLD START PROBLEM WHICH I HAVE HAD SINCE I PURCHASED THE CAR(WITH ONLY 7 MILES ON IT). ANYTIME I DRIVE MY CAR OVER 30 MILES AN HOUR IT SHAKES HAD THAT PROBLEM FIX 2 YEARS AGO AND NOW IT IS DOING IT AGAIN. MY DRIVER SIDE WINDOW SEAL LEAKS WHEN IT RAINS. NEW PRO…
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I HAVE SO MANY THINGS WRONG WITH MY 2004 SATURN OF COURSE I HAVE THE COLD START PROBLEM WHICH I HAVE HAD SINCE I PURCHASED THE CAR(WITH ONLY 7 MILES ON IT). ANYTIME I DRIVE MY CAR OVER 30 MILES AN HOUR IT SHAKES HAD THAT PROBLEM FIX 2 YEARS AGO AND NOW IT IS DOING IT AGAIN. MY DRIVER SIDE WINDOW SEAL LEAKS WHEN IT RAINS. NEW PROBLEM DON'T THINK I'VE SINCE THIS ONE YET THE TRANSMISSION IN THE WINDSHIELD WIPER GOES OUT ND GUESS WHAT FOR ONLY $275 SATURN WILL REPLACE THAT FOR YOU. THIS CAR IS SUCH A LEMON. CLEARLY AS I READ OVER COMPLAINTS OF THE SINGLE MOTHERS LIKE MYSELF, THE TEACHER OR JUST SOMEONE WHO WANT A RELIABLE CAR. THIS EXPERIENCE HAS TAUGHT ME NEVER BY AMERICAN AGAIN AND DO MY RESEARCH BEFORE BUYING ANOTHER CAR. THE THING I HATE THE MOST IS THAT THEY SEEM TO HAVE TO TAKE NO RESPONSIBILITY FOR THIS CAR. *TR
NHTSA ODI #10265203
70,000 miles · Jan 17, 2009
Electrical SystemEquipment
BOUGHT THE CAR UNDER WARRANTY, NO CRANK/NO START BECAUSE OF FAULTY PASSLOCK SYSTEM. SATURN "REBOOTED THE COMPUTER" (SATURNS WORDS). THIS WAS IN MAY OF 06. STRANGELY, THE CAR HAS "DIED" IN AT LEAST 3 DRIVEWAYS AS THOUGH THE BATTERY WAS DEAD. I HAVE TAKEN THE CAR TO A GARAGE AND HAD THE BATTERY TESTED AND IT WAS FINE. RECENT…
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BOUGHT THE CAR UNDER WARRANTY, NO CRANK/NO START BECAUSE OF FAULTY PASSLOCK SYSTEM. SATURN "REBOOTED THE COMPUTER" (SATURNS WORDS). THIS WAS IN MAY OF 06. STRANGELY, THE CAR HAS "DIED" IN AT LEAST 3 DRIVEWAYS AS THOUGH THE BATTERY WAS DEAD. I HAVE TAKEN THE CAR TO A GARAGE AND HAD THE BATTERY TESTED AND IT WAS FINE. RECENTLY, WHEN THE WEATHER IS COLD, THE CAR WILL NO CRANK/NO START AND THROW THE PASSLOCK CODE. ON THE DASH, SOMETIMES IT SAYS SERVICE ENGINE IT MAY OR MAY NOT RESET AFTER 10 MINUTES. THE VEHICLE HAS BECOME UNRELIABLE AS I AM NEVER SURE IF I AM GOING TO GET TO WORK ON TIME OR NOT. I CALLED SATURN LAST WEEK. APPARENTLY SATURN IS AWARE OF THE PROBLEM, BUT SINCE THEY ARE GOING TO INCONVENIENCE ME TO DRIVE 200 MILES TO THE DEALERSHIP AND THEN CHARGE ME $100 TO WALK THROUGH THE DOOR LAND THEN ANOTHER $1000 ON TOP OF THAT TO "FIX" THE CAR' THEY KNOW THEY ARE MAKING MONEY OFF THEIR FAULTY EQUIPMENT. I REFUSE TO PAY FOR IT, BUT IN THE MEANTIME MY CAR CONTINUES TO NOT START IF IT IS ZERO DEGREES. *TR
NHTSA ODI #10255401
79,500 miles · Dec 6, 2008
Equipment
THE IGNITION SWITCH IN THE 2004 SATURN ION HAS A MALFUNCTION. THE CAR IS ONLY FOUR YEARS OLD AND WILL NOT START IN COLD WEATHER. UPON CALLING THE LOCAL SATURN DEALERSHIP IN SPRINGFIELD, PA THE SERVICE RECEPTIONIST WAS ABLE TO TELL ME EXACTLY WHAT WAS WRONG WITH THE CAR AND THAT I HAD TO WAIT 15 MINUTES TO HALF AN HOUR AND THEN…
