NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
331 reportsClear category filter139,000 miles · Feb 26, 2014
Electrical System
MY 2004 SATURN ION INTERMITTENTLY WILL NOT RELEASE THE KEY FROM THE ACC POSITION AS WELL AS WHEN TRYING TO START IT THE SECURITY SYSTEM WILL INTERMITTENTLY KEEP THE CAR FROM STARTING, I WILL GO TO START THE VEHICLE AND THEN IT WILL START TO CRANK THEN SHUT DOWN, I HAVE TO WAIT 10 MIN THEN THE CAR WILL START. IT IS STARTING TO H…
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MY 2004 SATURN ION INTERMITTENTLY WILL NOT RELEASE THE KEY FROM THE ACC POSITION AS WELL AS WHEN TRYING TO START IT THE SECURITY SYSTEM WILL INTERMITTENTLY KEEP THE CAR FROM STARTING, I WILL GO TO START THE VEHICLE AND THEN IT WILL START TO CRANK THEN SHUT DOWN, I HAVE TO WAIT 10 MIN THEN THE CAR WILL START. IT IS STARTING TO HAPPEN MORE FREQUENTLY AND I SEEN THE JUST DID A RECALL ON 2/25/2014 ON IGNITION SWITCHES FOR MY YEAR AND MODEL OF SATURN BUT MY VIN WAS NOT INCLUDED AND I CAN SEE THAT SEVERAL COMPLAINTS HAVE BEEN PUT IN AND THIS IN MANY CASES WAS JUST A START TO WHAT OTHER PEOPLE HAVE INCURRED @ SOME POINT MOST OTHER PEOPLE COMPLAIN EVENTUALLY THEN CANNOT GET THE ENGINE TO STOP RUNNING. I AM TRYING TO FIND OUT WHY MY VIN IS NOT INCLUDED IN THIS RECALL AS I JUST TOOK MY VEHICLE TO THE SHOP COINCIDENTALLY FOR THIS PROBLEM AS THEY TOLD ME WAS THE IGNITION SWITCH BUT DID NOT HAVE THE FUNDS TO REPAIR IT. THIS TO ME IS ABSURD WHEN YOU SEE THE AMOUNT OF COMPLAINTS AND NOW I FIND OUT 13 PEOPLE HAVE DIED! *TR
NHTSA ODI #10565934
30,000 miles · Jan 31, 2014
Electrical System
IT TURNS OUT SATURN ION IGNITION SWITCHES CAME WITH A FLAW FROM THE FACTORY, EXCESSIVE GREASE WITH POOR COLD WEATHER PERFORMANCE.THE PASSLOCK ISSUE PRESENTS ITSELF AS YOUR CAR SUDDENLY NOT STARTING. SUFFICE IT TO SAY IF THERE'S NO OBVIOUS REASON FOR YOUR VEHICLE TO NOT START, IT'S PROBABLY PASSLOCK RELATED. IF YOU'VE NOTICED THA…
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IT TURNS OUT SATURN ION IGNITION SWITCHES CAME WITH A FLAW FROM THE FACTORY, EXCESSIVE GREASE WITH POOR COLD WEATHER PERFORMANCE.THE PASSLOCK ISSUE PRESENTS ITSELF AS YOUR CAR SUDDENLY NOT STARTING. SUFFICE IT TO SAY IF THERE'S NO OBVIOUS REASON FOR YOUR VEHICLE TO NOT START, IT'S PROBABLY PASSLOCK RELATED. IF YOU'VE NOTICED THAT WAITING A FEW MINUTES SEEMS TO HELP, THAT'S THE CLINCHER. TEN MINUTES IS THE MAGIC NUMBER, THAT'S WHEN THE COMPUTER RESETS. IF YOU WERE CHARGED FOR A NEW BATTERY, STARTER, IGNITION SWITCH OR A TOW I SUGGEST YOU NOT LET THE ISSUE DROP, IT WASN'T YOUR FAULT OR RESPONSIBILITY. GM SHOULD TAKE RESPONSIBILITY. FORGETTING THE UNPLEASANTNESS OF BEING STRANDED IN 10 MINUTE INCREMENTS (ALSO, THE CAR FAILS TO START SEVERAL TIMES IN A ROW, AS LONG AS 40 MINUTES BEFORE) THIS IS A SAFETY ISSUE THAT SHOULD BE DEALT WITH ACCORDINGLY. CALLING THE PROBLEM A SAFETY ISSUE MIGHT SEEM LIKE A STRETCH BUT LET'S THINK FOR A MOMENT. WHAT IF YOU'RE TRYING TO FLEE AN EMERGENCY SITUATION (STALKER, LANDSLIDE, FIRE, FLOOD, ETC.) AND YOUR CAR FAILS TO START? WHAT IF IT'S -10 OUTSIDE AND YOUR CAR WON'T START? YOU'RE NOW STUCK IN A FREEZING CAR FOR A MINIMUM OF 10 EXTRA MINUTES, GOING INSIDE ISN'T ALWAYS