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2004 Saturn Ion

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2004 Saturn Ion do not stand out strongly from the model-year median of 816.5.

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When problems were reported

Mileage at the reported incident

713 reports with mileage · 185 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Steering. Review the 345 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 331 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 60 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

51 crash reports4 fire reports29 injury reports

Electrical System complaints

331 reports
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40,000 miles · Mar 10, 2010
Electrical System

2004 SATURN ION THIS CAR HAS PROBLEMS STARTING WHEN IT IS COLD OUTSIDE, I AM LATE FOR WORK ALOT IT MIGHT TAKE 20 MINUTES TO START OR AN HOUR. I CALLED THE DEALERSHIP AND THEY SAID I I WOULD HAVE TO PAY FOR A DIAGNOSTIC EVALUATION. THIS HAPPENS IN THE COOLER MONTHS I CAN COUNT ON IT. THE MOST CURRENT BEING THIS MORNING YESTERD…

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2004 SATURN ION THIS CAR HAS PROBLEMS STARTING WHEN IT IS COLD OUTSIDE, I AM LATE FOR WORK ALOT IT MIGHT TAKE 20 MINUTES TO START OR AN HOUR. I CALLED THE DEALERSHIP AND THEY SAID I I WOULD HAVE TO PAY FOR A DIAGNOSTIC EVALUATION. THIS HAPPENS IN THE COOLER MONTHS I CAN COUNT ON IT. THE MOST CURRENT BEING THIS MORNING YESTERDAY MORNING THE DAY BEFORE THAT. *TR

NHTSA ODI #10318503

50,000 miles · Mar 6, 2010
Electrical SystemSteering

CAR DOES NOT START WHEN BELOW 35 DEGREES. I HAVE TO WAIT EXACTLY 10 MINUTES THEN IT WILL USUALLY START. POWER STEERING WOULD OCCASIONALLY TURN OFF WHILE DRIVING AROUND 50,000 TO 60,000 MILES AND GRADUALLY WORSENS OVER TIME. MY POWER STEERING IS NOW COMPLETELY NOT WORKING AND HAS ALMOST CAUSED ME SEVERAL MINOR TO MAJOR ACCIDENTS …

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CAR DOES NOT START WHEN BELOW 35 DEGREES. I HAVE TO WAIT EXACTLY 10 MINUTES THEN IT WILL USUALLY START. POWER STEERING WOULD OCCASIONALLY TURN OFF WHILE DRIVING AROUND 50,000 TO 60,000 MILES AND GRADUALLY WORSENS OVER TIME. MY POWER STEERING IS NOW COMPLETELY NOT WORKING AND HAS ALMOST CAUSED ME SEVERAL MINOR TO MAJOR ACCIDENTS WHEN IT SHUTS OFF WHILE DRIVING EITHER BY MYSELF OR WITH MY CHILDREN. I REPLACED THE ELECTRIC POWER STEERING FUSES FIRST TO SEE IF THAT SOLVED THE PROBLEM ONLY TO REALIZE ITS THE POWER STEERING COLUMN WILL HAVE TO BE REPLACED COSTING ME $1100. I CAN NO LONGER DRIVE MY CAR BECAUSE I AM NOT STRONG ENOUGH TO TURN THE WHEEL WITH THE CONSTANT FAILING OF THE POWER STEERING. *TR

NHTSA ODI #10317290

80,000 miles · Mar 3, 2010
Electrical System

I DRIVE A 2004 SATURN ION 2. WHEN THE TEMPERATURE IS 32 DEGREES OR LOWER MY CAR WILL NOT START IF IT HAS BEEN SITTING FOR MORE THAN 4 OR 5 HOURS. I HAVE BEEN LEFT STRANDED ON MULTIPLE OCCASIONS WITH THIS PROBLEM. I BELIEVE IT IS SOMETHING IN THE IGNITION SWITCH. DURING THE WINTER MONTHS THIS WILL HAPPEN EVERY MORNING AND OCC…

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I DRIVE A 2004 SATURN ION 2. WHEN THE TEMPERATURE IS 32 DEGREES OR LOWER MY CAR WILL NOT START IF IT HAS BEEN SITTING FOR MORE THAN 4 OR 5 HOURS. I HAVE BEEN LEFT STRANDED ON MULTIPLE OCCASIONS WITH THIS PROBLEM. I BELIEVE IT IS SOMETHING IN THE IGNITION SWITCH. DURING THE WINTER MONTHS THIS WILL HAPPEN EVERY MORNING AND OCCASIONALLY AFTER WORK IF THE TEMPERATURE IS TOO COLD. I HAVE NOT DONE ANYTHING TO FIX THE PROBLEM BECAUSE IT WILL COST AROUND $200.00 TO FIX. *TR

