NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
1,235 reports20,000 miles · Feb 27, 2014
Air BagsElectrical System
#1. KEY. IN 2008 THE KEY STARTED GETTING STUCK IN THE IGNITION WHEN I ATTEMPTED TO TURN THE CAR OFF. THE CAR KEPT RUNNING. IT WOULD TAKE UP TO 10 TRIES BEFORE THE ENGINE STOPPED. EVEN THEN I COULD NOT ALWAYS GET THE KEY TO COME OUT RIGHT AWAY. I COULD NOT GET THE KEY TO TURN WHEN TRYING TO START THE CAR. THE KEY OFTEN WOUL…
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#1. KEY. IN 2008 THE KEY STARTED GETTING STUCK IN THE IGNITION WHEN I ATTEMPTED TO TURN THE CAR OFF. THE CAR KEPT RUNNING. IT WOULD TAKE UP TO 10 TRIES BEFORE THE ENGINE STOPPED. EVEN THEN I COULD NOT ALWAYS GET THE KEY TO COME OUT RIGHT AWAY. I COULD NOT GET THE KEY TO TURN WHEN TRYING TO START THE CAR. THE KEY OFTEN WOULD ALSO GET STUCK IN THE IGNITION AND I COULD NOT GET IT OUT AND WOULD HAVE TO LEAVE IT IN. 2014 I COULD NOT GET IT TO COME OUT AT ALL AND AT ONE POINT THE CAR WOULD NOT SHUT OFF. MECHANIC REPLACED (AT MY EXPENSE) THE IGNITION. #2. WHEN I PURCHASED THE CAR AN ADD ON OFFERED WAS A PASSIVE KILL SWITCH CALLED ID SYSTEM. REPEATEDLY THE AIR BAG LIGHT WOULD COME ON, AND THE ON-STAR SYSTEM ALSO NOTIFIED ME. IT WOULD GO BACK OFF. I TOOK IT TO THE DEALER IN 2006 AND 2007 WAS TOLD SINCE THE LIGHT WAS NOT ON THEN THAT THEY COULD NOT/WOULD NOT DO ANYTHING. IN 2013 THE LIGHT WAS ALWAYS ON. I WAS ALSO HAVING OTHER ELECTRICAL PROBLEMS (SEE #3). I WENT TO AN AUTO ELECTRICAL SHOP. WHILE DIAGNOSING THE INITIAL PROBLEM THE SHOP FOUND THAT WHEN THE KILL SWITCH WAS PUT IN THE COMPANY HAD TAKEN OUT THE RELAY FOR THE AIR BAG AND PUT THE PUT THE ID SYSTEM RELAY IN IT'S PLACE. THE RESULT WAS THAT NEITHER WORKED. THE SHOP PULLED OUT THE KILL SWITCH RELAY AND REPLACED THE AIR BAG ONE. WHICH I PAID THE BILL FOR. NOW THE AIR BAG LIGHT IS STARTING TO COME BACK ON AT TIMES. I ASSUME THE AIR BAG IS NOT WORKING. #3. IN 2013 THE ALARM ON THE CAR STARTED GOING OFF BY ITS SELF.THAT DAY IT WENT ON AND OFF 5 OR 6 TIMES TILL I REALIZED IT MIGHT BE MY CAR. THE NEIGHBOR SAID THERE WAS NO ONE AROUND IT AT THE TIME. I DON'T TURN ON THE ALARM. I ENDED UP DISCONNECTING THE BATTERY. I TOOK IT TO THE SHOP (SEE #2) BUT SINCE IT WAS NOT DOING IT THEN THEY COULD NOT FIND THE PROBLEM. #4 I HAVE NEVER BEEN NOTIFIED BY GM THAT OTHERS WERE HAVING THESE PROBLEMS. *TR
NHTSA ODI #10566213
53,000 miles · Feb 26, 2014
Electrical System
THE CAR WOULD NOT START ON SEVERAL OCCASIONS. WOULD HAVE A HARD TIME TURNING THE KEY IN THE IGNITION AND IT WILL START AFTER 15-20 MINUTES. THIS WOULD HAPPEN ANYWHERE, ANYTIME. SO, WE TOOK IT TO THE DEALER BIDDULPH MAZDA, WHICH IS WHERE WE PURCHASED IT. THEY SERVICED THE CAR. THEY TESTED THE STARTER, THERE WAS NOTHING WRONG WITH…
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THE CAR WOULD NOT START ON SEVERAL OCCASIONS. WOULD HAVE A HARD TIME TURNING THE KEY IN THE IGNITION AND IT WILL START AFTER 15-20 MINUTES. THIS WOULD HAPPEN ANYWHERE, ANYTIME. SO, WE TOOK IT TO THE DEALER BIDDULPH MAZDA, WHICH IS WHERE WE PURCHASED IT. THEY SERVICED THE CAR. THEY TESTED THE STARTER, THERE WAS NOTHING WRONG WITH THE STARTER. THEY COULD NOT PIN POINT THE PROBLEM, SO THEY TOLD US TO HAVE A NEW KEY MADE. GOT A NEW KEY MADE, BUT THE PROBLEM CONTINUED. TO THIS DAY, IT STILL HAPPENS OCCASIONALLY. *TR
