2004 Chevrolet Malibu steering problems

What is wrong

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.

Risk

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.

Recall number 14V153000 · Recall details

In performing this engineering analysis, odi determined that the electric power steering system in the subject vehicles can malfunction or fail, causing the driver to lose power steering assistance; however, due to the following reasons, odi has decided that further expenditure of agency resources on this investigation is not warranted at this time: - gm issued customer satisfaction campaign (csc) 04050a indecember 2004 to address the alleged defect in approximately58,700 subject vehicles, encompassing at least 97 percent of thecomplaint and warranty claims population.vehicles outside thecsc 04050a population contain a newly designed torque andposition sensor and have experienced a relatively low complaintrate.this customer satisfaction campaign presently has acompletion rate of 52%. - the impact on the driver?s ability to control these relativelysmall and light vehicles was limited.vrtc test engineers wereunable to induce a failure mode that would cause the eps tosubstantially limit the driver?s ability to turn the vehicle in aparticular direction or to provide the driver with unintendedpower assistance.- there is no risk of fire.accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by the federal safety agency that a safety-related defect does not exist.the agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted by the circumstances.(for further details see attached engineering analysis (ea04-018)closing report.)

EA04018

Odi opened pe04-031 based on eight reports of alleged power steering failure in the subject vehicles.the complaints allege that the driver suddenly lost all electric power steering assistance without warning making the vehicle difficult to steer. The subject vehicle utilizes an electric power steering assist system (eps) that provides variable steering assistance based on steering wheel torque, steering wheel postion, and vehicle speed.general motors documents identified the following two factors that contributed to the alleged defect in the subject vehicles: a.contamination of the torque and position sensor from theseparation of grease applied to the steering column assembly. B.electrical noise generated on the power and ground slip ring surfaces of the torque and position sensor.the noise is generated as the sensor contact brushes move along the slip ring surfaces when the steering wheel is rotated.odi's analysis showed failurerates that are of concern to odi and indicated that the alleged defect is continuing to occur in the subject vehicles. This preliminary evaluation has been upgraded to an engineering analysis to further investigate this concern, to assess the potential safety-related consequences, and to determine the scope of the affected population.

PE04031