NHTSA ODI #10316112

Mileage unknown · Feb 16, 2010
Electrical System

I HAVE A 2004 SATURN ION 2. SEEMS TO BE A PROBLEM WITH THE IGNITION SWITCH IN THESE VEHICLES. MY CAR WILL NOT START WHEN COLD AND DAMP OUTSIDE. I HAVE REPLACED THE SWITCH IN MY VEHICLE SEVERAL TIMES AND STILL GET THE SAME PROBLEM IN TIME. THIS IS A SAFETY ISSUE BECAUSE I LIVE IN MO WHERE IT GETS VERY COLD AND NOT ALWAYS SOMEONE …

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I HAVE A 2004 SATURN ION 2. SEEMS TO BE A PROBLEM WITH THE IGNITION SWITCH IN THESE VEHICLES. MY CAR WILL NOT START WHEN COLD AND DAMP OUTSIDE. I HAVE REPLACED THE SWITCH IN MY VEHICLE SEVERAL TIMES AND STILL GET THE SAME PROBLEM IN TIME. THIS IS A SAFETY ISSUE BECAUSE I LIVE IN MO WHERE IT GETS VERY COLD AND NOT ALWAYS SOMEONE TO PICK ME UP WHEN THE CAR DIES. SO I AM LEFT STRANDED IN SUB ZERO TEMPERATURES. SATURN KNOWS VERY WELL ABOUT THIS PROBLEM AND WILL NOT RECALL THIS. PLEASE SEE THAT A RECALL TAKES PLACE. THIS IS AN ONGOING PROBLEM WITH THIS CAR. *TR

NHTSA ODI #10310813

9,000 miles · Feb 12, 2010
Electrical SystemEquipmentPower Train

AFTER ONLY 9 MONTHS OF OWNING MY ION I HAVE EXPERIENCED PROBLEMS WITH SHIFTING THE CAR IN AND OUT OF GEAR. IT IS A RANDOM OCCURRENCE AND CAN HAPPEN 8 TIMES IN A WEEK THEN NOT AT ALL FOR MONTHS. HOWEVER WHEN IT DOES HAPPEN IT IS A LIFE THREATENING EXPERIENCE AS I AM USUALLY DRIVING ON A MAJOR HIGHWAY. THE CAR WILL BE "LOCKED" INT…

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AFTER ONLY 9 MONTHS OF OWNING MY ION I HAVE EXPERIENCED PROBLEMS WITH SHIFTING THE CAR IN AND OUT OF GEAR. IT IS A RANDOM OCCURRENCE AND CAN HAPPEN 8 TIMES IN A WEEK THEN NOT AT ALL FOR MONTHS. HOWEVER WHEN IT DOES HAPPEN IT IS A LIFE THREATENING EXPERIENCE AS I AM USUALLY DRIVING ON A MAJOR HIGHWAY. THE CAR WILL BE "LOCKED" INTO 4TH FOR EXAMPLE AND WHEN I TRY TO SHIFT TO 5TH I CAN NOT GET IT OUT OF 4TH. I HAVE TAKEN THE CAR TO THE SATURN DEALERSHIP A MINIMUM OF 20 TIMES FOR THIS PROBLEM, ONLY TO BE TOLD THAT THEY COULD NOT DO ANYTHING. I THEN TOOK IT TO A DIFFERENT DEALERSHIP WHERE THE TECH TOOK THE CAR HOME FOR 1 WEEK, EXPERIENCED THE PROBLEM FOR HIMSELF, AND TOLD ME ALL HE COULD DO WAS REPLACE A WIRE AND HOPE IT HELPED BECAUSE SATURN WOULD NOT LET HIM INVESTIGATE ANY MORE OPTIONS. IT DID ABSOLUTELY NOTHING TO HELP MY CAR. AND SINCE THE LAST TIME MY CAR HAS BEEN AT THE SATURN DEALERSHIP MY POWER STEERING NOW GOES IN AND OUT. APPARENTLY THEY BUSTED A SEAL AND FAILED TO MENTION THAT TO ME, SO NOT ONLY DO I HAVE TO WORRY ABOUT NOT BEING ABLE TO SHIFT, BUT ALSO LOSING MY POWER STEERING. THEY ONLY SOLUTION I CAN COME UP WITH IS TO TRY MY BEST TO GET THE CAR TO A SAFE SPOT AND TURN IT OFF AND LET IT SIT. THIS CAR HAS HAD MORE PROBLEMS THAN ANYONE SHOULD HAVE TO DEAL WITH: REVERSE SWITCH GOING OUT, AIRCONDITIONING GOING OUT, POWER WINDOWS NO LONGER WORK, POWER STEERING, AND NOT BEING ABLE TO SHIFT. I HAVE TO DRIVE THIS EVERYDAY WITH MY CHILDREN IN THE CAR WITH ME AT MOST TIMES. THIS SHOULD HAVE ALL BEEN TAKEN CARE UNDER THE ORIG. WARRANTY, AS IT ALL HAPPENED WITHIN THE FIRST 6-12 MONTHS OF OWNING THE CAR. LOL THAT'S WHAT I GET FOR BUYING A GM PRODUCT. *TR