NHTSA ODI #10565950
160,000 miles · Feb 26, 2014
Fuel System, Gasoline
THE SAME PARTS LISTED IN THE BELOW RECALL ALL AFFECT THE 2006 SATURN ION 2 IN ILLINIOS. REPORT RECEIPT DATE: OCT 29, 2009 NHTSA CAMPAIGN NUMBER: 09V419000 COMPONENT(S): FUEL SYSTEM, GASOLINE ALL PRODUCTS ASSOCIATED WITH THIS RECALL EXPAND DETAILS CLOSE 15 ASSOCIATED DOCUMENTS EXPAND MANUFACTURER: GENERAL MOTORS CORP.…
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THE SAME PARTS LISTED IN THE BELOW RECALL ALL AFFECT THE 2006 SATURN ION 2 IN ILLINIOS. REPORT RECEIPT DATE: OCT 29, 2009 NHTSA CAMPAIGN NUMBER: 09V419000 COMPONENT(S): FUEL SYSTEM, GASOLINE ALL PRODUCTS ASSOCIATED WITH THIS RECALL EXPAND DETAILS CLOSE 15 ASSOCIATED DOCUMENTS EXPAND MANUFACTURER: GENERAL MOTORS CORP. SUMMARY: GENERAL MOTORS IS RECALLING CERTAIN MODEL YEAR 2006 CHEVROLET COBALT AND SATURN ION VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF ARIZONA AND NEVADA; AND MODEL YEAR 2007 CHEVROLET COBALT, PONTIAC G5 AND SATURN ION VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF ARIZONA, CALIFORNIA, FLORIDA, NEVADA AND TEXAS. THE PLASTIC SUPPLY OR RETURN PORT ON THE MODULAR RESERVOIR ASSEMBLY MAY CRACK. IF EITHER OF THESE PORTS DEVELOPS A CRACK, FUEL WILL LEAK FROM THE AREA. IF THE CRACK BECOMES LARGE ENOUGH, FUEL MAY BE OBSERVED DRIPPING ONTO THE GROUND AND VEHICLE PERFORMANCE MAY BE AFFECTED. CONSEQUENCE: FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE. REMEDY: DEALERS WILL REPLACE THE FUEL PUMP MODULE FREE OF CHARGE. A SPECIAL COVERAGE WILL BE IMPLEMENTED IN THE SAME TIME FRAME FOR MODEL YEAR 2006 VEHICLES REGISTERED IN ALABAMA, ARKANSAS, CALIFORNIA, FLORIDA, GEORGIA, HAWAII, LOUISIANA, MISSISSIPPI, NORTH CAROLINA, NEW MEXICO, OKLAHOMA, SOUTH CAROLINA, TENNESSEE AND TEXAS AND MODEL YEAR 2007 VEHICLES REGISTERED IN: ALABAMA, ARKANSAS, GEORGIA, HAWAII, LOUISIANA, MISSISSIPPI, NORTH CAROLINA, NEW MEXICO, OKLAHOMA, SOUTH CAROLINA AND TENNESSEE. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR BEFORE FEBRUARY 4, 2010. NOTES: GM RECALL NO. 090226. OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV . *TR
NHTSA ODI #10565945
58,000 miles · Feb 25, 2014
Electrical System
TL* THE CONTACT OWNS A 2006 SATURN ION. THE CONTACT STATED THAT SHE WAS UNABLE TO REMOVE THE KEY FROM THE IGNITION SWITCH. THE CONTACT INDICATED THAT THE BATTERY HAD TO BE DISCONNECTED IN ORDER TO TURN OFF THE POWER TO THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE …
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TL* THE CONTACT OWNS A 2006 SATURN ION. THE CONTACT STATED THAT SHE WAS UNABLE TO REMOVE THE KEY FROM THE IGNITION SWITCH. THE CONTACT INDICATED THAT THE BATTERY HAD TO BE DISCONNECTED IN ORDER TO TURN OFF THE POWER TO THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 58,000.
