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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.

About this comparison →

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

Power Train complaints

60 reports
Clear category filter
35,700 miles · May 18, 2005
Power Train

DURING BRAKING, WHEN GEARS SHOULD BE DOWNSHIFTING, MY AUTOMATIC SATURN ION 3 RPMS WOULD SEEM TO BE RACING UPWARDS BY SEVERAL 1000'S. I COMPLAINED ON 2 PRIOR OCCASSIONS TO DEALER WHO COULD NOT "DUPLICATE THE PROBLEM". ON 05/13/05 I WAS BACKING OUT OF MY GARAGE, CAR SEEMED TO LURCH BACKWARDS. WHEN I PUT IT IN DRIVE IT THE RPMS…

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DURING BRAKING, WHEN GEARS SHOULD BE DOWNSHIFTING, MY AUTOMATIC SATURN ION 3 RPMS WOULD SEEM TO BE RACING UPWARDS BY SEVERAL 1000'S. I COMPLAINED ON 2 PRIOR OCCASSIONS TO DEALER WHO COULD NOT "DUPLICATE THE PROBLEM". ON 05/13/05 I WAS BACKING OUT OF MY GARAGE, CAR SEEMED TO LURCH BACKWARDS. WHEN I PUT IT IN DRIVE IT THE RPMS RACED ABOVE 3000. IT LURCHED ME OUT OF MY DRIVEWAY AND INTO THE ROAD. PUT IN REVERSE AND WAS ABLE TO STOP AND PARK. TURNED IGNITION OFF AND RESTARTED. IN PARK CAR WAS IDLING AT 3500 RPMS. RESTARTED SEVERAL TIMES WITH SAME RESULT. CALLED ROADSIDE ASSISTANCE B/C CAR IS STILL UNDER WARRANTY. TOW GUY HAD TO BRAKE ENTIRE TIME HE WAS LOADING CAR ONTO STEEP INCLINE OF TRUCK BED B/C HE SAID CAR WAS QUICKLY MOVING FORWARD AND UP ON IT'S OWN. WAITED W/ SERVICE PEOPLE AT SATURN TO MAKE SURE THEY COULD "DUPLICATE THE PROBLEM". THEY DID. REPLACED THE THROTTLE POSITION SENSOR. COMPLAINED HARSHLY B/C THIS WAS 3RD TIME IN. CAR HAD TO BE TOWED IN MARCH B/C IT WOULDN'T START IN THE A.M. TOW GUY COULDN'T START EITHER. OF COURSE SATURN COULD NOT DUPLICATE THAT PROBLEM EITHER AND STATED THAT IT WAS PROBABLY THE COLD WEATHER. DON'T LIVE IN ALASKA... MARCH IN SOUTH CAROLINA DOES NOT WARRANT A 1 YR OLD, GARAGE KEPT CAR NOT STARTING. DEALERSHIP STATED THEY COULD NOT DUPLICATE PROBLEM OF NOT STARTING OR OF RPMS AND THEY DID NOTHING. SATURN MADE EFFORTS, AFTER THE MAY INCIDENT, TO COMPENSATE. WILL UPDATE WHEN ALL DETAILS ARE WORKED OUT.

NHTSA ODI #10121317

Mileage unknown · Jan 28, 2005
Power Train

TRANSMISSION SLIPS GEARS WHEN DRIVING DOWN HILL. CONSUMER DOES NOT HAVE TO DEPRESS THE ACCELERATOR OR BRAKE PEDAL. VEHICLE WILL JUST SLOW DOWN TO 10 MPH. WHILE DRIVING UP THE HILL VEHICLE WILL ACCELERATE UP TO 25 MPH. *AK

NHTSA ODI #10109179

Mileage unknown · Jan 3, 2005
Power Train

I BOUGHT MY 04 ION2 IN JANUARY OF LAST YEAR. ABOUT ONE MONTH AFTER MY PURCHASE I NOTICED THAT MY CAR WOULD DOWNSHIFT WHILE BRAKING DOWNHILLS, WHICH WOULD CAUSE THE RPMS TO ACCELERATE EXTREMELY HIGH. THE CAR WOULD THE JERK ITSELF BACK INTO THE GEAR IT WAS SUPPOSE TO BE IN. THIS WENT ON FOR MONTHS AND IS STILL OCCURING. I HAVE BRO…