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THE IGNITION SWITCH IN THE 2004 SATURN ION HAS A MALFUNCTION. THE CAR IS ONLY FOUR YEARS OLD AND WILL NOT START IN COLD WEATHER. UPON CALLING THE LOCAL SATURN DEALERSHIP IN SPRINGFIELD, PA THE SERVICE RECEPTIONIST WAS ABLE TO TELL ME EXACTLY WHAT WAS WRONG WITH THE CAR AND THAT I HAD TO WAIT 15 MINUTES TO HALF AN HOUR AND THEN TRY TO START THE CAR AGAIN TO SEE IF IT WILL START. GM AND SATURN KNOW THAT THE IGNITION SWITCH IS FAULTY WHICH IS PROVEN BY THE FACT THAT THE RECEPTIONIST KNEW HOW TO START MY CAR BUT THEY HAVE NOT DONE ANYTHING ABOUT IT. THE FIRST INSTANCE OF THIS OCCURRING FOR ME WAS ON NOVEMBER 19TH WHEN I TALKED THE RECEPTIONIST AND IT HAS CONTINUED TO OCCUR. ON DECEMBER 6, 2008 THE CAR WAS ABLE TO BROUGHT IN TO BE FIXED AND WAS CHARGED TO THE OWNER OF THE CAR EVEN THOUGH THEY KNOW THIS IS A DEFAULT OF THE CAR. *TR
NHTSA ODI #10250924
58,000 miles · Jan 31, 2008
Electrical SystemEquipmentInjury
THIS IS THE THIRD TIME I'VE HAD TO PUSH THIS SATURN INTO THE STREET TO GET OUR OTHER DRIVERS OFF TO WORK. THE FIRST TIME IT WAS ONLY A FEW MONTHS OLD AND WAS TOWED TO THE DEALER. THEY SAID MY FLOORMATS WERE TOO THICK AND NOT GENUINE SATURN PARTS AND CAUSED IT NOT TO START(NO KIDDING, THEY SAID THIS). A FEW WEEKS LATER IT ONCE AG…
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THIS IS THE THIRD TIME I'VE HAD TO PUSH THIS SATURN INTO THE STREET TO GET OUR OTHER DRIVERS OFF TO WORK. THE FIRST TIME IT WAS ONLY A FEW MONTHS OLD AND WAS TOWED TO THE DEALER. THEY SAID MY FLOORMATS WERE TOO THICK AND NOT GENUINE SATURN PARTS AND CAUSED IT NOT TO START(NO KIDDING, THEY SAID THIS). A FEW WEEKS LATER IT ONCE AGAIN FAILED TO TURN OVER. ANOTHER TOW TO THE DEALER AND THIS TIME THEY RE-CODED THE KEY AND IGNITION SWITCH. SEVERAL TIMES OVER THE PAST FEW YEARS IT HAS FAILED TO START. IF I WAIT 20 MINUTES, THE ANTI THEFT MODULE RE-SETS AND IT WILL START. THIS MORNING I SLIPPED ON ICE WHILE PUSHING IT INTO THE STREET AND FELL. MY BACK IS KILLING ME RIGHT NOW AND I'M VERY ANGRY. THIS IS AN OBVIOUS PROBLEM THAT SATURN IS IGNORING. NO SELF RESPECTING THIEF WOULD STEAL A SATURN IN THE FIRST PLACE. I SEE NO NEED FOR AN ANTI-THEFT DEVICE ON THIS AWFUL CAR. *TR
NHTSA ODI #10216574
14,703 miles · Dec 3, 2007
Electrical SystemEquipment
I PURCHASE A 2004 SATURN ION (6/11/04), BRAND NEW. THE FIRST SIGN OF COLD THAT YEAR, LATE NOVEMBER, THE CAR WOULD NOT START AT ALL. AFTER AWHILE(10-15 MIN.) IT WOULD START UP LIKE NOTHING WAS WRONG. I BROUGHT IT IN 12/28/04, WHICH THEY REPLACED THE IGNITION LOCK MODULE; SAYING "THAT WAS THE PROBLEM". I STILL HAD ISSUES WITH THE …
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I PURCHASE A 2004 SATURN ION (6/11/04), BRAND NEW. THE FIRST SIGN OF COLD THAT YEAR, LATE NOVEMBER, THE CAR WOULD NOT START AT ALL. AFTER AWHILE(10-15 MIN.) IT WOULD START UP LIKE NOTHING WAS WRONG. I BROUGHT IT IN 12/28/04, WHICH THEY REPLACED THE IGNITION LOCK MODULE; SAYING "THAT WAS THE PROBLEM". I STILL HAD ISSUES WITH THE CAR THROUGH THE WINTER, AND THEY DIDN'T KNOW WAS WHAT WRONG. EVERYTIME I BROUGHT IT IN, THEY WOULD FIND NOTHING WRONG AND SEND ME ON MY WAY SINCE THEY COULDN'T REPRODUCE THE ISSUE. THE NEXT WINTER THAN SAME THING HAPPENED. I WAS STUCK IN THE COLD A FEW MORNINGS BEFORE WORK TRYING TO GET THE CAR STARTED. SATURN CLAIMED IT WAS TOO COLD OUTSIDE FOR MY CAR TO START, AND TOLD ME TO WAIT A BIT BEFORE BRINGING IT IN. (IT MAYBE WENT BELOW 0 DEGREES THAT WEEK TWICE) FED UP I BROUGHT IT IN AGAIN ON 1/17/05, WHICH THEY REPLACED MY BLOCK ASSEMBLY, WIRE HARNESS, STARTER, BATTERY, AND WIRE CONNECTERS. THEY REALLY WEREN'T SURE WHAT WAS WRONG THEY ADMITTED, BUT IT SEEMS TO WORK NOW. THE CAR WOULD WORK FOR A FEW WEEKS, THEN THE SAME ISSUE ARISES AGAIN. ON 4/15/05 