AN OPTION! LEAVING ASIDE THE SAFETY EXAMPLES, THINK OF EVERYDAY LIFE, TODAY IS BIG MEETING DAY, YOU'RE READY TO LEAVE AND... CAR WON'T START. SAFETY & RELIABILITY ARE TWO (2) KEY ITEMS DEFINITELY FAILING IN ORDER FOR DRIVING TO AND FROM ANY DESTINATION. I FEEL GM/SATURN SHOULD BE HELD RESPONSIBLE FOR THIS DEFECT. AS FAR AS I KNOW, THERE HAS BEEN NO NOTIFICATION FROM GM/SATURN REGARDING THIS DEFECT. WITH THE RECENT FIX, I PAID $550.00 FOR THE REPAIR OF THE IGNITION SWITCH, NEW BATTERY, STARTER AND PLUGS, WHICH ALL NEEDED TO BE CHANGED DUE TO THE STRESS & STRAIN OF THIS "STARTING" ISSUE. I WOULD APPRECIATE REIMBURSEMENT OF THE AMOUNT STATED. PLEASE REPLY...[XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10562308
Mileage unknown · Jan 9, 2014
Electrical SystemEngine And Engine CoolingSteering
2004 SATURN ION. CONSUMER WRITES IN REGARDS TO ELECTRONIC POWER STEERING FAILURE. *SMD THE CONSUMER STATED SHE FIRST STARTED HAVING FRONT SUSPENSION PROBLEMS, WHICH THE DEALER FIXED FREE OF CHARGE. THE EXHAUST WAS LEAKING AND SHE PAID TO HAVE IT REPLACED, ALONG WITH THE CATALYTIC CONVERTER. ALSO, THE HORN STOPPED WORKING. THE…
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2004 SATURN ION. CONSUMER WRITES IN REGARDS TO ELECTRONIC POWER STEERING FAILURE. *SMD THE CONSUMER STATED SHE FIRST STARTED HAVING FRONT SUSPENSION PROBLEMS, WHICH THE DEALER FIXED FREE OF CHARGE. THE EXHAUST WAS LEAKING AND SHE PAID TO HAVE IT REPLACED, ALONG WITH THE CATALYTIC CONVERTER. ALSO, THE HORN STOPPED WORKING. THE CONSUMER RECEIVED A LETTER IN JULY 2012, FROM GM STATING THE WARRANTY WAS BEING EXTENDED BECAUSE THE ELECTRIC POWER STEERING COULD FAIL. ON DECEMBER 16, 2013, THE POWER STEERING FAILED, AS THE CONSUMER WAS LEAVING A PARKING LOT. SHE HAD TO USE EXTRA FORCE TO TURN THE STEERING WHEEL. AFTER A COUPLE OF MINUTES, IT WAS BACK TO NORMAL. A TEST REVEALED, THERE WAS INDEED A FAILURE. WHEN THE CONSUMER CALLED GM, SHE WAS INFORMED THE EXTENDED WARRANTY HAD EXPIRED ON 11/28/13 THE CONSUMER NO LONGER OWNS THE VEHICLE. UPDATED 02/5/14
NHTSA ODI #10558808
62,720 miles · Dec 31, 2013
Electrical SystemSteering
I WAS DRIVING INTO PARKING LOT AND ELECTRIC POWER STEERING WARNING WITH ALARM CAME ON THE READOUT ON THE DASH. AT THAT TIME IT HAD BECOME NEARLY IMPOSSIBLE TO TURN THE STEERING WHEEL IN ANY DIRECTION. IF ANYONE HAD BEEN CLOSE ENOUGH TO ME THERE WOULD HAVE BEEN A COLLISION. I TURNED THE IGNITION OFF AND THEN ON AGAIN AND THE E…
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I WAS DRIVING INTO PARKING LOT AND ELECTRIC POWER STEERING WARNING WITH ALARM CAME ON THE READOUT ON THE DASH. AT THAT TIME IT HAD BECOME NEARLY IMPOSSIBLE TO TURN THE STEERING WHEEL IN ANY DIRECTION. IF ANYONE HAD BEEN CLOSE ENOUGH TO ME THERE WOULD HAVE BEEN A COLLISION. I TURNED THE IGNITION OFF AND THEN ON AGAIN AND THE ELECTRIC STEERING RETURNED. I AM THE ORIGINAL OWNER OF THE VEHICLE AND THIS INCIDENT PUT ME IN A PANIC MODE BECAUSE I AM PHYSICALLY DISABLED WITH DISABILITIES THAT AFFECT MY ARMS AND LEGS. TRYING TO TURN THE STEERING WHEEL WHEN THE ELECTRIC STEERING FAILED CAUSED ME GREAT PAIN. I FEAR THAT IF THIS HAPPENS AGAIN THERE COULD BE A SERIOUS ACCIDENT WITH OTHER VEHICLES OR EVEN SERIOUS INJURIES TO PEDESTRIANS. THERE WAS NO WAY I COULD CONTROL THAT VEHICLE WITHOUT A FULLY FUNCTIONAL ELECTRIC STEERING. I CONSIDER MYSELF LUCKY THAT THE VEHICLE WAS GOING AT A VERY SLOW RATE OF SPEED AND NOT ON THE ROADWAY WHEN THIS HAPPENED. *TR