NHTSA ODI #10565870
192,000 miles · Feb 17, 2014
EngineFire
WHILE TRAVELING BETWEEN 70-75MPH ON I-35 SOUTHBOUND BETWEEN 2ND ST. MERGE AND 15TH STREET EXIT IN EDMOND OK, WE WENT TO CHANGE LANES (MIDDLE LANE TO RIGHT LANE) AND THERE WAS A SUDDEN BOOM, THE CAR LOST CONTROL, BEGAN TO SPIN OUT OF CONTROL (NUMEROUS SLIDES AND 2-360 DEG TURNS AND BEING FLUNG IN A BACKWARDS MOTION). AS WE AT…
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WHILE TRAVELING BETWEEN 70-75MPH ON I-35 SOUTHBOUND BETWEEN 2ND ST. MERGE AND 15TH STREET EXIT IN EDMOND OK, WE WENT TO CHANGE LANES (MIDDLE LANE TO RIGHT LANE) AND THERE WAS A SUDDEN BOOM, THE CAR LOST CONTROL, BEGAN TO SPIN OUT OF CONTROL (NUMEROUS SLIDES AND 2-360 DEG TURNS AND BEING FLUNG IN A BACKWARDS MOTION). AS WE ATTEMPTED TO GET TO THE SIDE OF THE ROAD, OUR CAR BEGAN TO SPIN OUT OF CONTROL - WE SPUN INTO A 360 DEGREE TURN, CAR CAUGHT FIRE AS THE OIL WAS DUMPED FROM MY CAR AND SPRAYED ALL ALONG THE UNDERNEATH OF MY CAR AND TIRES, WE SLID SIDEWAYS TOWARDS CONCRETE BARRIER SEPARATING N-S BOUND TRAFFIC, WENT INTO A SECOND 360 DEGREE TURN, SLID SIDEWAYS - AS WE STARTED HEADING ONCE AGAIN FORWARD TOWARDS ONCOMING TRAFFIC THE VEHICLE SUDDENLY STARTED GOING BACKWARDS (EVEN THOUGH CAR WAS IN DRIVE)... WE FINALLY STOPPED FACING ONCOMING TRAFFIC IN SIDEWAYS MOTION. TOW/MECHANIC INSPECTED THE CAR AND FOUND 3-4INCH HOLE IN THE ENGINE BLOCK - DIAGNOSIS - THAT PUSH PIN BROKE WITHOUT WARNING AND BLEW THE HOLE. NO WARNING WAS GIVEN OF ANY KIND OF ENGINE MALFUNCTION ISSUE - NO WARNING LIGHTS, NOTHING. WE COULD OF / SHOULD OF BEEN KILLED (PER THE EYE WITNESSES WHO STOPPED TO HELP US), OUR ONLY SAVING GRACE WAS THE OIL WHICH SPRAYED THE ROAD AND OUR TIRES KEEPING US UPRIGHT AND NOT ROLLING. THIS NEEDS TO BE INVESTIGATED, RECALLED AND FIXED BEFORE SOMEONE IS NOT AS LUCKY AS US. *TR
NHTSA ODI #10564714
106,000 miles · Feb 14, 2014
Engine And Engine CoolingPower Train
ON FRIDAY WE GOT OUR 2006 SATURN ION OUT OF THE GM SERVICE DEPARTMENT AFTER HAVING A FROZEN AIR COMPRESSOR AND RIPPED SERPENTINE BELT REPLACED ($1400), ALONG WITH A TRANSMISSION LINE. AFTER DRIVING AND STOPPING THROUGHOUT THE DAY ON THE FOLLOWING MONDAY, I WAS UNABLE TO TURN THE VEHICLE ENGINE OFF AFTER I PUT THE CAR IN PARK IN…