SATURN HAD TO REPLACE MY RADIO RECEIVER FOR FAULTY ISSUES. THAT SAME WINTER, MY CAR WOULD NOT START IN THE COLD AGAIN. IT WAS BROUGHT IN ON 12/20/05, WHICH THEY REPLACED MY IGNITION SWITCH SAYING THE USUAL "THIS WILL FIX THE PROBLEM". NOW, JUST UNDER TWO YEARS LATER, I AM BACK TO HAVING THE SAME ISSUES OF MY CAR NOT STARTING IN THE COLD. SATURN IS NOW THROWING THEIR HANDS UP SAYING I MUST PURCHASE ANOTHER IGNITION SWITCH, AND PAY THEM TO PUT IT IN FOR A TOTAL OF $220. UNACCEPTABLE. I MAY HAVE TAKEN ACTIONS SOONER, BUT I WASN'T AWARE THERE WERE MANY MORE SATURN ION DRIVERS WITH THE SAME ISSUES I HAD. *TR
NHTSA ODI #10210720
25,000 miles · Apr 19, 2007
EquipmentPower Train
IT IS BECOMING APPARENT THAT THE CLUTCH MASTER CYLINDER ON THE 2.2L AND 2.4L SATURN ION IS DEFECTIVE. THERE HAVE BEEN MANY COMPLAINTS ABOUT THIS ON MULTIPLE FORUMS ACROSS THE INTERNET. I PERSONALLY HAVE HAD MINE REPLACED ONCE AND IT NEEDS REPLACED AGAIN. MY FEAR IS THAT I WILL BE DRIVING AND THAT IT WILL GO OUT COMPLETELY AND…
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IT IS BECOMING APPARENT THAT THE CLUTCH MASTER CYLINDER ON THE 2.2L AND 2.4L SATURN ION IS DEFECTIVE. THERE HAVE BEEN MANY COMPLAINTS ABOUT THIS ON MULTIPLE FORUMS ACROSS THE INTERNET. I PERSONALLY HAVE HAD MINE REPLACED ONCE AND IT NEEDS REPLACED AGAIN. MY FEAR IS THAT I WILL BE DRIVING AND THAT IT WILL GO OUT COMPLETELY AND NOT ALLOW ME TO SHIFT, POSSIBLY CAUSING AN ACCIDENT. *JB
NHTSA ODI #10188401
Official recalls
8Apr 10, 2014
General Motors LLC (GM) is recalling certain model year 2005-2010 Chevrolet Cobalt, 2006-2011 Chevrolet HHR, 2007-2010 Pontiac G5, 2006-2010 Pontiac Solstice, 2003-2007 Saturn Ion, and 2007-2010 Saturn Sky vehicles. In the affected vehicles, the key can be removed from the ignition when the ignition is not in the "Off" position.
Consequence & remedy
Consequence: If the key can be removed from the ignition when the ignition is not in the "off" position, the vehicle could roll away: (a) for an automatic transmission, if the transmission is not in the "Park" position; or (b) for a manual transmission, if the parking brake is not engaged and the transmission is not in the "Reverse" position. This potential for rollaway increases the risk for a crash and occupant or pedestrian injuries.
Remedy: General Motors will notify owners, and for vehicles that were built with the defective ignition cylinder and have not previously had the ignition cylinder replaced with the redesigned part, dealers will replace the ignition cylinder and cut and, if necessary, re-learn two ignition/door keys for each vehicle. For vehicles that were built with the redesigned ignition cylinder or had the ignition cylinder replaced with the redesigned part, dealers will cut and, if necessary, re-learn two ignition/door keys for each vehicle. The recall began on April 18, 2014. Chevrolet owners may contact General Motors at 1-800-222-1020, Pontiac owners at 1-800-762-2737, and Saturn owners at 1-800-553-6000. General Motors' number for this recall is 14113 for the ignition lock cylinder and key replacement, and 14133 for only key replacements. Note: Until a vehicle has been remedied, owners and operators are advised that when exiting, to be sure that the vehicle is in "Park," or in the case of a manual transmission, that the vehicle is in the "Reverse" position and the parking brake is engaged.
