NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
898 reports55,000 miles · Oct 28, 2009
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2004 SATURN ION. AFTER DRIVING FOR APPROXIMATELY TEN MINUTES THE VEHICLE INTERMITTENTLY STALLS. THE VEHICLE WAS IN THE PROCESS OF BEING TAKEN TO THE DEALER FOR INSPECTION. HOWEVER ON THE INTERNET SHE DISCOVERED MANY COMPLAINTS DESCRIBING THE FAILURE. THE FAILURE MILEAGE WAS 55,000 . THE VEHICLE IDENTIFICA…
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TL* THE CONTACT OWNS A 2004 SATURN ION. AFTER DRIVING FOR APPROXIMATELY TEN MINUTES THE VEHICLE INTERMITTENTLY STALLS. THE VEHICLE WAS IN THE PROCESS OF BEING TAKEN TO THE DEALER FOR INSPECTION. HOWEVER ON THE INTERNET SHE DISCOVERED MANY COMPLAINTS DESCRIBING THE FAILURE. THE FAILURE MILEAGE WAS 55,000 . THE VEHICLE IDENTIFICATION NUMBER WAS UNAVAILABLE.
NHTSA ODI #10290119
62,591 miles · Oct 23, 2009
Electrical System
WE PURCHASED OUR SATURN ION (USED- FROM A DEALERSHIP) AND WITHIN A FEW WEEKS IT BEGAN NOT STARTING ON THE FIRST TRY WE WOULD HAVE TO WAIT FOR 15-20 MINUTES TO START IT. THEN WHEN THE MORNING WEATHER TURNED COLD IT WOULD NOT START. AT ALL. IN THE AFTERNOONS WHEN IT WOULD WARM UP SOME IT WOULD START AGAIN. WE THOUGHT IT WAS THE BA…
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WE PURCHASED OUR SATURN ION (USED- FROM A DEALERSHIP) AND WITHIN A FEW WEEKS IT BEGAN NOT STARTING ON THE FIRST TRY WE WOULD HAVE TO WAIT FOR 15-20 MINUTES TO START IT. THEN WHEN THE MORNING WEATHER TURNED COLD IT WOULD NOT START. AT ALL. IN THE AFTERNOONS WHEN IT WOULD WARM UP SOME IT WOULD START AGAIN. WE THOUGHT IT WAS THE BATTERY SO REPLACED THE BATTERY. NEXT MORNING IT WOULDN'T START. I WENT ONLINE TO SEE IF THERE WAS A RECALL. THERE WAS NONE. BUT, I DID FIND HUNDREDS OF POSTS ABOUT THE SAME THING. I EVEN FOUND VIDEOS POSTED TO YOUTUBE.COM ON HOW IT MIGHT BE FIXED. SCARY!! ALSO I FOUND POSTS WHERE PEOPLE WENT TO THE DEALERSHIPS FOR FIXES AND THE DEALERSHIPS FIXED THE PROBLEM ONLY FOR IT TO CROP UP AGAIN WITHIN A SHORT TIME. PLEASE CAN YOU HELP? I FOUND YOU BY ACCIDENT OTHERS WOULD MAKE COMPLAINTS BUT THEY DON'T KNOW YOU EXIST TO HELP. OUR CAR IS BASICALLY USELESS BECAUSE WE CANNOT COUNT ON IT TO START WHEN WE NEED IT. THE DATE I GAVE YOU WAS A GUESSTIMATE OF THE FIRST TIME IT HAPPENED. WE HAVE NOT TAKEN OUR CAR TO THE DEALERSHIP BECAUSE OF THE NUMEROUS POST WHERE FOLKS TOOK THEIR CARS IN, HAD REPAIRS , ONLY TO HAVE THE TREND START OVER AGAIN. *TR
NHTSA ODI #10289463
60,000 miles · Oct 20, 2009
Electrical System