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I BOUGHT MY 04 ION2 IN JANUARY OF LAST YEAR. ABOUT ONE MONTH AFTER MY PURCHASE I NOTICED THAT MY CAR WOULD DOWNSHIFT WHILE BRAKING DOWNHILLS, WHICH WOULD CAUSE THE RPMS TO ACCELERATE EXTREMELY HIGH. THE CAR WOULD THE JERK ITSELF BACK INTO THE GEAR IT WAS SUPPOSE TO BE IN. THIS WENT ON FOR MONTHS AND IS STILL OCCURING. I HAVE BROUGHT MY CAR TO SATURN OF SPRINGFIELD COUNTLESS TIMES. AT ONE POINT I WAS IN THERE MUTLIPLE TIMES IN ONE WEEK. NOT ONLY DID IS ACCELERATE GOING DOWNHILL BUT IT WON'T SHIFT INTO THE NEXT GEAR GOING UP HILL, AND TO TOP IT OFF WHEN I ENTER THE HIGHWAY THE CAR WONT SHIFT INTO 5 GEAR WHEN I AM ACCELERATING, I HAVE TO REMOVE MY FOOT FROM THE GAS PEDAL TO ALLOW THE CAR TO SHIFT. SATURN HAS TOLD ME COUNTLESS TIMES THAT THERE IS NOTHING WRONG WITH MY CAR. I ONLY AVERAGE ABOUT 16 MILES TO THE GALLON NO MATTER IF IT IS THE HIGHWAY OR CITY. I HAVE GOTTEN TO THE POINT WERE SATURN CALLS ME THE NEXT DAY AFTER EVERY SERVICE CALL. OH AND I JUST HAD TO HAVE MY POSTIVE BATTERY CABLE REPLACED BECAUSE IT WOULDN'T STAY ATTACHED TO THE BATTERY WHICH WOULD'T ALLOW THE CAR TO START.*AK

NHTSA ODI #10105626

50 miles · Oct 11, 2004
Power TrainService Brakes, HydraulicSuspension

RECEIVED FIRST SATURN ION 04 AND WITHIN ONE WEEK OF PURCHASE CAR WAS DISPLAYING CLEAR SIGNS OF EITHER AN ELECTRICAL OR COMPUTER PROBLEM. WAS REPLACED WITH A SECOND ION O4. NOTICED A STRANGE CLUNKING SOUND. BROUGHT CAR IN AT 3600 MILES, AND IT WAS TRANSMISSION MOUNTS, WHEEL BEARINGS, AXELS, AND BREAK ROTORS. CAR WAS RETURNED …

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RECEIVED FIRST SATURN ION 04 AND WITHIN ONE WEEK OF PURCHASE CAR WAS DISPLAYING CLEAR SIGNS OF EITHER AN ELECTRICAL OR COMPUTER PROBLEM. WAS REPLACED WITH A SECOND ION O4. NOTICED A STRANGE CLUNKING SOUND. BROUGHT CAR IN AT 3600 MILES, AND IT WAS TRANSMISSION MOUNTS, WHEEL BEARINGS, AXELS, AND BREAK ROTORS. CAR WAS RETURNED WITH A BROKEN PIECE IN THE INTERIOR, AND SMELLING OF BURNING PLASTIC. I BELIEVE THAT THIS CAR IS DEFECTIVE, AND SATURN REFUSES TO DO ANYTHING OTHER THAN MAKE REPAIRS UNDER WARRANTY. I THINK THAT I SHOULD BE ISSUED A REFUND, DUE TO FAULTY CONSTRUCTION. *NM

NHTSA ODI #10093934

48 miles · Sep 13, 2004
Power Train

VEHICLE WAS PURCHASED BRAND NEW AND HAD TRANSMISSION REPLACED. THERE HAD BEEN A LEAK IN THE TRANSMISSION , AND GRINDING SOUND WHEN VEHICLE WAS COLD . CONSUMER STATED THAT DEALERSHIP WAS DOING NOTHING TO HELP WITH THIS PROBLEM. CONSUMER DID NOT FEEL SAFE DRIVING, FEARING THAT THE VEHICLE WILL SHUT DOWN. *AK

NHTSA ODI #10091890

22,960 miles · Aug 12, 2004
Power Train

WHILE ACCELERATING, THE VEHICLE DOWN SHIFTED. THE CONSUMER WAS ABLE TO MAINTAIN CONTROL OF THE VEHICLE AND DROVE IT TO THE DEALER FOR INSPECTION. THE MECHANIC INFORMED THE CONSUMER THAT THE TRANSMISSION CHIP NEEDED TO BE REPLACED. THE PROBLEM RECURRED AND WAS TAKEN BACK TO THE DEALER FOUR TIMES. THE MECHANIC WAS UNABLE TO …