Mar 31, 2014
General Motors LLC (GM) is recalling certain model year 2004-2006 and 2008-2009 Chevrolet Malibu, 2004-2006 Malibu Maxx, 2009-2010 HHR (non-turbo), 2010 Cobalt, 2008-2009 Saturn Aura and 2004-2007 Ion, and 2005-2009 Pontiac G6. In the affected vehicles, there may be a sudden loss of electric power steering (EPS) assist that could occur at any time while driving.
Consequence & remedy
Consequence: If power steering assist is lost, greater driver effort would be required to steer the vehicle at low speeds, increasing the risk of a crash.
Remedy: GM will notify owners, and dealers will perform one of four bulletins. Parts are not currently available. GM expects to send an interim notification around May 28, 2014. When parts are available, owners will be mailed a second letter to come in to have the applicable bulletin applied. Bulletin 14115 covers model year 2004-2007 Saturn Ion, 2009-2010 Chevrolet HHR and 2010 Chevrolet Cobalts. Dealers will replace the EPS motor. Bulletin 14116 covers model year 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from March 1, 2008, through June 27, 2008. Dealers will replace the torque sensor assembly. Bulletin 14117 covers model year 2008 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from February 1, 2008, through February 28, 2008. Dealers will replace the torque sensor assembly and EPS motor controller unit. Bulletin 14118 covers model year 2008 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from October 1, 2007, through January 31, 2008. Dealers will replace the EPS motor controller unit. The recall began on July 17, 2014. Owners may contact Chevrolet at 1-800-630-2438, Saturn at 1-800-553-6000, and Pontiac at 1-800-620-7668. GM's number for this recall is N140115. Note: GM bulletin number 14119 will be implemented for model year 2006-2008 and early production of 2009 Chevrolet HHR (non-turbo) and model year 2003 Saturn ION to provide EPS Motor replacement for the life of the vehicle.
Feb 10, 2014
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
Consequence & remedy
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
Additional source detail variants (2)
Air Bags
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
Electrical System:ignition:switch
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
Nov 16, 2004
CERTAIN PASSENGER VEHICLES HAVE A CONDITION IN WHICH THE TURN SIGNAL LAMP AND DAYTIME RUNNING LAMP (DRL) ON EITHER FRONT SIDE CAN STOP WORKING BECAUSE OF LOSS OF CONTACT BETWEEN THE BULB AND SOCKET.
Consequence & remedy
Consequence: IF A FRONT TURN SIGNAL LAMP IS INOPERATIVE, OTHERS MAY REACT MORE SLOWLY TO A TURNING VEHICLE AND A CRASH COULD OCCUR.
Remedy: DEALERS WILL REPLACE THE DRL/TURN SIGNAL BULB ON BOTH THE LEFT AND RIGHT FRONT SIDE AND INSPECT FOR AND ADD A DRL JUMPER KIT IF NOT PRESENT. THE RECALL BEGAN NOVEMBER 17, 2004. OWNERS SHOULD CONTACT SATURN AT 1-800-972-8876.
Jun 8, 2004
CERTAIN VEHICLES EQUIPPED WITH SUPERCHARGED 2.0L 4-CYLINDER (LSJ) ENGINE WERE BUILT WITH A FUEL FEED PIPE THAT COULD CRACK AND LEAK FUEL NEAR THE FUEL RAIL. IF FUEL LEAKS FROM THE FUEL FEED PIPE, THERE WOULD BE A NOTICEABLE FUEL ODOR AROUND THE VEHICLE.
Consequence & remedy
Consequence: FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE FUEL FEED PIPE ASSEMBLY. OWNER NOTIFICATION BEGAN ON JUNE 9, 2004. OWNERS SHOULD CONTACT SATURN AT 1-800-972-8876.
Jan 6, 2004
ON CERTAIN PASSENGER VEHICLES, SOME WELDS BETWEEN THE PASSENGER'S SIDE MOTOR RAIL AND THE FRONT BUMPER BRACKET DO NOT MEET ENGINEERING SPECIFICATIONS.
Consequence & remedy
Consequence: LONG TERM DURABILITY OF THE JOINT MAY BE REDUCED AND SEPARATION OF THE BUMPER FROM THE FRAME ON THE PASSENGER'S SIDE OF THE VEHICLE MAY RESULT, INCREASING THE RISK OF A CRASH.
Remedy: ALL VEHICLES ARE STILL IN DEALER'S POSSESSIONS.
Jan 5, 2004
CERTAIN PASSENGER VEHICLES EQUIPPED WITH 2.2L 4-CYLINDER (L61) ENGINES WERE BUILT WITH A FUEL FILTER THAT COULD CORRODE PREMATURELY ON THE EXTERIOR SURFACE.
Consequence & remedy
Consequence: IF CORROSION ON THE EXTERIOR SURFACE OF THE FUEL FILTER PROGRESSES TO THE POINT OF CREATING A HOLE IN THE SHELL, FUEL DROPLETS COULD FORM AND DROP TO THE GROUND. IF AN IGNITION SOURCE IS PRESENT, A FIRE COULD RESULT.
