After a preliminary review of consumer complaints and other information related to alleged defects, NHTSA obtains information from the manufacturer(including data on complaints, crashes, injuries, warranty claims, modifications, and part sales) and determines whether further analysis is warranted. If warranted, the investigator will conduct a more detailed and complete analysis of the character and scope of the alleged defect.
NHTSA Action Number: PE11037
Date Opened: 2011-11-25
Date Closed: 2012-01-20
Manufacturer’s Name: General Motors
, LLC
Component Description: ELECTRICAL SYSTEM:12V/24V/48V BATTERY
Summary Description: Post-Crash EV Fire Hazard
Summary
The subject vehicles, which employ emerging technology, are range-extended electric vehicles that utilize a high voltage (HV) battery to provide energy for propulsion. The HV battery is lithium-ion based technology that has a nominal full charge of 390 VDC, a 16 kWh capacity, and a control system that incorporates liquid (antifreeze) cooling and various electronic devices (control modules, sensors, wiring, etc) to monitor and manage the HV battery. The HV battery, portions of the cooling system, and the control system are contained within a common enclosure.During an NCAP oblique side pole impact test conducted by NHTSA in May 2011, the pole struck and deformed the sill plate under the driver's door at a location where there is a structural member. The lateral member displaced inward, pierced the HV battery enclosure and battery, and caused a battery coolant leak. Thereafter, the Agency conducted a rollover test (the rollover test consists of four 90-degree rotate-and-hold movements about the vehicle's longitudinal axis). In that test, the HV battery and electronics were exposed to coolant that leaked as a result of the crash. The vehicle fire that occurred three weeks later and the additional testing NHTSA conducted are discussed in a report titled 2011 Chevrolet Volt Battery Fire Incident Report a copy of which is available in the public file. The report indicates that intrusion induced coolant leakage, and subsequent rollover that saturates electronic components, were the only test conditions which resulted in a subject vehicle HV battery fire.GM announced its intention to conduct a free-of-charge customer satisfaction campaign (CSP) on the subject vehicles on January 5, 2012. The action affects 14,735 vehicles produced prior to December 21, 2011. The CSP addresses three areas related to the issue under investigation. The first involves a modification/strengthening of the structure of the vehicle in the area where battery intrusion occurred in the May 2011 test. The second involves adding a sensor that detects excessive HV battery coolant loss, and control system software that then alerts the driver and prevents recharging of the HV battery. When the battery cannot be recharged, it will be depleted to a lower energy state as the vehicle continues to operate on the internal combustion engine. Lastly, a tamper-proofing device will be added to the system to prevent consumers from adding coolant. GM discusses these revisions in its response to an Information Request (IR) issued by NHTSA, noting that vehicles produced in calendar year 2012 and later will be manufactured to this condition.In December 2011, and at the same test facility, NHTSA repeated the May 2011 side impact test using a model year 2012 Volt modified to the structural condition described in the CSP. The test did not produce intrusion of the HV battery, a coolant leakage, or a fire (see test 7611, available at www.nhtsa.gov/Research/Databases+and+Software). In its IR response, GM describes four (4) additional side impact tests of modified subject vehicles it recently conducted using various build configurations and impact speeds (including higher speeds). GM reports that none produced HV battery intrusion, coolant leakage, or a fire.As noted in the complaint counts above, ODI has not identified a crash occurring in consumer's use of the vehicle that has resulted in a vehicle fire, or produced coolant leakage. ODI notes that side impact crashes with pole-like structures, such as would strike the sill plate, occur fairly infrequently, and such crashes with rollovers are even less frequent. A defect trend has not been identified at this time, and further investi
NHTSA Action Number: EA11015
Date Opened: 2011-11-10
Date Closed: 2014-06-02
Manufacturer’s Name: General Motors, LLC
Component Description: POWER TRAIN:AUTOMATIC TRANSMISSION:GEAR POSITION INDICATION (PRNDL)
Recall Campaign: 14V224
Summary Description: Transmission Shift Cable Failure
Summary