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WHILE ACCELERATING, THE VEHICLE DOWN SHIFTED. THE CONSUMER WAS ABLE TO MAINTAIN CONTROL OF THE VEHICLE AND DROVE IT TO THE DEALER FOR INSPECTION. THE MECHANIC INFORMED THE CONSUMER THAT THE TRANSMISSION CHIP NEEDED TO BE REPLACED. THE PROBLEM RECURRED AND WAS TAKEN BACK TO THE DEALER FOUR TIMES. THE MECHANIC WAS UNABLE TO DUPLICATE THE PROBLEM. *JB ON NUMEROUS OCCASIONS THE VEHICLE DID NOT SHIFT PROPERLY. THE VEHICLE WOULD FEEL AS IF THE TRANSMISSION WAS SLIPPING. THE RPM WOULD GO UP BUT THE VEHICLE DID NOT ACCELERATE AND NO PROBLEM WOULD BE FOUND BY THE SERVICE DEALER. THE CONSUMER HAD ALMOST EXPERIENCED 2 REAR END COLLISIONS AND 1 BROADSIDE COLLISION. *SC *JB

NHTSA ODI #10083516

2,674 miles · Jul 23, 2004
Power Train

I BOUGHT A SATURN ION 2 IN JANUARY SINCE THAT DAY I HAVE ONLY GOT AN AVERAGE OF 22.5 MPG THAT IS 270 MILES PER 12 GALLON TANK (AND IT STILL CONTINUES). IN MARCH AS I WAS DRIVING DOWN A BACK ROAD, IT LURCHED, THE CHECK ENGINE LIGHT CAME ON, IT BOGGED DOWN, AND WOULD NOT ACCELERATE OVER 50MPH AND WAS EXTREMELY SLUGGISH, FELT LIKE …

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I BOUGHT A SATURN ION 2 IN JANUARY SINCE THAT DAY I HAVE ONLY GOT AN AVERAGE OF 22.5 MPG THAT IS 270 MILES PER 12 GALLON TANK (AND IT STILL CONTINUES). IN MARCH AS I WAS DRIVING DOWN A BACK ROAD, IT LURCHED, THE CHECK ENGINE LIGHT CAME ON, IT BOGGED DOWN, AND WOULD NOT ACCELERATE OVER 50MPH AND WAS EXTREMELY SLUGGISH, FELT LIKE I WAS DRIVING A GOLF CART. I HAD IT TOWED TO THE DEALER. THE RECALLS ON THE FUEL FILTER AND COMPUTER SYSTEM WERE COMPLETED. THE DEALER INFORMED ME THAT THE CAR WAS "OPERATING AS DESIGNED" AND THE PROBLEM COULD NOT BE REPEATED. JUNE 10TH, THE CAR REPEATED THE SAME PROBLEM. I TOOK IT IN AGAIN, THEY DID THE 6,000 MILE SERVICE ON IT. PER MY RECORDS, EVERYTHING "CHECKED OUT". THE PROBLEM COULD NOT BE REPEATED. THE CAR WAS "OPERATING AS DESIGNED. 3 WEEKS LATER, DRIVING ON THE FREEWAY, THE CAR ONCE AGAIN, LURCHED, THE CHECK ENGINE LIGHT CAME ON, AND WENT FROM 65  40 MPH. THANKFULLY I DID NOT GET REAR-ENDED. I EXITED THE FREEWAY, HAD TO STOP AT A LIGHT, THEN DURING A LEFT HAND TURN HAD DIFFICULTY GETTING THE CAR TO ACCELERATE. THE CAR FINALLY CORRECTED ITS PROBLEM, AND I WAS ABLE TO DRIVE HOME. I TOOK THE CAR TO THE DEALERSHIP YET AGAIN, THEY COULD NOT REPLICATE THE PROBLEM. THEY REPLACED MY VALVE BODY AND NOW MY CAR IS RUNNING WORSE THEN IT WAS BEFORE. I STOPPED BY THE DEALERSHIP A DAY AGO, AND TALKED TO THE MAINTENANCE MANAGER, AND HE STATED THAT HE HOPES THEY REPLACE THE CAR, SINCE THERE IS NOTHING THEY CAN DO ABOUT IT. THEY HAVE TRIED EVERYTHING. MY CAR IS UNSAFE TO ME AND OTHERS AROUND. IT IS A SAFETY ISSUE. I AM NO LONGER COMFORTABLE DRIVING MY CAR. I HAVE OPENED A CASE WITH SATURN CUSTOMER ASSISTANCE. THIS PROBLEM THAT I HAVE EXPERIENCED AND AS I HAVE READ OTHERS TOO, IS EXTREMELY UNSAFE!*AK