NHTSA ODI #10558037
122,000 miles · Oct 2, 2013
Electrical SystemSteering
DRIVING ON THE FREEWAY, AT APPROXIMATELY 65 MPH, WHEN A CHIME WENT OFF. STEERING IMMEDIATELY BECAME DIFFICULT AND I NOTICED THAT THE POWER STEERING INDICATOR LIGHT WAS ON. I EXITED THE FREEWAY CAREFULLY AND PULLED OVER, TURNED OFF THE CAR, THEN RESTARTED IT AND THE POWER STEERING CAME BACK ON. SINCE THIS INITIAL INCIDENT THE…
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DRIVING ON THE FREEWAY, AT APPROXIMATELY 65 MPH, WHEN A CHIME WENT OFF. STEERING IMMEDIATELY BECAME DIFFICULT AND I NOTICED THAT THE POWER STEERING INDICATOR LIGHT WAS ON. I EXITED THE FREEWAY CAREFULLY AND PULLED OVER, TURNED OFF THE CAR, THEN RESTARTED IT AND THE POWER STEERING CAME BACK ON. SINCE THIS INITIAL INCIDENT THE PROBLEM HAS BECOME MORE FREQUENT. I AM UNABLE TO SAFELY DRIVE THE CAR AND HAVE BEEN TOLD IT WILL COST OVER $1,000.00 TO REPLACE A POWER STEERING MOTOR IN THE STEERING COLUMN. ALSO I HAVE DISCOVERED THIS TO BE A FREQUENT ISSUE FOR THIS MODEL VEHICLE. WITH THE DANGER INVOLVED SHOULDN'T A RECALL BE IN ORDER? *TR
NHTSA ODI #10546547
1,000 miles · Sep 5, 2013
Electrical System
TL* THE CONTACT OWNS A 2004 SATURN ION. THE CONTACT STATED THAT AFTER POWERING OFF THE VEHICLE, THE KEY WAS UNABLE TO BE REMOVED FROM THE IGNITION. THE CONTACT MENTIONED THAT THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS TAKEN TO A DEALER WHERE THE FAILURE WAS UNABLE TO BE REPLICATE AND TWO NEW KEYS WERE PROVIDED T…
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TL* THE CONTACT OWNS A 2004 SATURN ION. THE CONTACT STATED THAT AFTER POWERING OFF THE VEHICLE, THE KEY WAS UNABLE TO BE REMOVED FROM THE IGNITION. THE CONTACT MENTIONED THAT THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS TAKEN TO A DEALER WHERE THE FAILURE WAS UNABLE TO BE REPLICATE AND TWO NEW KEYS WERE PROVIDED TO THE CONTACT. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 1,000 AND THE CURRENT MILEAGE WAS 28,000. UPDATED 9/24/13 *CN
NHTSA ODI #10542080
34,000 miles · Feb 20, 2013
Electrical System
TL* THE CONTACT OWNS A 2004 SATURN ION. THE CONTACT STATED THAT THE IGNITION SWITCH KEY WAS ENGAGED REPEATEDLY AND THE ENGINE WOULD NOT OPERATE. THE FAILURE OCCURRED TEN TIMES. THE VEHICLE WAS TOWED TO THE AUTHORIZED DEALER FOR DIAGNOSTIC TESTING WHICH DETECTED A TROUBLE CODE RELATED TO A MODULE. THE CONTACT WAS UNCERTAIN OF THE…
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TL* THE CONTACT OWNS A 2004 SATURN ION. THE CONTACT STATED THAT THE IGNITION SWITCH KEY WAS ENGAGED REPEATEDLY AND THE ENGINE WOULD NOT OPERATE. THE FAILURE OCCURRED TEN TIMES. THE VEHICLE WAS TOWED TO THE AUTHORIZED DEALER FOR DIAGNOSTIC TESTING WHICH DETECTED A TROUBLE CODE RELATED TO A MODULE. THE CONTACT WAS UNCERTAIN OF THE PART THAT WAS REPLACED. THE PROBLEM CONTINUED AND THE VEHICLE REMAINED AT THE DEALER FOR FURTHER INVESTIGATION. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 34,000.