On April 29, 2014, GM submitted a Part 573 defect information report initiating Safety Recall 14V-224 to remedy the subject vehicles equipped with four speed automatic transmissions manufactured before October 31, 2007.On May 22, 2014 GM expanded 14V-224 to include MY 2004-2008 Chevrolet Malibu/Malibu Maxx and MY 2005 - 2008 Pontiac G6 (total recall population 1,131,113).GM will install a replacement shift cable assembly to remedy the affected vehicles.The subject shift cable's protective outer conduit (jacket) deteriorates with time and use.Jacket deterioration could lead to a tear of the conduit material which allows moisture to reach the lay wires, potentially causing them to corrode and weaken.The lay wires provide support to the inner core wire that performs the shift detent actuation of the transmission.Without sufficient lay wire support, the shifter position inside the vehicle and the actual transmission gear selection may not align.A complete loss of shift function can occur when the core wire fractures and fails fully.The failure data supports that the problem affects subject vehicles equipped with four-speed automatic transmissions. Aura vehicles manufactured with other transmission types use a different shift cable assembly, as do four speed equipped Aura's manufactured after October 31, 2007.Transmission shift cable failure can cause multiple shift function failure modes.One involves an engine no-start condition where the gear shifter is in the park position but the transmission is actually in drive or reverse gear (engine starting is inhibited in this circumstance).A second involves non-powered vehicle movement where the driver turns the engine off and moves the shifter to park but the transmission fails to engage the park gear; the vehicle may roll away if the driver exits without setting the park brake.A third involves powered vehicle movements, where the driver moves the gearshift but the transmission fails to engage the intended gear, and the engine remains running.For instance the driver can shift to park but the transmission may remain in drive or reverse, resulting in vehicle movement when the driver does not expect it.Another failure involves the driver shifting to reverse but the transmission remains in drive, resulting in the vehicle moving in a direction opposite to that the driver intended.Another failure mode results in complete loss of shifting.Both NHTSA and GM have received complaints alleging one or more of these failure scenarios, and in some cases consumers report experiencing multiple problems over the course of several drive cycles.In one incident, the vehicle unexpectedly moved forward after the driver placed the gear selector in park resulting in the vehicle striking a fixed object (porch railing).Among the crashes identified above, nine involved property damage and two involved minor injuries when the vehicles rolled and struck the driver as they exited the vehicle.The recall action initiated by the manufacturer appears to address the safety risks of concern to ODI.Accordingly, the investigation is closed.The VOQs cited above can be viewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10274914, 10404010, 10432953, 10446285, 10458417, 10495979, 10547333, 10354195 , 10404496, 10435560, 10447211, 10461922, 10498567, 10547683, 10374834, 10405577, 10435633, 10447303, 10464207, 10513116, 10553840, 10378975, 10409341, 10435653, 10449759, 10464388, 10513875, 10554335, 10382559, 10411913, 10435677, 10452089, 10467958, 10516001, 10565628, 10383044, 10412157, 10435996, 10452662, 10478887, 10522732, 10566451, 1039013
NHTSA Action Number: PE11036
Date Opened: 2011-10-11
Date Closed: 2012-06-11
Manufacturer’s Name: BMW of North America, LLC
Component Description: ENGINE AND ENGINE COOLING
Recall Campaign: 12V008
Summary Description: Engine compartment fire
Summary
In a January 10, 2012 letter to NHTSA, BMW of North America, LLC. (BMW) submitted a Defect Information Report (DIR) identifying a defect in the electric auxiliary water pump in approximately 88,911 model year (MY) 2007-2011 Mini Cooper vehicles manufactured from November 14, 2006 through January 18, 2011 (Recall 12V-008).According to BMW, the auxiliary water pump on vehicles equipped with 4-cylinder turbocharged engines may overheat.Electro-migration can cause the pump electronic circuit board to overheat resulting in smoldering of the water pump. If smoldering occurs, it may lead to an engine compartment or vehicle fire.The pump supplier, Pierburg Pump Technology GmbH, redesigned the pump to address factors that may contribute to circuit board overheating.The redesigned pumps were completely implemented in production vehicles by January 2011.Recall 12V-008 was the third recall initiated by BMW to address electric auxiliary water pump fires in vehicles equipped with Pierburg pumps.In two October 20, 2011 letters to NHTSA, BMW submitted DIRs for similar auxiliary water pump defect conditions in approximately 32,084 MY 2008-2011 BMW 5-Series, 7-Series, X5 and X6 models equipped with 8- and 12-cylinder engines and manufactured from