NHTSA ODI #10082541

7,100 miles · Jul 6, 2004
Power Train

WE OWN A 2004 SATURN ION3 QUAD COUPE, IT HAS A DIFFERENT TRANSMISSION THEN THE OTHERS. WE BOUGHT THE VEHICLE ON DECEMBER 31, 2003. IT HAD 91 MILES ON IT. WE NOTICED THE TRANSMISSION SEEMED TO HESITATE A LITTLE GOING FROM FIRST INTO SECOND. WHEN WE TOOK IT IN FOR IT'S FIRST OIL CHANGE IN MARCH, WE ASKED THEM TO LOOK AT THE TRAN…

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WE OWN A 2004 SATURN ION3 QUAD COUPE, IT HAS A DIFFERENT TRANSMISSION THEN THE OTHERS. WE BOUGHT THE VEHICLE ON DECEMBER 31, 2003. IT HAD 91 MILES ON IT. WE NOTICED THE TRANSMISSION SEEMED TO HESITATE A LITTLE GOING FROM FIRST INTO SECOND. WHEN WE TOOK IT IN FOR IT'S FIRST OIL CHANGE IN MARCH, WE ASKED THEM TO LOOK AT THE TRANSMISSION. THEY REPORTED BACK THAT IT WAS NORMAL FOR A 4 CYLINDER TO ACT THE WAY IT WAS. ASSUMING THEY KNEW WHAT THEY WERE TALKING ABOUT WE LEFT IT AT THAT. WE TOOK IT IN AGAIN FOR PAINT DAMAGE THEY HAD CAUSED WHEN THEY HAD THE VEHICLE FOR THE OIL CHANGE, AND AGAIN ASKED THEM TO LOOK AT THE TRANSMISSION (ONLY ABOUT A WEEK LATER). THEY AGAIN REPORTED THEY TEST DROVE AND IT WAS FINE. NOW THIS PAST WEEK FOR IT'S SECOND OIL CHANGE ON TUESDAY, JUNE 29TH, WE AGAIN ASKED THEM BECAUSE IT SEEMED TO HAVE GOTTEN WORSE. THEY AGAIN REPORTED IT WAS NORMAL OPERATION. NOT A WEEK AFTER THAT REPORT ON SUNDAY, JULY 4TH AMIDST OUT 4TH OF JULY CELEBRATION WE DROVE A BLOCK AND A HALF FROM HOME AND TURNED A CORNER ONTO THE MAIN ROAD. WHEN I WENT TO ACCELERATE THE CAR REVVED AND DIDN'T SWITCH INTO SECOND GEAR. IT FOUGHT TO GO FASTER IN FIRST GEAR, BUT NEVER SWITCHED. WE NOTICED IMMEDIATELY AND TRIED PARKING AND AGAIN MOVING INTO DRIVE, THINKING MAYBE IT HAD DROPPED ITSELF INTO NEUTRAL. AGAIN THE SAME THING, WE SLOWLY TURNED THE CORNER AND PUTTED OUR WAY BACK DOWN THE BLOCK TO THE DRIVEWAY AT 5 MILES AN HOUR SO AS NOT TO FURTHER DAMAGE THE ENGINE DUE TO TRANSMISSION FAILURE. THE CAR CURRENTLY HAS 7000 MILES ON IT AND A TRANSMISSION THAT DOESN'T WORK. WE MEET WITH THE DEALERSHIP TODAY TO DISCUSS RETRIBUTION. *NM

NHTSA ODI #10080405

1,500 miles · Mar 22, 2004
Power Train

WHEN I ACCELERATE ON HIGHWAY THE CAR DOES NOT PICK UP SPEED, IT BUCKS THEN PUSHES ITSELF. THE ENGINE IS VERY LOUD. SOUNDS LIKE GRINDING OR WHIRRING. THEY HAVE HAD TO CALIBRATE THE VEHICLE 2 TIMES IN THE 3 MONTHS I HAVE HAD THIS CAR. IT IS IN THE SHOP AGAIN TODAY. (3RD TIME). *AK

NHTSA ODI #10063610

3,000 miles · Mar 2, 2004
Power Train

VTI TRANSMISSION CAUSES SUDDEN VEHICLE DECELERATION. *AK

NHTSA ODI #10060217

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.