Remedy: DEALERS WILL REPLACE THE FUEL FILTER ASSEMBLY. OWNER NOTIFICATION BEGAN ON DECEMBER 30, 2003. OWNERS SHOULD CONTACT SATURN AT 1-800-972-8876.
Jan 5, 2004
CERTAIN PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 118, "POWER-OPERATED WINDOW, PARTITION, AND ROOF PANEL SYSTEMS." THE POWER WINDOWS AND/OR SUNROOF MAY BE OPERABLE AFTER THE IGNITION HAS BEEN TURNED TO THE "OFF" POSITION AND THE FRONT PASSENGER DOOR IS OPENED.
Consequence & remedy
Consequence: IF UNSUPERVISED CHILDREN ARE LEFT UNATTENDED IN THE VEHICLE AND OPERATE THE POWER WINDOWS OR SUNROOF, THERE IS AN INCREASED RISK OF INJURY TO THE CHILD.
Remedy: DEALERS WILL UPGRADE THE BODY CONTROL MODULE (BCM) CALIBRATION. OWNER NOTIFICATION BEGAN ON DECEMBER 30, 2003. OWNERS SHOULD CONTACT SATURN AT 1-800-972-8876.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
4EA11014 · Electric Power Steering Failure
Opened Sep 29, 2011 · Closed Apr 15, 2014
Status: closed (inferred from source dates) · Steering:electric Power Assist System
On March 31, 2014, General Motors Company (GM) submitted a Defect Information Report (DIR) to NHTSA describing a safety defect that may result in a sudden loss of power steering assist in approximately 1,340,447 model year (MY) 2004 through 2010 vehicles equipped with electric power steering (EPS), including 334,728 MY 2004 through 2007 Saturn ION vehicles that are the subject of EA11-014.GM has assigned the recall number N140115.The NHTSA recall number is 14V-153.According to the DIR, if power steering assist is lost, a message is displayed on the Driver Information Center and a chime sounds to inform the driver.GM indicated that steering control can be maintained in manual (unassisted) steering mode, but would require greater driver effort at low vehicle speeds, which could increase the risk of a crash.Sudden loss of power steering assist can occur in the subject vehicles if the system loses electrical power or whenever the system detects a fault that requires it to enter fail-safe operation mode, removing power from the EPS motor.GM?s DIR identifies three basic conditions that may result in loss of power steering assist in the recalled vehicles:power steering motor faults, torque sensor assembly faults, and power steering motor controller unit faults.GM will issue four service bulletins providing different repair procedures for recalled vehicles.Bulletin 14115 will provide repair instructions for replacing the power steering motor in MY 2004-2007 Saturn ION, 2009-2010 Chevrolet HHR (non-turbo), 2010 Chevrolet Cobalt and vehicles repaired in recall 10V-073 that received repairs prior to May 31, 2010.Bulletin 14116 will provide repair instructions for replacing the torque sensor assembly in MY 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Malibu, Pontiac G6 and Saturn Aura vehicles built from March 1, 2008 through June 27, 2008.Bulletin 14117 will provide repair instructions for replacing the torque sensor assembly and power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from February 1, 2008 through February 28, 2008.Bulletin 14118 will provide repair instructions for replacing the power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from October 1, 2007 through January 31, 2008.Analysis of information from all sources identified a total of 4,787 complaints and 30,560 warranty claims related to loss of power steering assist while driving in the MY 2004 through 2007 Saturn ION vehicles, resulting in a complaint rate of 14.3 incidents per thousand vehicles and a warranty claim rate of 9.1 percent.ODI?s analysis of alleged steering related crashes identified 12 with evidence indicating the incident was related to a loss of power steering assist. Two of the crash allegations involved low-speed curb impacts and are excluded from the resume crash count.Three incidents occurred in parking lots, six occurred while turning at street intersections, and one occurred on a highway exit ramp.The crashes in parking lots or intersections all occurred at speeds less than 30 mph.The crash on the highway exit ramp involved impact into a guard rail at approximately 35 mph.Two of the crashes resulted in injuries to the drivers.This investigation is closed.All ODI complaints associated with this closing resume are listed in the attachment pages.
