NHTSA Investigation PE06021

CROSSMEMBER CORROSION FAILURE

ON SEPTEMBER 15TH, 2006 GENERAL MOTORS (GM) SUBMITTED INFORMATION REGARDING APPROXIMATELY 128,000 MODEL YEAR (MY) 1999 -2001 CHEVROLET TRACKER VEHICLES.ACCORDING TO GM, THESE VEHICLES WERE MANUFACTURED WITH FRONT CROSSMEMBERS DESIGNED AND MADE BY SUZUKI THAT CAN RUST FROM THE INSIDE OUT BECAUSE OF INSUFFICIENT CORROSION PROTECTION.THE DESIGN OF THE CROSSMEMBER LIMITED THE COVERAGE OF PAINT ON THE INTERIOR SURFACES DURING THE PAINTING PROCESS.IN MARCH 2006 SUZUKI MADE DESIGN CHANGES TO THE CROSSMEMBER TO ENHANCE THE COVERAGE OF PAINT TO THE INSIDE OF THE PART. GM INDICATED THAT WHEN OPERATED IN AREAS OF THE COUNTRY THAT USE ROAD SALT FOR DE-ICING, OVER TIME WATER AND SALT/MUD CAN ACCUMULATE INSIDE THE CROSSMEMBER AND CAUSE CREVICE CORROSIONTHAT CAN LEAD TO PERFORATION.THESE PERFORATIONS AT THE FRONT CONTROL ARM BRACKETS CAN CAUSE THE FRONT SUSPENSION TO BECOME PARTIALLY DETACHED FROM THE VEHICLE. GM PROVIDED VEHICLE TEST DATA SHOWING THAT CROSSMEMBERS THAT FAIL IN THIS MANNER DO NOT CAUSE A LOSS OF VEHICLE CONTROL AND, THEREFORE, DO NOT REPRESENT AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA06-018) TO FURTHER ASSESS THE SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT CONDITION.

An investigation is a separate record from a recall and from a manufacturer communication. A manufacturer campaign to repair a safety defect or a failure to meet a federal safety standard.