2004 SATURN ION- IGNITION FAILS TO RELEASE THE KEY, CANNOT REMOVE THE KEY FROM IGNITION WITHOUT STRUGGLING. HAVE RESEARCHED THE CONSUMER AFFAIRS WEBSITE AND THERE ARE SO MANY COMPLAINTS ABOUT THIS OCCURRING, THAT IS UNREAL. FORTUNATELY WE HAVE NOT HAD TO LEAVE THE CAR RUNNING YET... AS SO MANY OTHER CUSTOMERS AND SOME HAVE HAD T…
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2004 SATURN ION- IGNITION FAILS TO RELEASE THE KEY, CANNOT REMOVE THE KEY FROM IGNITION WITHOUT STRUGGLING. HAVE RESEARCHED THE CONSUMER AFFAIRS WEBSITE AND THERE ARE SO MANY COMPLAINTS ABOUT THIS OCCURRING, THAT IS UNREAL. FORTUNATELY WE HAVE NOT HAD TO LEAVE THE CAR RUNNING YET... AS SO MANY OTHER CUSTOMERS AND SOME HAVE HAD TO REMOVE A FUSE TO GET THE CAR TO TURN OFF. SATURN NEEDS TO DO A VOLUNTARY RECALL ON THIS AND REPLACE ALL OF THE IGNITION SWITCHES BEFORE A TRAGEDY OCCURS. *TR
NHTSA ODI #10289194
34,000 miles · Oct 18, 2009
Electrical System
SATURN ION 2004 WILL NOT START IN COLD WEATHER. THE SYMPTOMS IS SPORADIC AND UNPREDICTABLE AND LINKED TO FAULTY SECURITY MODULE (ANTI-THEFT) WHICH DISABLES THE CAR IN COLD WEATHER. THIS IS A WELL KNOWN PROBLEM DOCUMENTED IN VARIOUS FORUMS AS WELL AS WELL KNOWN TO SATURN DEALERS. YET GM DID NOT MAKE A RECALL ON THIS ISSUE FOR MOR…
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SATURN ION 2004 WILL NOT START IN COLD WEATHER. THE SYMPTOMS IS SPORADIC AND UNPREDICTABLE AND LINKED TO FAULTY SECURITY MODULE (ANTI-THEFT) WHICH DISABLES THE CAR IN COLD WEATHER. THIS IS A WELL KNOWN PROBLEM DOCUMENTED IN VARIOUS FORUMS AS WELL AS WELL KNOWN TO SATURN DEALERS. YET GM DID NOT MAKE A RECALL ON THIS ISSUE FOR MORE THAN 5 YEARS. I HAVE HAD THIS PROBLEM SINCE 2005 AND ADVISED THE DEALERS AND SATURN CUSTOMER SERVICE SEVERAL TIMES WITH NO SUCCESS. *TR
NHTSA ODI #10288858
42,000 miles · Oct 15, 2009
Unknown Or Other
ON FOUR DIFFERENT OCCASIONS WHILE DRIVING MY 2004 SATURN ION ON THE HIGHWAY, AFTER HITTING AN UNUSUAL BUMP OR DIPS IN THE ROAD, I?VE EXPERIENCE A COMPLETE SHUTDOWN OF THE CAR?S SYSTEMS, INCLUDING LOSS OF POWER, LOSS OF STEERING AND ANY ABILITY TO ACCELERATE, BRAKE OR NAVIGATE THE CAR. THE CAR SLOWS TO A COMPLETE STOP. FROM MY PA…