May 2008 through December 2010 (Recall 11V-521); and for approximately 589 MY 2010 Rolls-Royce Ghost vehicles manufactured from September 2009 through September 2010 (Recall 11V-522).In three separate April 5, 2012 letters to NHTSA, BMW submitted amendments to Recalls 11V-521, 11V-522 and 12V-008.The amendments all described a common defect condition related to a manufacturing process deviation in a certain production range of the redesigned Pierburg water pumps that could result in cracks in the pump housing, which may allow coolant to enter and contact the pump?s circuit board.BMW indicated that further analysis identified a specific machine process error at the sub-supplier that manufactures the water pump housing.Pump housing cracks may cause the circuit board to overheat and lead to smoldering of the water pump.Recall 12V-008 was, thus, amended to include approximately 1,457 MY 2011 Mini Cooper vehicles manufactured from March 31, 2011 through April 22, 2011, when pumps manufactured with the suspect manufacturing process may have been used in vehicle assembly.The amendment to Recall 11V-521 was assigned a new recall number, Recall 12V-161, and covered approximately 2,846 MY 2011-2012 BMW 5-Series, 6-Series, 7-Series, X5, and X6 vehicles manufactured from April 1, 2011 through August 1, 2011.The amendment to Recall 11V-522 was assigned a new recall number, Recall 12V-166, and covered approximately 69 MY 2011 Rolls-Royce Ghost vehicles manufactured from April 7, 2011 through June 2, 2011.The Office of Defects Investigation (ODI) analyzed complaint data provided by BMW as well as complaints submitted to ODI from consumers. In total, there were 30 unique Mini Cooper reports indicating engine fire.In addition, BMW provided warranty data showing 493 claims for replacement of the subject component on Mini Cooper vehicles.Owners of the recalled vehicles are notified to take their vehicle to a BMW dealer, who will replace the auxiliary water pump to prevent any incidents related to this issue.This preliminary evaluation is closed.The ODI reports cited above can be viewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers (ODI Nos.):10286597, 10286663, 10289793, 10310677, 10314796, 10342365, 10394808, 10394192, 10403982, 10418325, 10422646, 10429003.
NHTSA Action Number: EA11014
Date Opened: 2011-09-29
Date Closed: 2014-04-15
Manufacturer’s Name: General Motors, LLC
Component Description: STEERING:ELECTRIC POWER ASSIST SYSTEM
Recall Campaign: 14V153
Summary Description: Electric Power Steering Failure
Summary
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.
NHTSA Action Number: PE11034
Date Opened: 2011-09-23
Date Closed: 2012-02-29
Manufacturer’s Name: Honda (American Honda Motor Co.)
Component Description: LATCHES/LOCKS/LINKAGES:HATCHBACK/LIFTGATE:LOCK
Recall Campaign: 12V062
Summary Description: Unexpected Closing of Power Liftgate
Summary
The investigation found that the liftgate struts were failing prematurely and at an abnormal rate in certain model year (MY) 2008 Honda Odyssey Touring and 2009 Honda Odyssey Touring and EX-L model vehicles equipped with power-operated rear liftgates (note: MY 2008 Odyssey EX-L was not equipped with a power liftgate).Unlike vehicles with non-powered (manual) liftgates, the subject vehicle's liftgate can be opened automatically (via the power liftgate motor) even when the struts are in a degraded condition and can no longer support it in the open position.Consumers standing or accessing the rear cargo area under the liftgate and expecting the liftgate will stay open, can be struck when the liftgate unexpectedly drops, or can be trapped under the liftgate as it power closes, both of which can occur when the system detects and reacts to degraded struts.By contrast, users of a manual liftgate assist in lifting it, and thus notice the lack of support as the struts degrade.Honda is conducting a recall to replace the liftgate struts in approximately 45,747 MY 2008 and early MY 2009 Odyssey vehicles equipped with power liftgates built before a manufacturing change of the liftgate strut assembly that occurred on January 13, 2009 (see NHTSA Safety Recall No. 12V-062 for further details).The vehicles subject to the recall account for 101 complaints, 12 injuries, and 5,630 of the warranty claims shown above (i.e., the MY 2009 and 2010 vehicles built after the manufacturing change experience lower failure rates).In addition, and based on consumer complaints to NHTSA, Odyssey vehicles without power liftgates experience lower complaint and injury rates than the Odyssey vehicles equipped with power liftgates (subject vehicles).The reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10442027, 10441232, 10437461, 10432557, 10430420, 10429962, 10412908, 10401388, 10395475, 10390216, 10343678, 10336744, 10294156
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