2007 Saturn Aura problems

What is wrong

General Motors LLC (GM) is recalling certain model year 2004-2012 Chevrolet Malibu vehicles manufactured May 16, 2003, through October 11, 2012, 2004-2007 Malibu Maxx vehicles manufactured June 25, 2003, through April 5, 2007, 2005-2010 Pontiac G6 vehicles manufactured May 26, 2004, through January 4, 2010, and 2007-2010 Saturn Aura vehicles manufactured April 24, 2006, through May 26, 2009. In the affected vehicles, increased resistance in the Body Control Module (BCM) connection may result in voltage fluctuations in the Brake Apply Sensor (BAS) circuit. These fluctuations can cause one or more of these conditions: the brake lights to illuminate without the brake pedal being pushed; the brake lights to not illuminate when the pedal is pushed; difficulty disengaging the cruise control; moving the gear shifter out of the 'PARK' position without pushing the brake; and disablement of crash avoidance features such as traction control, electronic stability control, and panic braking assist features.

Risk

Any of the above failure conditions increases the risk of a crash.

Remedy

GM will notify owners, and dealers will attach the wiring harness to the BCM with a spacer, apply dielectric lubricant to both the BCM and harness connector and the BAS and harness connector, and will relearn the brake pedal home position, free of charge. The manufacturer distributed an Interim letter to customers on July 14, 2014. The recall began on August 18, 2014. Owners may contact General Motors customer service at 1‑800‑222‑1020 (Chevrolet), 1‑800‑762‑2737 (Pontiac), 1‑800‑553‑6000 (Saturn). GM's number for this recall is 13036.

Recall number 14V252000 · Recall details

What is wrong

General Motors LLC (GM) notified the agency on April 29, 2014, that they are recalling 56,214 model year 2007 and 2008 Saturn Aura vehicles. On May 22, 2014, GM increased the recall to include an additional 1,074,899 model year 2004-2008 Chevrolet Malibu vehicles manufactured from May 16, 2003, through October 5, 2007, model year 2004-2007 Malibu Maxx vehicles manufactured from June 25, 2003, through April 5, 2007, and model year 2005-2008 Pontiac G6 vehicles manufactured from May 26, 2004, through September 28, 2007, and equipped with 4-speed transmissions. The total number vehicles being recalled is now 1,131,113.

Risk

If the transmission shift cable fractures while the vehicle is being driven, the transmission gear selection may not match the indicated gear and the vehicle may move in an unintended or unexpected direction, increasing the risk of a crash. Furthermore, when the driver goes to stop and park the vehicle, despite selecting the ‘PARK’ position, the transmission may not be in ‘PARK.’ If the vehicle is not in the "PARK" position there is a risk the vehicle will roll away as the driver and other occupants exit the vehicle or anytime thereafter. A vehicle rollaway increases the risk of injury to exiting occupants and bystanders.

Remedy

GM will notify owners, and GM dealers will replace the shift cable assembly and mounting bracket, free of charge. The manufacturer has not yet provided a notification schedule. Owners may contact General Motors at 1‑800‑553‑6000. GM's number for this recall is 14152.

Recall number 14V224000 · Recall details

What is wrong

General Motors (GM) is recalling certain model year 2007-2010 Saturn Aura and model year 2008-2010 Chevrolet Malibu and Pontiac G6 vehicles, equipped with a 4-speed automatic transmission. On these vehicles, the tabs on the transmission shift cable end may fracture and separate.

Risk

If the tabs were to fracture and separate, the shift lever and the actual position of the transmission gear may not match. The driver would be able to move the shifter to 'PARK' and remove the ignition key, but the transmission gear may not be in 'PARK.' The vehicle may not be able to be restarted and the vehicle could roll away after the driver has exited the vehicle, resulting in a possible crash without prior warning.

Remedy

GM will notify owners, and dealers will install a retainer over the cable end or replace the shift cable as necessary. This service will be performed free of charge. Notification to owners began on on November 9, 2012. Owners were instructed to not bring their vehicles for repair until January 2013. Owners may contact General Motors at 1‑800‑521‑7300.

Recall number 12V460000 · Recall details

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 the federal safety agency 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.the federal safety agency.dot.gov/owners/Searchreference 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

EA11015

GM advised that the shift cable's protective outer conduit (jacket) deteriorates with time and use.Variables that affect jacket life include installation variability (routing, etc), environmental and temperature effects, and material quality.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 match.A complete loss of shift function can occur when the core wire fractures and fails fully.GM asserts that the problem primarily affects the four-speed equipped subject vehicles, but not the six-speed transmissions, and notes that similar cable installations are used in other model and MY GM vehicles (2004-2008 Chevrolet Malibu and 2005-2008 Pontiac G6). In reviewing consumer reports ODI notes multiple failure modes that occur as the cable allegedly fails and shift function is affected.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.Or the driver may shift 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 the federal safety agency 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 the crash incident reported to the federal safety agency (ODI 10383044) the driver reportedly placed the gear shift selector into park but the transmission remained in drive causing the vehicle to unexpectedly move (accelerate) forward and strike a building.In one of the crash incidents reported to GM, the driver placed the shifter in park but the transmission remained in reverse.When the driver exited with the engine running, the vehicle continued (accelerated) in reverse and struck a building.In the injury incident reported to GM, the driver reportedly placed the shifter in park, exited the vehicle, and was struck when the vehicle unexpectedly rolled backwards. ODI is upgrading this investigation to evaluate the frequency of shift cable failure, the consequences, and the scope of vehicles that may be affected, including the models, model years and transmissions types.

PE11021