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ON FOUR DIFFERENT OCCASIONS WHILE DRIVING MY 2004 SATURN ION ON THE HIGHWAY, AFTER HITTING AN UNUSUAL BUMP OR DIPS IN THE ROAD, I?VE EXPERIENCE A COMPLETE SHUTDOWN OF THE CAR?S SYSTEMS, INCLUDING LOSS OF POWER, LOSS OF STEERING AND ANY ABILITY TO ACCELERATE, BRAKE OR NAVIGATE THE CAR. THE CAR SLOWS TO A COMPLETE STOP. FROM MY PAST EXPERIENCE I'VE LEARNED THAT THE CAR WILL NEED TO COME TO A COMPLETE STOP AND THEN SHIFTED INTO PARK. THE CAR KEY WILL THEN PHYSICALLY NEED TP BE REMOVED AND REINSERT THE KEY TO GET THE VEHICLE RESTARTED. (TRYING TO START THE CAR WITHOUT REMOVING THE KEY WILL NOT WORK.) ON ALL OCCASIONS THIS HAS PRESENTED AN EXTREMELY DANGEROUS SITUATION AS OTHER CARS TRAVELING ON THE HIGHWAY AT SPEEDS OF 55-75 MPH ARE FORCED TO MANEUVER AROUND MY STALLED VEHICLE, WHICH DOES NOT EVEN HAVE THE POWER OR CONTROL TO BE PULL OFF TO THE SIDE OF THE ROAD. THE CAR WAS TAKEN TO THE SATURN DEALERSHIP ON OCTOBER 17, 2007 AFTER THE FIRST 3 INCIDENTS, HOWEVER DIAGNOSTIC TESTS COULD NOT IDENTIFY OR REPLICATE THE PROBLEM. THE DEALERSHIP ADJUSTED A FUSE BOX IN THE UNDER CARRIAGE OF THE CAR. BUT COULD NOT NEITHER ASSURE ME THE PROBLEM WAS RESOLVED, OR WOULD NOT HAPPEN AGAIN. THE SITUATION RECURRED RECENTLY ON OCT 4, 2009 WHILE ON INTERSTATE 95. THE SEVERITY OF THE SITUATION COULD HAVE EASILY RESULTED IN A FATAL ACCIDENT AS I SAT STRANDED IN THE FAST-LANE OF THE HIGHWAY. THE CAR IS PRESENTLY AT ANOTHER SATURN DEALERSHIP WHERE THEY AGAIN SAY THEY ARE UNABLE TO IDENTIFY OR REPLICATE THE PROBLEM. I AM NO LONGER CONFIDENT IN THE SAFETY OF THIS VEHICLE AND SEEK THE NHTSA ASSISTANCE IN RESOLVING THE MATTER. *TR
NHTSA ODI #10288568
94,039 miles · Oct 15, 2009
Power Train
I WAS ONCE A LOYAL GENERAL MOTORS CUSTOMER ' THAT IS UNTIL GM NEARLY KILLED ME. I'M THE UNFORTUNATE OWNER OF A 2004 SATURN ION WITH AN AILING TRANSMISSION THE DEALERSHIP REFUSES TO REPAIR, AND I AM NOT ALONE. IN MY CASE, THE TRANSMISSION FAILURE NEARLY COST ME MY LIFE. THIS PAST SATURDAY, I WAS ATTEMPTING TO MERGE FROM 315 N …
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I WAS ONCE A LOYAL GENERAL MOTORS CUSTOMER ' THAT IS UNTIL GM NEARLY KILLED ME. I'M THE UNFORTUNATE OWNER OF A 2004 SATURN ION WITH AN AILING TRANSMISSION THE DEALERSHIP REFUSES TO REPAIR, AND I AM NOT ALONE. IN MY CASE, THE TRANSMISSION FAILURE NEARLY COST ME MY LIFE. THIS PAST SATURDAY, I WAS ATTEMPTING TO MERGE FROM 315 N ONTO INTERSTATE 270 E. EXITING THE ENTRANCE RAMP AT THAT INTERCHANGE IS OFTEN A HAZARD UNDER THE BEST CONDITIONS. AS I ACCELERATED INTO THE RIGHT-HAND LANE OF TRAFFIC, MY CAR SHUTTERED VIOLENTLY AND LOST ALL FORWARD MOMENTUM. I SWERVED BACK TO AVOID BEING REAR-ENDED BY THE CLOSING TRAFFIC ON 270 E, NEARLY SIDESWIPING ANOTHER VEHICLE STILL IN THE EXIT LANE. I DRIFTED TO THE SIDE OF THE ROAD UNABLE TO GET THE TRANSMISSION TO ENGAGE. AFTER LETTING THE CAR REST FOR