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ON FRIDAY WE GOT OUR 2006 SATURN ION OUT OF THE GM SERVICE DEPARTMENT AFTER HAVING A FROZEN AIR COMPRESSOR AND RIPPED SERPENTINE BELT REPLACED ($1400), ALONG WITH A TRANSMISSION LINE. AFTER DRIVING AND STOPPING THROUGHOUT THE DAY ON THE FOLLOWING MONDAY, I WAS UNABLE TO TURN THE VEHICLE ENGINE OFF AFTER I PUT THE CAR IN PARK IN THE DRIVEWAY OF MY HOME. I TRIED SEVERAL TIMES TO TURN THE KEY TO THE OFF POSITION, BUT IT WAS LOCKED. I PUT THE CAR IN REVERSE AND IT MOVED FINE, BUT WHEN I DROVE BACK INTO PLACE AND TRIED TO SHUT IT OFF AGAIN, THE KEY WOULDN'T BUDGE SO THE ENGINE CONTINUED TO RUN. WE DROVE IT BACK TO THE DEALER WHO WANTED TO CHARGE US AGAIN TO HAVE THE VEHICLE SERVICED. WE ALSO NOTICED THE COOLANT LIGHT CAME ON, EVEN THOUGH WE HAD ALL THE FLUIDS CHECKED TWO WEEKS PRIOR WHEN GETTING AN OIL CHANGE. THE DEALER SAID TO DISCONNECT THE BATTERY TO SHUT THE ENGINE OFF. THIS DIDN'T WORK. ANOTHER RELIABLE SOURCE INSTRUCTED US TO DISCONNECT THE DISTRIBUTOR CAP TO AVOID THE ENGINE RUNNING ON THE ALTERNATOR. AFTER SEVERAL ATTEMPTS TO FIND A DISTRIBUTOR CAP, WE REALIZED THERE WAS NONE. A NEIGHBOR CAME AND DISCONNECTED A FUSE. THE KEY IS STILL LODGED IN THE IGNITION. WE HAVE HAD MULTIPLE PROBLEMS WITH THIS VEHICLE, BEYOND WHAT WOULD BE CONSIDERED NORMAL WEAR AND TEAR MAINTENANCE: POWER STEERING REPLACED AND THE GAS TANK REPLACED BECAUSE OF A CRACK IN THE NIPPLE. I AM PETITIONING THAT THIS VEHICLE BE RECALLED AS IT WAS IN CERTAIN "HOT" STATES. THE EXTREME TEMPERATURES EXPERIENCED IN MID-EAST STATES, COUPLED BY INADEQUATE SERVICE AND MATERIALS HAVE CREATED CIRCUMSTANCES WHICH ARE NO LESS THAN THOSE EXPERIENCED IN THE INITIAL STATES WHERE RECALLS HAPPENED. WHAT ALSO SHOULD BE NOTED IS THAT CONSUMER REPORT DOCUMENT 491 COMPLAINTS REGARDING THESE ISSUES. *TR
NHTSA ODI #10564404
115,000 miles · Feb 13, 2014
Engine
TL* THE CONTACT OWNS A 2006 SATURN ION. THE CONTACT WAS DRIVING 65 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT MERGED OFF ROAD AND RESTARTED THE VEHICLE. THE VEHICLE WAS NOT TAKEN FOR INSPECTION OR REPAIRS. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE APPROXIMATE FAILURE MILEAGE WAS 115,000. *TR
NHTSA ODI #10564163
137,647 miles · Jan 30, 2014
Steering
TL* THE CONTACT OWNS A 2006 SATURN ION. THE CONTACT STATED THAT WHILE DRIVING 50 MPH, THE POWER STEERING WARNING LIGHT ILLUMINATED AS THE STEERING WHEEL TIGHTENED. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSIS. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE AND CUR…
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TL* THE CONTACT OWNS A 2006 SATURN ION. THE CONTACT STATED THAT WHILE DRIVING 50 MPH, THE POWER STEERING WARNING LIGHT ILLUMINATED AS THE STEERING WHEEL TIGHTENED. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSIS. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 137,647.
