2006 Chevrolet Trailblazer EXT 370 problems

On August 15, 2012 General Motors (GM) announced a regional recall action (12V‑406) involving model year (MY) 2006-2007 Chevrolet Trailblazer, GMC Envoy, Buick Rainier, Isuzu Ascender and MY2005-2007 SAAB 9-7x vehicles originally sold or currently registered in the salt belt states of Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and the District of Columbia. The recall remedy requires the inspection and repair or replacement of the master power window switch, which GM refers to as a driver door module (DDM). At the same time, GM implemented a special coverage program to replace failed DDMs for vehicles registered outside of these states. ODI was not satisfied with GM's exclusion of non-salt belt vehicles and continued its investigation. On June 13, 2013, GM submitted a related recall notification (13V‑248) to reclassify the initial special coverage program into a safety recall for vehicles that were not previously repaired under special coverage.The Office of Defects Investigation (ODI) opened Engineering Analysis EA12-004 on June 11, 2012 to further investigate allegations of DDM thermal incidents in model year (MY) 2006-2007 Chevrolet Trailblazer vehicles. Thermal incidents involve cases where fire-related events such as smoke and melt are present. ODI has received 170 reports alleging a thermal event occurred. Complainants stated that the DDM melted and in some cases produced odor and/or smoke. Fourteen of these incidents led to a fire where visible flames were reported or the damage extended significantly beyond the DDM. In addition to the 170 reports listed above, ODI received 63 reports alleging the DDM acted erratically or became inoperative. In response to ODI's Information Request (IR), GM provided 619 unique consumer complaints that related to the alleged problem. Seventy-seven of those reports led to a fire with flame, and 4 reported injuries of smoke inhalation and/or slight burns from contact with hot switches. GM also submitted 20,400 warranty claims for replacement of the DDM, most of which involved inoperative switches. The problem condition is caused by fluids, such as rain water, entering the driver's door module and subsequently causing corrosion that could result in an electrical short in the printed circuit board. A short may cause the power door lock and power window switches to function intermittently or become inoperative. However, the electrical short may also cause overheating that could melt components of the door module, producing odor, smoke or in some cases fire with flame. The circuit board was redesigned and GM implemented the new design into vehicle production on May 14, 2007. All failures cited above occurred in vehicles produced before this build date (i.e., with the original design DDM). GM also reported that all MY 2006-2007 GMT360/370 platform vehicles and MY 2005 SAAB 9-7x vehicles utilized the same DDM and therefore ODI expanded the subject population to include these vehicles.This investigation is closed on the basis of GM's announcement of safety recalls 12V‑406 and 13V‑248. The ODI complaints cited above can be reviewed at: http://www-odi.the federal safety agency.dot.gov/owners/Searchreference, see the attached list for ODI numbers.

EA12004

The Office of Defects Investigation (ODI) opened this investigation on February 9, 2012 in response to complaints alleging driver door module melting and/or burning in MY 2006-2007 Chevrolet Trailblazers. In response to ODI's Information Request letter, General Motors presented 167 reports and 698 warranty claims that related to the alleged problem. ODI has received a total of 83 complaints, 66 alleging the door module had melted or burned, and the remaining 17 stating that the window switches acted erratically or were inoperative. Twenty-eight of the reports received have led to driver door fires, some of which allege the vehicle was keyed off and unattended. Based on the agency's current analysis, ODI has upgraded its investigation to an Engineering Analysis (EA12-004) to determine whether the subject vehicles contain a defect that presents an unreasonable risk to safety.The vehicle models and production dates of affected vehicles will be evaluated, particularly other GMT360 vehicles. The ODI reports cited above can be reviewed online at www-odi.the federal safety agency.dot.gov/owners/Searchreference under the following identification (ODI) numbers: 10247838, 10260600, 10274337, 10275626, 10284010, 10396958, 10406203, 10409023, 10414691, 10417938, 10423865, 10426281, 10434446, 10445657, 10447754, 10447757, 10447770, 10447788, 10447813, 10447831, 10447865, 10447880, 10447892, 10447938, 10447994, 10447996, 10447997, 10448028, 10448086, 10448138, 10448176, 10448201, 10448337, 10448455, 10448464, 10448478, 10448540, 10448900, 10448941, 10449150, 10449166, 10449169, 10449236, 10449722, 10450055, 10450202, 10450284, 10451584, 10451878, 10451918, 10452197, 10452301, 10452586, 10452743, 10452895, 10453161, 10453227, 10453261, 10453578, 10453746, 10453951, 10454196, 10454211, 10454539, 10454673, 10455122, 10455150, 10455279, 10455469, 10456285, 10456529, 10457116, 10457644, 10457811, 10458224, 10458485, 10458599, 10458743, 10458846, 10460062, 10460141, 10460732, 10460843

PE12003

The office of defects investigations (ODI) analyzed complaint data provided by General Motors (GM) as well as complaints submitted to ODI from consumers.In total, there were 5,089 unique reports indicating an inaccurate fuel level reading while driving.General Motors stated that this condition occurs when the contacts of the fuel sensor wear prematurely.Most of the complaints indicated an empty fuel gauge reading after filling the tank.Less than 10 percent of theODI complaints involved an engine stall incident.During this investigation, GM developed a remedy procedure and issued special coverage bulletin instructing dealers to install a new design fuel level sensor.The bulletin was sent to dealers on August 10, 2011 and the owner letter mailing began on August 15, 2011.See the investigative file for copies of GM's bulletin and owner letter.This preliminary evaluation is closed.

PE11014

The Office of Defects Investigation has received 668 complaints alleging inaccurate fuel gauge reading while driving in model year 2005-07 Chevrolet Trailblazer, GMC Envoy, Buick Rainier, and Saab 9-7x vehicles.Of the 668 complaints, 58 incidents were alleged to result in a vehicle stall.Of the 58 stalling incidents, 43 complaints reported stalling because the fuel level reading indicated more fuel availability than what is actually in the fuel tank. One complaint alleged a vehicle crash after the vehicle stalled while exiting the interstate, became disabled, and was struck from behind.Summarily, the complaints show an apparent increasing trend, with most complaints received within the past year.A Preliminary Evaluation has been opened to assess the scope, frequency and potential safety consequences associated with the alleged defect.

DP10001