NHTSA ODI #10308874

55,000 miles · Feb 4, 2010
Electrical System

MY 2004 SATURN ION WONT START IN COLD TEMPERATURES LEAVING ME STRANDED. IF I LIVED IN GUAM THIS WOULD BE NO PROBLEM, BUT I LIVE IN CALGARY ALBERTA CANADA AND ITS GETS TO -40 CELSIUS AND ONLY TAKES MINUTES FOR FROST BITE TO SETTLE IN. *TR

NHTSA ODI #10305972

75,000 miles · Jan 28, 2010
Electrical SystemCrash

TL*THE CONTACT OWNS A 2004 SATURN ION. THE CONTACT STATED WHEN THE TEMPERATURE DROPPED BELOW 30 DEGREES THE VEHICLE WOULD NOT START DUE TO THE IGNITION SWITCH FAILURE. THE FAILURE WAS CAUSED BY THE PASS LOCK CIRCUIT THAT WAS INSIDE THE IGNITION SWITCH AND THE RESISTANCE VALUE WITHIN THE PASS LOCK SYSTEM. THE VEHICLE WAS TOWED TO…

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TL*THE CONTACT OWNS A 2004 SATURN ION. THE CONTACT STATED WHEN THE TEMPERATURE DROPPED BELOW 30 DEGREES THE VEHICLE WOULD NOT START DUE TO THE IGNITION SWITCH FAILURE. THE FAILURE WAS CAUSED BY THE PASS LOCK CIRCUIT THAT WAS INSIDE THE IGNITION SWITCH AND THE RESISTANCE VALUE WITHIN THE PASS LOCK SYSTEM. THE VEHICLE WAS TOWED TO THE DEALER WHERE THEY REPLACED THE IGNITION SWITCH. THE VEHICLE WAS UNDER WARRANTY AND THERE WERE NO RECALLS. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 45,000.

NHTSA ODI #10302992

Mileage unknown · Jan 15, 2010
Electrical System

I DRIVE A 2004 SATURN ION AND LAST YEAR, THE WINTER OF 2008 WHENEVER THE TEMPERATURE DROPPED BELOW 40, WHICH WAS ONCE OR TWICE, MY CAR WOULDN'T START. THIS YEAR, 2009, THE TEMPERATURE HAS BEEN BELOW 40 FOR ABOUT 2 WEEKS NOW AND OUT OF THE 5 WORK DAYS OF THIS WEEK MY CAR STARTED ONCE ON THE FIRST TRY. WHEN I TRY TO START IT,…

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I DRIVE A 2004 SATURN ION AND LAST YEAR, THE WINTER OF 2008 WHENEVER THE TEMPERATURE DROPPED BELOW 40, WHICH WAS ONCE OR TWICE, MY CAR WOULDN'T START. THIS YEAR, 2009, THE TEMPERATURE HAS BEEN BELOW 40 FOR ABOUT 2 WEEKS NOW AND OUT OF THE 5 WORK DAYS OF THIS WEEK MY CAR STARTED ONCE ON THE FIRST TRY. WHEN I TRY TO START IT, THE ENGINE TURNS OVER AND SHUTS OFF IMMEDIATELY. I HAVE TO WAIT AT LEAST 10 MINUTES TO START AGAIN. SOMETIMES IT WILL WORK THE SECOND TIME, USUALLY I HAVE TO WAIT UNTIL THE THIRD TRY. *TR