A FEW MINUTES I TRIED AGAIN TO GET IT INTO GEAR, ULTIMATELY HAVING TO LEAVE IT IN A PARKING LOT. DESPITE GM AGREEING TO A CLASS ACTION SETTLEMENT ON APRIL 16, 2009, SATURN DEALERSHIPS HAVE RECENTLY BEEN ADVISED TO SUSPEND ALL EXTENDED WARRANTY REPAIRS UNDER THE AGREEMENT. SATURN CUSTOMER SERVICE, UNDER DIRECT INSTRUCTION FROM GM, HAS TAKE THE POSITION THAT THE AGREEMENT WAS MADE BY GM PRIOR TO THE DECLARATION OF BANKRUPTCY ON JUNE 1, 2009 AND NOW HAS NO LEGAL OBLIGATION TO COMPLETE THE REPAIRS. GM ALSO FAILED TO NOTIFY THE 150,000 OWNERS OF AFFECTED VUE AND ION MODELS THAT DUE TO AN ACKNOWLEDGED DESIGN FLAW, THEIR CARS MIGHT DROP IN OR OUT OF GEAR, EVEN AT HIGH SPEEDS, POSING SIGNIFICANT DANGER TO OPERATORS, PASSENGERS AND OTHER MOTORISTS. HOW MANY ACCIDENTS AND INJURIES HAVE AND WILL OCCUR DUE TO GM'S LACK OF ACTION? LIVES LIKELY HAVE AND WILL BE LOST DUE TO THIS KNOWN DEFECT. GM IS PAYING ROULETTE WITH THE LIVES OF ITS CUSTOMERS AND THE DRIVERS WHO SHARE THE ROADS WITH THEM. GM HAS FAILED TO COMPLY WITH THE LEGAL TERMS OF A CLASS ACTION SETTLEMENT, FAILED TO NOTIFY CUSTOMERS OF A POTENTIALLY DEADLY DEFECT AND FAILED TO PAY THE COST OF REPAIRS THEY AGREED IN FEDERAL DISTRICT COURT. *TR
NHTSA ODI #10287468
40,000 miles · Oct 12, 2009
Engine And Engine Cooling
I TRIED TO START MY 2004 SATURN ION AT ABOUT 11 PM LAST NIGHT AND IT TOOK FIFTEEN MINUTES FOR IT TO TURN OVER. THE TEMPERATURE WAS ABOUT 28 DEGREES (F). THIS HAS HAPPENED SEVERAL DOZEN TIMES OVER THE PAST FEW YEARS, ALWAYS WHEN THE TEMPERATURE IS BELOW FREEZING. I KNOW THAT SATURN IS AWARE OF THIS PROBLEM AND THAT IT IS ACKNO…
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I TRIED TO START MY 2004 SATURN ION AT ABOUT 11 PM LAST NIGHT AND IT TOOK FIFTEEN MINUTES FOR IT TO TURN OVER. THE TEMPERATURE WAS ABOUT 28 DEGREES (F). THIS HAS HAPPENED SEVERAL DOZEN TIMES OVER THE PAST FEW YEARS, ALWAYS WHEN THE TEMPERATURE IS BELOW FREEZING. I KNOW THAT SATURN IS AWARE OF THIS PROBLEM AND THAT IT IS ACKNOWLEDGED TO BE A PROBLEM WITH THE IGNITION. I HAVE FOUND REPORTS OF HUNDREDS OF OTHER ION OWNERS WHO HAVE EXPERIENCED THIS PROBLEM. I THINK THIS NEEDS TO BE RECALLED AND FIXED BY SATURN AS SITTING FOR 10-20 MINUTES OR MORE IN FREEZING TEMPERATURES WAITING FOR ONE'S CAR TO START IS NOT SAFE, ESPECIALLY AT NIGHT. PLEASE MAKE THIS A RECALL ISSUE!! *TR
NHTSA ODI #10287159
77,042 miles · Oct 2, 2009
Steering