Additional source detail variants (2)
Steering:electric Power Assist System
On March 31, 2014, General Motors Company (GM) submitted a Defect Information Report (DIR) to NHTSA describing a safety defect that may result in a sudden loss of power steering assist in approximately 1,340,447 model year (MY) 2004 through 2010 vehicles equipped with electric power steering (EPS), including 334,728 MY 2004 through 2007 Saturn ION vehicles that are the subject of EA11-014.GM has assigned the recall number N140115.The NHTSA recall number is 14V-153.According to the DIR, if power steering assist is lost, a message is displayed on the Driver Information Center and a chime sounds to inform the driver.GM indicated that steering control can be maintained in manual (unassisted) steering mode, but would require greater driver effort at low vehicle speeds, which could increase the risk of a crash.Sudden loss of power steering assist can occur in the subject vehicles if the system loses electrical power or whenever the system detects a fault that requires it to enter fail-safe operation mode, removing power from the EPS motor.GM?s DIR identifies three basic conditions that may result in loss of power steering assist in the recalled vehicles:power steering motor faults, torque sensor assembly faults, and power steering motor controller unit faults.GM will issue four service bulletins providing different repair procedures for recalled vehicles.Bulletin 14115 will provide repair instructions for replacing the power steering motor in MY 2004-2007 Saturn ION, 2009-2010 Chevrolet HHR (non-turbo), 2010 Chevrolet Cobalt and vehicles repaired in recall 10V-073 that received repairs prior to May 31, 2010.Bulletin 14116 will provide repair instructions for replacing the torque sensor assembly in MY 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Malibu, Pontiac G6 and Saturn Aura vehicles built from March 1, 2008 through June 27, 2008.Bulletin 14117 will provide repair instructions for replacing the torque sensor assembly and power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from February 1, 2008 through February 28, 2008.Bulletin 14118 will provide repair instructions for replacing the power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from October 1, 2007 through January 31, 2008.Analysis of information from all sources identified a total of 4,787 complaints and 30,560 warranty claims related to loss of power steering assist while driving in the MY 2004 through 2007 Saturn ION vehicles, resulting in a complaint rate of 14.3 incidents per thousand vehicles and a warranty claim rate of 9.1 percent.ODI?s analysis of alleged steering related crashes identified 12 with evidence indicating the incident was related to a loss of power steering assist. Two of the crash allegations involved low-speed curb impacts and are excluded from the resume crash count.Three incidents occurred in parking lots, six occurred while turning at street intersections, and one occurred on a highway exit ramp.The crashes in parking lots or intersections all occurred at speeds less than 30 mph.The crash on the highway exit ramp involved impact into a guard rail at approximately 35 mph.Two of the crashes resulted in injuries to the drivers.This investigation is closed.All ODI complaints associated with this closing resume are listed in the attachment pages.
Steering:electric Power Assist System
On March 31, 2014, General Motors Company (GM) submitted a Defect Information Report (DIR) to NHTSA describing a safety defect that may result in a sudden loss of power steering assist in approximately 1,340,447 model year (MY) 2004 through 2010 vehicles equipped with electric power steering (EPS), including 334,728 MY 2004 through 2007 Saturn ION vehicles that are the subject of EA11-014.GM has assigned the recall number N140115.The NHTSA recall number is 14V-153.According to the DIR, if power steering assist is lost, a message is displayed on the Driver Information Center and a chime sounds to inform the driver.GM indicated that steering control can be maintained in manual (unassisted) steering mode, but would require greater driver effort at low vehicle speeds, which could increase the risk of a crash.Sudden loss of power steering assist can occur in the subject vehicles if the system loses electrical power or whenever the system detects a fault that requires it to enter fail-safe operation mode, removing power from the EPS motor.GM?s DIR identifies three basic conditions that may result in loss of power steering assist in the recalled vehicles:power steering motor faults, torque sensor assembly faults, and power steering motor controller unit faults.GM will issue four service bulletins providing different repair procedures for recalled vehicles.Bulletin 14115 will provide repair instructions for replacing the power steering motor in MY 2004-2007 Saturn ION, 2009-2010 Chevrolet HHR (non-turbo), 2010 Chevrolet Cobalt and vehicles repaired in recall 10V-073 that received repairs prior to May 31, 2010.Bulletin 14116 will provide repair instructions for replacing the torque sensor assembly in MY 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Malibu, Pontiac G6 and Saturn Aura vehicles built from March 1, 2008 through June 27, 2008.Bulletin 14117 will provide repair instructions for replacing the torque sensor assembly and power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from February 1, 2008 through February 28, 2008.Bulletin 14118 will provide repair instructions for replacing the power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from October 1, 2007 through January 31, 2008.Analysis of information from all sources identified a total of 4,787 complaints and 30,560 warranty claims related to loss of power steering assist while driving in the MY 2004 through 2007 Saturn ION vehicles, resulting in a complaint rate of 14.3 incidents per thousand vehicles and a warranty claim rate of 9.1 percent.ODI?s analysis of alleged steering related crashes identified 12 with evidence indicating the incident was related to a loss of power steering assist. Two of the crash allegations involved low-speed curb impacts and are excluded from the resume crash count.Three incidents occurred in parking lots, six occurred while turning at street intersections, and one occurred on a highway exit ramp.The crashes in parking lots or intersections all occurred at speeds less than 30 mph.The crash on the highway exit ramp involved impact into a guard rail at approximately 35 mph.Two of the crashes resulted in injuries to the drivers.This investigation is closed.All ODI complaints associated with this closing resume are listed in the attachment pages.