NHTSA ODI #10562208
124,900 miles · Jan 29, 2014
Engine
TL* THE CONTACT SUBMITTED AN EMAIL COMPLAINT AND REQUESTED TO HAVE THE COMPLAINT SUBMITTED VERBATIM TO THE EMAIL SUBMISSION.RE: 2006 SATURN ION GENERAL MOTORS CASE NUMBER: 71-1262884818 DEAR MS. DAVIS: I AM WRITING THIS LETTER TO EXPRESS MY EXTREME DISSATISFACTION WITH A RECENT REPAIR THAT WAS DONE ON MY 2006 SATURN ION. ON SATU…
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TL* THE CONTACT SUBMITTED AN EMAIL COMPLAINT AND REQUESTED TO HAVE THE COMPLAINT SUBMITTED VERBATIM TO THE EMAIL SUBMISSION.RE: 2006 SATURN ION GENERAL MOTORS CASE NUMBER: 71-1262884818 DEAR MS. DAVIS: I AM WRITING THIS LETTER TO EXPRESS MY EXTREME DISSATISFACTION WITH A RECENT REPAIR THAT WAS DONE ON MY 2006 SATURN ION. ON SATURDAY, JANUARY 4, 2014, MY SON ARRIVED HOME WITH MY CAR AND SAID HE COULD NOT TURN THE CAR OFF. FINDING THIS STRANGE, I WENT OUTSIDE TO TRY, AND COULD NOT REMOVE THE KEY FROM THE IGNITION OR TURN OFF THE CAR. I CALLED EMERGENCY ROAD ASSISTANCE TO SEE IF THEY COULD ASSIST ME. UPON THEIR ARRIVAL, THEY COULD NOT GET THE KEY OUT, SO I HAD THE TECHNICIAN TO FOLLOW ME TO THE NEAREST AUTO REPAIR SHOP. ONCE THERE, THE EMERGENCY ROAD TECHNICIAN RECEIVED INSTRUCTIONS OVER THE PHONE ON HOW TO AT LEAST TURN THE CAR OFF BY REMOVING A FUSE. I LOCKED MY CAR, WITH THE KEY STILL IN THE IGNITION. BETWEEN THE TIME I DROPPED MY CAR OFF, UNTIL THE SHOP WAS SCHEDULED TO OPEN ON MONDAY, THE TEMPERATURES PLUMMETED TO A RECORD LOW OF AT LEAST 45 DEGREES BELOW ZERO. I WAS INFORMED THAT MY LOCKS WERE FROZEN AND MY CAR WAS NOT ACCESSIBLE. THE EXTREMELY COLD TEMPERATURES DID NOT ALLOW MERLIN ACCESS TO THE INSIDE OF MY CAR. MERLIN?S WAS ABLE TO DETERMINE WHAT THE PROBLEM WAS, AND THAT THEY HAD ALREADY VERIFIED IT COULD ONLY BE FIXED BY THE MANUFACTURER OF THE CAR. THE VEHICLE WAS TOWED TO A DEALER. THE DEALER TOLD ME THE IGINITION SWITCH NEEDED TO BE REPLACE. NEXT, I CONTACTED THE GENERAL MOTORS CUSTOMER SERVICE CENTER TO REPORT WHAT HAD HAPPENED.GM INFORMED ME THAT THE IGNITION SWITCH HAS BEEN REDESIGNED TO AVOID THE NATURE OF REPAIRS SUCH AS MINE, FROM HAPPENING IN THE FUTURE.THE IGNITION SWITCH SHOULD DEFINITELY BE CLASSIFIED AS A RECALL.