NHTSA ODI #10299944

Mileage unknown · Dec 28, 2009
Electrical System

IN COLD WEATHER (BELOW 20F), THE CAR REFUSES TO START, OR EVEN TRY TO TURN OVER. *TR

NHTSA ODI #10297138

76,176 miles · Dec 23, 2009
Electrical System

I PURCHASES A 2004 SATURN ION IN 2006. IN OCTOBER OF 2007, MY VEHICLE WOULD NOT START FOR NO APPARENT REASON. AFTER WAITING ABOUT 15 MINUTES, MY VEHICLE STARTED AND RAN NORMALLY. THIS HAPPENED AGAIN ABOUT 3 DAYS LATER WHILE I WAS VISITING RELATIVES 2 HOURS FROM MY HOME WHICH DETAINED ME ON MY TRIP BACK HOME. I TOOK MY VEHICLE …

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I PURCHASES A 2004 SATURN ION IN 2006. IN OCTOBER OF 2007, MY VEHICLE WOULD NOT START FOR NO APPARENT REASON. AFTER WAITING ABOUT 15 MINUTES, MY VEHICLE STARTED AND RAN NORMALLY. THIS HAPPENED AGAIN ABOUT 3 DAYS LATER WHILE I WAS VISITING RELATIVES 2 HOURS FROM MY HOME WHICH DETAINED ME ON MY TRIP BACK HOME. I TOOK MY VEHICLE TO THE SATURN DEALERSHIP IN HARRISBURG, PA TO HAVE IT CHECKED. I WAS TOLD THAT THE PROBLEM WAS THE IGNITION SWITCH WHICH NEEDED TO BE REPLACED (THEY REPLACED IT). TWO YEARS LATER IN DECEMBER, 2009 THE PROBLEM OCCURRED AGAIN, THIS TIME ON MY WAY TO WORK ON AN EXTREMELY COLD WINTER MORNING. I TOOK THE VEHICLE TO THE SATURN DEALERSHIP AGAIN AND WAS TOLD THAT I WOULD NEED ANOTHER IGNITION SWITCH TO REPLACE THE ONE THEY HAD REPLACED 2 YEARS EARLIER. AFTER READING ABOUT SO MANY OTHER COMPLAINTS AND DANGEROUS SITUATIONS THAT SATURN OWNERS HAVE GOTTEN INTO BECAUSE OF FAILING IGNITION SWITCHES, IT IS CLEAR THAT THERE IS A DEFECT IN THESE PARTS. I HAVE READ ABOUT COUNTLESS SITUATIONS WHERE PEOPLE WERE UNABLE TO TURN THEIR CARS OFF! AN IGNITION SWITCH SHOULD NOT GO BAD EVERY 2 YEARS. THIS IS NOT A HIGH WEAR AND TEAR PART. A CAR SHOULD BE ABLE TO TURN ON AND OFF A LARGE NUMBER OF TIMES WITHOUT FAIL. A CAR THAT FAILS TO TURN OFF IS AN ENORMOUS SAFETY ISSUE. IF YOU LEAVE THE CAR UNATTENDED AND TURNED ON, SOMEONE COULD BE HURT OR KILLED. NOT BEING ABLE TO START A CAR IS ALSO A DANGEROUS ESPECIALLY WHEN IT HAPPENS IN BITTERLY COLD WEATHER. SATURN/GM IS DOING NOTHING TO GET THESE UNSAFE VEHICLE OFF THE ROADS TO BE FIXED. THEY ARE NOT TAKING RESPONSIBILITY FOR THE COUNTLESS NUMBER OF IGNITION SWITCH PROBLEMS THAT SATURN OWNERS ARE EXPERIENCING. GM HAS A HISTORY OF IGNITION SWITCH FAILURES AND SHOULD STAND BEHIND THEIR PRODUCT BY OFFERING A RECALL OF THE DEFECTIVE PART AND REPLACING IT. *TR

NHTSA ODI #10296865

Official recalls

8

14V171000 · Electrical System:ignition

Apr 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.

14V153000 · Steering:electric Power Assist System

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.

14V047000 · Air Bags; Electrical System:ignition:switch

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. GM’s 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. GM’s 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. GM’s 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.

04V547000 · Exterior Lighting:turn Signal

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.

04V281000 · Fuel System, Other:delivery:fuel Pump

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.

04V002000 · Structure:body:bumpers

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.

04V003000 · Fuel System, Gasoline

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.

04V004000 · Visibility:power Window Devices And Controls

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

4

EA11014 · 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.