NHTSA ODI #10499388
150,000 miles · Jan 2, 2013
Electrical SystemEngine
WHEN STARTING THE SATURN ON A COLD MORNING, THE IGNITION FAILS TO START THE CAR. I GET A SERVICE MESSAGE. AFTER WAITING ABOUT 10 MINUTES THE CAR WILL START AS IF THE SECURITY WAS RESETTING ITSELF. I'VE READ SEVERAL COMPLAINTS OF THIS PROBLEM ON THE INTERNET. GM WILL NOT OWN UP TO A FAULTY PRODUCT THAT LEAVES SATURN OWNERS COMPLE…
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WHEN STARTING THE SATURN ON A COLD MORNING, THE IGNITION FAILS TO START THE CAR. I GET A SERVICE MESSAGE. AFTER WAITING ABOUT 10 MINUTES THE CAR WILL START AS IF THE SECURITY WAS RESETTING ITSELF. I'VE READ SEVERAL COMPLAINTS OF THIS PROBLEM ON THE INTERNET. GM WILL NOT OWN UP TO A FAULTY PRODUCT THAT LEAVES SATURN OWNERS COMPLETELY STRANDED. THIS PROBLEM OCCURS AT RANDOM TIMES, EVEN ON WARM DAYS. A RECALL MUST BE APPROVED FOR THIS MASSIVE SAFETY PROBLEM. IT'S A SAFETY CONCERN BECAUSE IN AN EMERGENCY THE CARS SHOULDN'T HAVE TO SIT FOR AN ADDITIONAL TEN MINUTES OR STALL OUT IN UNSAFE AREAS. THE PROBLEM SEEMS TO CORRECT ITSELF AFTER THIS IGNITION SWITCH INSIDE OF THE STEERING COLUMN HAS BEEN REPLACED BASED ON HUNDREDS OF TESTAMENTS. I HAVE REPLACED MY STATER AND BATTERY BEFORE REALIZING THE PROBLEM WAS A FAULTY IGNITION SWITCH THAT NUMEROUS OTHER SATURN OWNERS HAVE HAD THE UNPLEASANT EXPERIENCE OF DEALING WITH. *TR
NHTSA ODI #10490745
80,000 miles · Sep 30, 2012
Electrical System
THE IGNITION WOULD NOT ENGAGE COULD NOT START THE CAR AND REPLACED THE ENTIRE SYSTEM AT 400.00 COST. LESS THAN A YEAR LATER, THE KEY NOW WILL NOT COME OUT OF THE IGNITION AND THE CAR WILL NOT TURN OFF. I DISCONNECTED THE BATTERY AND IT STILL WOULD NOT TURN OFF. AFTER MORE THAN 30 MINUTES, AND THE ENGINE OVERHEATING WE WERE ABL…
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THE IGNITION WOULD NOT ENGAGE COULD NOT START THE CAR AND REPLACED THE ENTIRE SYSTEM AT 400.00 COST. LESS THAN A YEAR LATER, THE KEY NOW WILL NOT COME OUT OF THE IGNITION AND THE CAR WILL NOT TURN OFF. I DISCONNECTED THE BATTERY AND IT STILL WOULD NOT TURN OFF. AFTER MORE THAN 30 MINUTES, AND THE ENGINE OVERHEATING WE WERE ABLE TO PULL ENOUGH FUSES TO SHUT THE ENGINE OFF. THEY SAY I HAVE TO REPLACE THE SAME SYSTEM AGAIN. I HAVE HEARD THAT THIS IS A RECURRING PROBLEM WITH THIS CAR AND I CAN'T GET ANY ANSWERS FROM GM. I CAN NOT AFFORD TO REPLACE THIS SYSTEM AGAIN AT A COST OF 400.00 PLEASE HELP ME WITH. *TR
NHTSA ODI #10478020
110,000 miles · Sep 29, 2012
Electrical SystemFuel/propulsion SystemFire
OUR CAR, 2004, SATURN ION3, CAUGHT ON FIRE IN THE DRIVEWAY ON IT'S OWN ABOUT 2 HOURS AFTER IT WAS DRIVEN HOME ON 4 NOV 2011. NO DRIVER - NO KEY IN THE VEHICLE WHEN IT CAUGHT FIRE. I SUBMITTED AN INITIAL REQUEST FOR REVIEW TO GM CLAIMS ALONG WITH ALL DOCUMENTATION THAT WE HAD VIA EMAILS AND OUR CLAIM WAS DENIED. *TR
NHTSA ODI #10477968
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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