2006 Saturn Ion

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.

ODI has received 846 complaints and GM identified 3,489 reports alleging sudden loss of steering power assist in model year (MY) 2004 through 2007 Saturn Ion vehicles manufactured and sold by General Motors Corporation (GM).Sixteen of these complaints alleged that the EPS warning lamp had illuminated before or during the loss of steering assist and the increased steering effort contributed to a crash. Two of the GM crash claims indicated that the driver was injured in the crash. In a previous Preliminary Evaluation PE10-005, ODI investigated the sudden loss of power steering assist in MY 2005 through 2010 Chevrolet Cobalt vehicles. In May 2011, in response to an ODI information request letter for RQ10-004, GM provided ODI with complaint, warranty and EPS system information related to EPS loss of assist for the Saturn ION and Peer vehicles Pontiac G6 and Chevrolet Malibu. In that response, GM indicated that the EPS system used in the subject vehicles was the same as that used in the MY2005 to 2010 Chevrolet Cobalt and Pontiac G5. In March 2010, GM recalled approximately 1.05 million Chevrolet Cobalt and Pontiac G5 vehicles (NHTSA recall no. 10V-073) to correct a defect with the EPS assist motor. The defect identified was described as a buildup of brush debris mixed with oily material on the EPS electric motor armature which causes the motor to stop functioning; the same problem identified in the current subject vehicles.ODI has duplicated this failure in both a Chevrolet Cobalt and Saturn Ion previously tested at the Vehicle Research and Test Center (VRTC). In the defect notification letter for the previously recalled Cobalt and G5 vehicles, GM stated that the vehicles may experience a sudden loss of assist that could occur at any time while driving and that if power steering was lost the vehicle would revert to manual steering mode and would require increased steering effort from the driver.ODI believes that, depending on driving circumstances this increase in steering effort could result in some loss of control and a crash.This investigation has been upgraded to an engineering analysis (EA11-014) to further assess the frequency, scope and safety consequences of a sudden loss of steering assist in the subject vehicles.

The contact owns a 2006 Saturn Ion. The contact stated that the instrument panel and radio were intermittently inoperable. The contact stated that the ignition switch failed to turn to the OFF position as needed intermittently. Additionally, the contact stated that while driving and turning the steering wheel to the right to make a right turn, the steering was significantly wobbly. The contact related the failure to NHTSA Campaign Numbers: 14V171000 (Electrical System) and 14V153000 (Steering). Additionally, the contact stated that the vehicle was experiencing a fuel leak. The vehicle was taken to the Subaru dealer, where it was purchased. The vehicle was not diagnosed or repaired. An unknown Chevrolet dealer was contacted and confirmed that the VIN was not included in a recall. The manufacturer was notified of the failure and informed the contact that unknown recalls were previously performed on the vehicle. The failure mileage was approximately 85,200.

NHTSA ID

11649410

Incident

Jan 30, 2025

Mileage

85,200 mi

Airbags

NHTSA ID

11570686

Incident

Feb 7, 2024

The contact owns a 2006 Saturn Ion. The contact stated that while driving at an undisclosed speed, the vehicle stalled. Additionally, the key was stuck in the ignition switch. The vehicle was taken to the dealer, who informed the contact that the ignition lock cylinder needed to be replaced. The vehicle was repaired; however, the failure recurred. The vehicle was taken back to the dealer; however, the parts to do the repair were not available. The manufacturer was made aware of the failure. The failure mileage was approximately 100,764.

NHTSA ID

11536214

Incident

Jan 3, 2014

Mileage

100,764 mi

The contact owns a 2006 Saturn Ion. The contact stated while exiting a driveway and making a turn, the steering wheel became difficult to turn. There was no warning light illuminated. The contact checked the power steering fluid reservoir and there was power steering fluid in the reservoir. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was 90,000.

NHTSA ID

11502837

Incident

Dec 20, 2022

Mileage

90,000 mi

The contact's mother owns a 2006 Saturn Ion. The contact stated that after driving the vehicle to his residence and parking the vehicle in the garage, he observed that a puddle of gasoline had accumulated overnight underneath the vehicle from the fuel tank by the driver's side rear wheel. The contact had not taken the vehicle to a local dealer or independent mechanic. The vehicle had not been diagnosed or repaired. The contact stated that the failure might be related to NHTSA Campaign Number: 09V419000 (Fuel System, Gasoline). The manufacturer had been informed of the failure. The failure mileage was approximately 84,000.

NHTSA ID

11460956

Incident

Apr 14, 2022

Mileage

84,000 mi

Fuel and evap line rusted out inside heat wrap for exhaust pipe near rear drivers tire. Pumped out fuel onto street.

NHTSA ID

11442332

Incident

Oct 14, 2020

The contact owns a 2006 Saturn Ion. The contact stated that upon switching gears to reverse, the vehicle made an abnormal grinding sound. The contact stated that she was unable to shift gears and continued to drive the vehicle in third gear. There were no warning lights illuminated. The independent mechanic diagnosed that the clutch was fractured and needed to be replaced. The manufacturer was notified of the failure and referred the contact to the dealer. The dealer was notified of the failure and informed the contact to take the vehicle to their location in two weeks for diagnosis. The vehicle was not diagnosed nor repaired. The approximate failure mileage was 195,000.

NHTSA ID

11439091

Incident

Nov 1, 2021

Mileage

195,000 mi

The year, make, and model of my car has a factory recall for the fuel pump failing. I went to the dealership and they informed me my Vin # wasn't included and their was nothing they could do about it. My vehicle started leaking fuel last week so I dropped the tank and removed the fuel pump. I have done my homework on this including watching several videos on YouTube concerning this issue and I'm 100% positive this fuel pump has failed in the exact location that all the other recalls have and yet my Vin number isn't on the recall according to this GMC service department manager. I am going to have to put a fuel pump in at my expense today because it's my transportation for work but I'm very upset about this situation and GMCs failure to have my vehicle included and having to replace their defected fuel pump. It's very frustrating knowing I'm putting my time and money towards it because I have my hands full trying to replace the house that Hurricane Ida destroyed about a month ago. We need help with this situation because our money is very tight and don't really have it to fix GMCs mistake. I will keep the fuel pump that came out of it along with the receipt for it so anyone can clearly see that I'm not only correct but being shafted on the recall. Thanks have a nice day I'll be eagerly awaiting your response

NHTSA ID

11436989

Incident

Oct 1, 2021

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.

This Preliminary Information communication provides information to the technician about the use of J-35616-64B terminal test probe, replacement terminals, and terminated leads. The J-35616-64B is the latest test probe released for checking tension or probing the .64 series terminals. The test probe terminal has been released in the terminal repair kit (J-38125-620H) located in Lear Tray 7 part number 963716-2. There are 5 terminated leads in a package part number is 13505346, which can be ordered through your normal General Motors Customer Care and Aftersales parts channel.