NHTSA ODI #10562126
Mileage unknown · Jan 18, 2014
SteeringCrashInjury
I PURCHASED A 2006 SATURN ION IN MAY OF 2009 FROM ROCKENBACH CHEVROLET IN GRAYSLAKE ILLINOIS. THE VEHICLE WAS INSPECTED THREE TIMES FOR THIS POWER STEERING PROBLEM PRIOR TO THE ACCIDENT BY ROCKENBACK MECHANICS. THE MECHANICS SAID THAT THEY COULD NOT FIND ANYTHING WRONG WITH THE VEHICLE, AND THE SALES MANAGER SAID I WAS NOT TO …
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I PURCHASED A 2006 SATURN ION IN MAY OF 2009 FROM ROCKENBACH CHEVROLET IN GRAYSLAKE ILLINOIS. THE VEHICLE WAS INSPECTED THREE TIMES FOR THIS POWER STEERING PROBLEM PRIOR TO THE ACCIDENT BY ROCKENBACK MECHANICS. THE MECHANICS SAID THAT THEY COULD NOT FIND ANYTHING WRONG WITH THE VEHICLE, AND THE SALES MANAGER SAID I WAS NOT TO BRING THE VEHICLE IN FOR ANY MORE CHECKS BECAUSE I HAD PURCHASED THE VEHICLE WITHOUT A WARRANTY. THE VEHICLE WAS TOTALED AFTER A START UP FROM AN INTERSECTION WHEN THE POWER STEERING CUT OUT ON JULY 14, 2009. SINCE THAT TIME I HAVE SPOKEN WITH THREE SATURN ION OWNERS WHO HAVE EXPERIENCED THE SAME PROBLEM. THIS PROBLEM SHOULD BE CHECKED OUT BEFORE ANYONE ELSE IS HURT. *TR
NHTSA ODI #10560490
Official recalls
4Apr 10, 2014
General Motors LLC (GM) is recalling certain model year 2005-2010 Chevrolet Cobalt, 2006-2011 Chevrolet HHR, 2007-2010 Pontiac G5, 2006-2010 Pontiac Solstice, 2003-2007 Saturn Ion, and 2007-2010 Saturn Sky vehicles. In the affected vehicles, the key can be removed from the ignition when the ignition is not in the "Off" position.
Consequence & remedy
Consequence: If the key can be removed from the ignition when the ignition is not in the "off" position, the vehicle could roll away: (a) for an automatic transmission, if the transmission is not in the "Park" position; or (b) for a manual transmission, if the parking brake is not engaged and the transmission is not in the "Reverse" position. This potential for rollaway increases the risk for a crash and occupant or pedestrian injuries.
Remedy: General Motors will notify owners, and for vehicles that were built with the defective ignition cylinder and have not previously had the ignition cylinder replaced with the redesigned part, dealers will replace the ignition cylinder and cut and, if necessary, re-learn two ignition/door keys for each vehicle. For vehicles that were built with the redesigned ignition cylinder or had the ignition cylinder replaced with the redesigned part, dealers will cut and, if necessary, re-learn two ignition/door keys for each vehicle. The recall began on April 18, 2014. Chevrolet owners may contact General Motors at 1-800-222-1020, Pontiac owners at 1-800-762-2737, and Saturn owners at 1-800-553-6000. General Motors' number for this recall is 14113 for the ignition lock cylinder and key replacement, and 14133 for only key replacements. Note: Until a vehicle has been remedied, owners and operators are advised that when exiting, to be sure that the vehicle is in "Park," or in the case of a manual transmission, that the vehicle is in the "Reverse" position and the parking brake is engaged.