TL*THE CONTACT OWNS A 2004 SATURN ION. WHILE DRIVING 65 MPH HE NOTICED THAT THE VEHICLE SUDDENLY LOST ALL POWER STEERING. A LOCAL MECHANIC STATED THAT THE STEERING CHIP NEEDED TO BE REPLACED. THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WERE 77042. UPDATED 02/1710 *BF THE STEERING CONTROLLER WAS REPLACED, HOWE…
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TL*THE CONTACT OWNS A 2004 SATURN ION. WHILE DRIVING 65 MPH HE NOTICED THAT THE VEHICLE SUDDENLY LOST ALL POWER STEERING. A LOCAL MECHANIC STATED THAT THE STEERING CHIP NEEDED TO BE REPLACED. THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WERE 77042. UPDATED 02/1710 *BF THE STEERING CONTROLLER WAS REPLACED, HOWEVER THE PROBLEM CONTINUED. THE CONSUMER STATED HE WOULD HAVE TO PAY AN ADDITIONAL $1000 TO REPLACE THE MAIN COMPUTER. UPDATED 02/19/10
NHTSA ODI #10286093
112,000 miles · Sep 22, 2009
Steering
EXPERIENCING CONTINUOUS FAILURE OF THE POWER STEERING IN MY '04 SATURN ION. STEERING CAN LOCK UP AT ANY GIVEN TIME AFTER START UP AND HAS DONE SO ON AN EVERY TRIP BASIS FOR THE PAST 6 MONTHS. THE DEALERSHIP'S DIAGNOSTIC DIDN'T FIND ANYTHING, BUT OFFERED TO REPLACE THE POWER STEERING COLUMN FOR ALMOST $800; WHICH AS I HAVE READ D…
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EXPERIENCING CONTINUOUS FAILURE OF THE POWER STEERING IN MY '04 SATURN ION. STEERING CAN LOCK UP AT ANY GIVEN TIME AFTER START UP AND HAS DONE SO ON AN EVERY TRIP BASIS FOR THE PAST 6 MONTHS. THE DEALERSHIP'S DIAGNOSTIC DIDN'T FIND ANYTHING, BUT OFFERED TO REPLACE THE POWER STEERING COLUMN FOR ALMOST $800; WHICH AS I HAVE READ DOESN'T GUARANTEE FIXING THE PROBLEM. LOSING YOUR POWER STEERING WHILE DRIVING IS A SAFETY ISSUE AND I FEEL THAT IF THIS ISSUE IS PREVALENT IN THE ION SERIES, SATURN/GM SHOULD ADDRESS IT ACCORDINGLY. *TR
NHTSA ODI #10284844
60,000 miles · Sep 14, 2009
Steering
2004 SATURN ION QUAD COUPE. 2.2L MAN. POWER STEERING FAILS SEEMS TO BE RANDOM AS TO WHEN IT FAILS. REPEATED FAILS, USUALLY MULTIPLE TIMES IN A DAY. MAKES DRIVING THE VEHICLE VERY DIFFICULT AND IF NOT EXPECTING IT CAN MAKE FOR A CLOSE CALL. FAILURE HAS NOT BEEN CORRECT AS OF THIS TIME. OLD PART CAN BE MADE AVAILAB…
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2004 SATURN ION QUAD COUPE. 2.2L MAN. POWER STEERING FAILS SEEMS TO BE RANDOM AS TO WHEN IT FAILS. REPEATED FAILS, USUALLY MULTIPLE TIMES IN A DAY. MAKES DRIVING THE VEHICLE VERY DIFFICULT AND IF NOT EXPECTING IT CAN MAKE FOR A CLOSE CALL. FAILURE HAS NOT BEEN CORRECT AS OF THIS TIME. OLD PART CAN BE MADE AVAILABLE ONCE REPAIR IS COMPLETED. *TR
NHTSA ODI #10283931
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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