RQ10004 · Electric Power Steering Failure
Opened Dec 15, 2010 · Closed Oct 5, 2011
Status: closed (inferred from source dates) · Steering; Steering:electric Power Assist System
ODI has received 846 complaints and GM identified 3,489 reports alleging sudden loss of steering power assist in model year (MY) 2004 through 2007 Saturn Ion vehicles manufactured and sold by General Motors Corporation (GM).Sixteen of these complaints alleged that the EPS warning lamp had illuminated before or during the loss of steering assist and the increased steering effort contributed to a crash. Two of the GM crash claims indicated that the driver was injured in the crash. In a previous Preliminary Evaluation PE10-005, ODI investigated the sudden loss of power steering assist in MY 2005 through 2010 Chevrolet Cobalt vehicles. In May 2011, in response to an ODI information request letter for RQ10-004, GM provided ODI with complaint, warranty and EPS system information related to EPS loss of assist for the Saturn ION and Peer vehicles Pontiac G6 and Chevrolet Malibu. In that response, GM indicated that the EPS system used in the subject vehicles was the same as that used in the MY2005 to 2010 Chevrolet Cobalt and Pontiac G5. In March 2010, GM recalled approximately 1.05 million Chevrolet Cobalt and Pontiac G5 vehicles (NHTSA recall no. 10V-073) to correct a defect with the EPS assist motor. The defect identified was described as a buildup of brush debris mixed with oily material on the EPS electric motor armature which causes the motor to stop functioning; the same problem identified in the current subject vehicles.ODI has duplicated this failure in both a Chevrolet Cobalt and Saturn Ion previously tested at the Vehicle Research and Test Center (VRTC). In the defect notification letter for the previously recalled Cobalt and G5 vehicles, GM stated that the vehicles may experience a sudden loss of assist that could occur at any time while driving and that if power steering was lost the vehicle would revert to manual steering mode and would require increased steering effort from the driver.ODI believes that, depending on driving circumstances this increase in steering effort could result in some loss of control and a crash.This investigation has been upgraded to an engineering analysis (EA11-014) to further assess the frequency, scope and safety consequences of a sudden loss of steering assist in the subject vehicles.
Additional source detail variants (2)
Steering:electric Power Assist System
ODI has received 846 complaints and GM identified 3,489 reports alleging sudden loss of steering power assist in model year (MY) 2004 through 2007 Saturn Ion vehicles manufactured and sold by General Motors Corporation (GM).Sixteen of these complaints alleged that the EPS warning lamp had illuminated before or during the loss of steering assist and the increased steering effort contributed to a crash. Two of the GM crash claims indicated that the driver was injured in the crash. In a previous Preliminary Evaluation PE10-005, ODI investigated the sudden loss of power steering assist in MY 2005 through 2010 Chevrolet Cobalt vehicles. In May 2011, in response to an ODI information request letter for RQ10-004, GM provided ODI with complaint, warranty and EPS system information related to EPS loss of assist for the Saturn ION and Peer vehicles Pontiac G6 and Chevrolet Malibu. In that response, GM indicated that the EPS system used in the subject vehicles was the same as that used in the MY2005 to 2010 Chevrolet Cobalt and Pontiac G5. In March 2010, GM recalled approximately 1.05 million Chevrolet Cobalt and Pontiac G5 vehicles (NHTSA recall no. 10V-073) to correct a defect with the EPS assist motor. The defect identified was described as a buildup of brush debris mixed with oily material on the EPS electric motor armature which causes the motor to stop functioning; the same problem identified in the current subject vehicles.ODI has duplicated this failure in both a Chevrolet Cobalt and Saturn Ion previously tested at the Vehicle Research and Test Center (VRTC). In the defect notification letter for the previously recalled Cobalt and G5 vehicles, GM stated that the vehicles may experience a sudden loss of assist that could occur at any time while driving and that if power steering was lost the vehicle would revert to manual steering mode and would require increased steering effort from the driver.ODI believes that, depending on driving circumstances this increase in steering effort could result in some loss of control and a crash.This investigation has been upgraded to an engineering analysis (EA11-014) to further assess the frequency, scope and safety consequences of a sudden loss of steering assist in the subject vehicles.
Steering
ODI has received 846 complaints and GM identified 3,489 reports alleging sudden loss of steering power assist in model year (MY) 2004 through 2007 Saturn Ion vehicles manufactured and sold by General Motors Corporation (GM).Sixteen of these complaints alleged that the EPS warning lamp had illuminated before or during the loss of steering assist and the increased steering effort contributed to a crash. Two of the GM crash claims indicated that the driver was injured in the crash. In a previous Preliminary Evaluation PE10-005, ODI investigated the sudden loss of power steering assist in MY 2005 through 2010 Chevrolet Cobalt vehicles. In May 2011, in response to an ODI information request letter for RQ10-004, GM provided ODI with complaint, warranty and EPS system information related to EPS loss of assist for the Saturn ION and Peer vehicles Pontiac G6 and Chevrolet Malibu. In that response, GM indicated that the EPS system used in the subject vehicles was the same as that used in the MY2005 to 2010 Chevrolet Cobalt and Pontiac G5. In March 2010, GM recalled approximately 1.05 million Chevrolet Cobalt and Pontiac G5 vehicles (NHTSA recall no. 10V-073) to correct a defect with the EPS assist motor. The defect identified was described as a buildup of brush debris mixed with oily material on the EPS electric motor armature which causes the motor to stop functioning; the same problem identified in the current subject vehicles.ODI has duplicated this failure in both a Chevrolet Cobalt and Saturn Ion previously tested at the Vehicle Research and Test Center (VRTC). In the defect notification letter for the previously recalled Cobalt and G5 vehicles, GM stated that the vehicles may experience a sudden loss of assist that could occur at any time while driving and that if power steering was lost the vehicle would revert to manual steering mode and would require increased steering effort from the driver.ODI believes that, depending on driving circumstances this increase in steering effort could result in some loss of control and a crash.This investigation has been upgraded to an engineering analysis (EA11-014) to further assess the frequency, scope and safety consequences of a sudden loss of steering assist in the subject vehicles.