Mar 31, 2014
General Motors LLC (GM) is recalling certain model year 2004-2006 and 2008-2009 Chevrolet Malibu, 2004-2006 Malibu Maxx, 2009-2010 HHR (non-turbo), 2010 Cobalt, 2008-2009 Saturn Aura and 2004-2007 Ion, and 2005-2009 Pontiac G6. In the affected vehicles, there may be a sudden loss of electric power steering (EPS) assist that could occur at any time while driving.
Consequence & remedy
Consequence: If power steering assist is lost, greater driver effort would be required to steer the vehicle at low speeds, increasing the risk of a crash.
Remedy: GM will notify owners, and dealers will perform one of four bulletins. Parts are not currently available. GM expects to send an interim notification around May 28, 2014. When parts are available, owners will be mailed a second letter to come in to have the applicable bulletin applied. Bulletin 14115 covers model year 2004-2007 Saturn Ion, 2009-2010 Chevrolet HHR and 2010 Chevrolet Cobalts. Dealers will replace the EPS motor. Bulletin 14116 covers model year 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from March 1, 2008, through June 27, 2008. Dealers will replace the torque sensor assembly. Bulletin 14117 covers model year 2008 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from February 1, 2008, through February 28, 2008. Dealers will replace the torque sensor assembly and EPS motor controller unit. Bulletin 14118 covers model year 2008 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from October 1, 2007, through January 31, 2008. Dealers will replace the EPS motor controller unit. The recall began on July 17, 2014. Owners may contact Chevrolet at 1-800-630-2438, Saturn at 1-800-553-6000, and Pontiac at 1-800-620-7668. GM's number for this recall is N140115. Note: GM bulletin number 14119 will be implemented for model year 2006-2008 and early production of 2009 Chevrolet HHR (non-turbo) and model year 2003 Saturn ION to provide EPS Motor replacement for the life of the vehicle.
Feb 10, 2014
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
Consequence & remedy
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
Additional source detail variants (2)
Air Bags
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
Electrical System:ignition:switch
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
Oct 29, 2009
GENERAL MOTORS IS RECALLING CERTAIN MODEL YEAR 2006 CHEVROLET COBALT AND SATURN ION VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF ARIZONA AND NEVADA; AND MODEL YEAR 2007 CHEVROLET COBALT, PONTIAC G5 AND SATURN ION VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF ARIZONA, CALIFORNIA, FLORIDA, NEVADA AND TEXAS. THE PLASTIC SUPPLY OR RETURN PORT ON THE MODULAR RESERVOIR ASSEMBLY MAY CRACK. IF EITHER OF THESE PORTS DEVELOPS A CRACK, FUEL WILL LEAK FROM THE AREA. IF THE CRACK BECOMES LARGE ENOUGH, FUEL MAY BE OBSERVED DRIPPING ONTO THE GROUND AND VEHICLE PERFORMANCE MAY BE AFFECTED.
Consequence & remedy
Consequence: FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE FUEL PUMP MODULE FREE OF CHARGE. A SPECIAL COVERAGE WILL BE IMPLEMENTED IN THE SAME TIME FRAME FOR MODEL YEAR 2006 VEHICLES REGISTERED IN ALABAMA, ARKANSAS, CALIFORNIA, FLORIDA, GEORGIA, HAWAII, LOUISIANA, MISSISSIPPI, NORTH CAROLINA, NEW MEXICO, OKLAHOMA, SOUTH CAROLINA, TENNESSEE AND TEXAS AND MODEL YEAR 2007 VEHICLES REGISTERED IN: ALABAMA, ARKANSAS, GEORGIA, HAWAII, LOUISIANA, MISSISSIPPI, NORTH CAROLINA, NEW MEXICO, OKLAHOMA, SOUTH CAROLINA AND TENNESSEE. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR BEFORE FEBRUARY 4, 2010. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, SATURN AT 1-800-972-8876 AND PONTIAC AT 1-800-620-7668 OR AT THE OWNER CENTER AT WWW.GMOWNERCENTER.COM.
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
2EA11014 · 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.
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