EA04035 · Front Turn Signal/drl Failure
Opened Dec 22, 2004 · Closed Oct 20, 2005
Status: closed (inferred from source dates) · Exterior Lighting:turn Signal
THE COMBINATION FRONT TURN SIGNAL/DRL IN MY 2003 SATURN ION COUPES EXPERIENCED SIGNIFICANT EARLY-LIFE FAILURES DUE TO VARIOUS BULB QUALITY ISSUES DUE TO INADEQUATE DESIGN AND MANUFACTURE.THIS PROBLEM TREND APPEARS TO HAVE DISAPPEARED AFTER THE FALL OF 2003.THE CHANGE OF LEAD WIRE MATERIAL NEAR THE START OF MY 2004 VEHICLE PRODUCTION APPEARS TO HAVE REDUCED THE FAILURE RATE FOR MY 2004 SATURN ION COUPES.ALTHOUGH OPERATING TEMPERATURES IN THE SUBJECT VEHICLES' LAMP ASSEMBLIES ARE BELOW THE SOCKET MATERIAL MAXIMUM TEMPERATURE SPECIFICATION, THEY ARE ONLY SLIGHTLY BELOW THE SPECIFICATION.IN DECEMBER 2004, GM REDUCED THE VOLTAGE TO THE LAMP ASSEMBLY IN ORDER TO REDUCE THE TEMPERATURE IN THE ASSEMBLY OF THE SUBJECT VEHICLES.WARRANTY CLAIMS ON THE SUBJECT VEHICLES DO NOT INDICATE AN INCREASING TREND OVER TIME.WARRANTY CLAIM RATE OF SUBJECT VEHICLES (EXCLUDING EARLY MY 2003 CLAIMS) IS NOT SIGNIFICANTLY HIGHER THAN OTHER GM VEHICLES THAT USE COMBINATION TURN SIGNAL/DRLS.A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED SUMMARY REPORT.
PE04061 · Front Turn Signal/drl Failure
Opened Aug 17, 2004 · Closed Dec 22, 2004
Status: closed (inferred from source dates) · Exterior Lighting:turn Signal
ON NOVEMBER 16, 2004, GM NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL OF 178,798 MODEL YEAR (MY) 2003 AND 2004 SATURN ION SEDAN VEHICLES FOR INOPERATIVE FRONT TURN SIGNAL/DRL BULBS.GM STATED THAT TEMPERATURES IN THE LAMP ASSEMBLY EXCEED THE MATERIAL SPECIFICATION FOR THE BULB SOCKETS AND BULB BASE SLEEVES, WHICH CAUSE DEFORMATION.THE DEFORMED SOCKETS CAN CAUSE LOSS OF BULB AND SOCKET CONTACT.THE DEFORMED SLEEVES CAN CAUSE STRESS CRACKS TO FORM ON THE BULB THAT CAN LEAD TO PREMATURE BULB FAILURE.THE RECALL REMEDY IS TO REPLACE THE FRONT TURN SIGNAL/DRL BULBS AND INSPECT FOR VOLTAGE-REDUCING JUMPER (WHICH REDUCES TEMPERATURE IN LAMP ASSEMBLY) AND ADD IF NOT PRESENT.SEE NHTSA RECALL NO. 04V547 FOR DETAILS.THE BULBS FOR THE TURN SIGNAL/DRL IN THE SATURN ION SEDAN AND ION COUPE ARE IDENTICAL IN DESIGN AND MADE BY THE SAME SUPPLIER.BUT THE TURN SIGNAL/DRL SOCKETS, WIRING AND HOUSING ARE DIFFERENT IN DESIGN FOR THE SEDAN AND COUPE, AND WERE MADE BY DIFFERENT SUPPLIERS.GM'S DATA SHOWS A LOWER OPERATING TEMPERATURE FOR THE COUPE'S LAMP ASSEMBLY THAT DOES NOT EXCEED THE MATERIAL SPECIFICATION FOR THE BULB SOCKET AND THE BULB BASE SLEEVE.COMPLAINT AND WARRANTY RATE IS ALSO LOWER FOR THE COUPE.HOWEVER, GM'S WARRANTY DATA SHOWS A CONTINUING TREND FOR THE COUPE.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA04-035) FOR FURTHER INVESTIGATION OF THE MY 2003 AND 2004 SATURN ION COUPE VEHICLES.
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