Tag Archives: manufacturing defect

2021-2022 Chevrolet Silverado And GMC Sierra – Under Hood Fire

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General Motors has decided that a defect relating to vehicle safety exists in certain 2021-2022 Chevrolet Silverado 2500/3500 and 2021-2022 GMC Sierra 2500/3500 trucks.

GM first became aware of the problem in September 2021 when two 2021 GMC Sierra 2500 vehicles experienced under hood fires at the assembly plant. Both vehicles were parked outside awaiting shipment and had been exposed to heavy rainfall the day before. Using X-ray and CT scans on the vehicles showed a gap between the bolt head and brake pressure modulator valve (BPMV), indicating that the assembly had not been properly sealed to prevent water intrusion. Both vehicles had been subject to temporary production process changes that involved offline replacement of the electronic brake control module (EBCM), which is a sub-assembly of the BPMV. Analysis of the vehicles also found that the fire started in this area.

According to the defect report, bolts attaching the BPMV may have not been properly tightened, failing to create the seal between two sub-assemblies that is intended to prevent water intrusion. If water becomes trapped in the BPMV, it could result in a short circuit, which could lead to an under hood fire.

Owners of these trucks are advised to park outside and away from other structures until the recall repair is completed. Dealers will correct the problem by replacing the BPMV assembly.. GM’s number for this recall is N212349181 and the NHTSA campaign number is 21V-758.

Fuel Pump Failure In 2021 General Motors Full Size SUVs

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In July 2021 General Motors (GM) opened an investigation into fuel pump failures after a review of warranty data from certain 2021 GM full size SUVs. The data showed that there was a higher than expected rate of fuel pump control modules replaced for vehicles built within certain months. As part of the investigation, GM looked at the returned parts replaced in warranty claims and found the condition was caused by a manufacturing issue at the Tier 3 supplier.

According to the defect report, certain 2021 Cadillac, Chevrolet and GMC full size SUVs may have been manufactured with fuel pump power control modules which contain a defect that can cause the fuel pump to fail or operate intermittently. When this happens, fuel flow to the engine will be interrupted and the vehicle could unexpectedly stall.

The Vehicles Affected Include:
2021 Cadillac Escalade
2021 Cadillac Escalade ESV
2021 Chevrolet Suburban
2021 Chevrolet Tahoe
2021 GMC Yukon
2021 GMC Yukon XL

Owners receiving notices will be asked to return to their dealers to have the fuel pump power control module replaced. GM’s number for this recall is N212332040 and the NHTSA campaign number is 21V-739.

Don’t Park Your Chevrolet Bolt In Your Garage Or Near Structures – Fire Warning

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If you are a Chevy Bolt owner living in California and you received a recall notice for battery fires, you may find it difficult to park your vehicle.

General Motor’s recent recall of certain 2017-2019 Chevy Bolt EVs is caused by the presence of two manufacturing defects in the N2.1 battery cell produced at their Korea facility. The problem is aggravated by charging the battery to a full or nearly full state of charge after it has been substantially depleted. The battery could overheat, emit smoke and catch fire, causing damage to vehicle components and structures around it. As a temporary solution, GM have asked owners to reprogram their hybrid propulsion control module to limit a full charge, but some owners say they are experiencing problems.

The safety recall from the NHTSA states the following:

As an interim remedy, dealers will reprogram the hybrid propulsion control module to limit full charge to 90%. Until this interim is completed, customers should enable either “Hilltop Reserve” (for 2017-2018 model year vehicles) or “Target Charge Level” (for 2019 model year vehicles) using their vehicle’s infotainment center. These two features will limit the vehicle’s state of charge to 90% until the HPCM2 software re-calibration is applied. If customers are unable to successfully make these changes, or do not feel comfortable making these changes, they will be advised to not park their car in their garage or carport until after they have visited their dealer.

What options does that leave you? Possibly parking your car on the street or driveway which has problems in itself. Most charging cables are not long enough to reach the street, the cables could be damaged or stolen or someone could trip on them. Also in some cities there are restrictions against parking in the street and driveways.

If you own a Chevy Bolt and are concerned, we will be glad to talk with you. Please contact us today at 888-EX-Lemon (888-395-3666) for a free consultation or complete the short form at the top of this page.

2021 Ford F-150 Reduced Brake Performance

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A small number of 2021 Ford F-150 trucks could experience an electronic brake booster leak. The leak could result in brake fluid entering the electronic control unit (ECU), causing longer break pedal travel, higher pedal effort and reduced braking.

In May 2021, Ford’s Critical Concern Review Group reviewed three F-150 truck warranty claims where brake fluid from the electronic brake booster leaked into the ECU. Ford’s review of supplier records found that the supplier had identified 169 2021 model year F-150 brake booster assemblies in December 2020 because they were potentially assembled with a broken clinching tool, used to secure the pressure sensor to the booster housing. Further review of supplier and Ford records determined that 51 of the 169 quarantined parts were inadvertently shipped to Ford’s Dearborn Truck Plant and assembled into vehicles, all of which were shipped to dealers in the U.S.

Engineering analysis found that a brake booster with an incomplete clinch between the pressure sensor and the brake booster housing can cause brake fluid to leak through the pressure sensor into the ECU. This can reduce braking effectiveness of the brake circuits.

Those receiving notifications will be asked to return to their dealerships to have the ECU replaced. Ford’s number for this recall is 21S33 and the NHTSA campaign number is 21V-533.

Unsecured Side Curtain Air Bags Found In GM Vehicles

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General Motors has decided that a safety defect affecting airbags exists in certain 2010-2015 and 2017 Buick Enclave, 2010-2019 Chevrolet Traverse and 2011-2016 GMC Acadia vehicles.

According to the defect report, in October 2020, a third-party vehicle repair business contacted GM requesting repair assistance on a 2018 Buick Enclave. After removing the headliner to attempt to repair a sunroof water leak, the repair shop identified two fasteners that were not installed and one missing weld nut attaching the roof-rail airbag (RRAB) to the vehicle. Further investigation found that certain stampings associated with the connection of the roof rail airbag to the vehicles had damaged, out of position or missing weld nuts. Although the problem was identified during vehicle assembly, the repairs may have been missed or preformed incorrectly.

GM will notify owners, and dealers will inspect and, if necessary, realign or replace the weld nuts GM’s number for this recall is N202321200 and the NHTSA campaign number is 21V246.

2021 Porsche Cayenne – Rear Axle Lock Nuts Could Break

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Porsche North America, Inc. (Porsche) will be contacting the owners of certain 2021 Cayenne vehicles because of a problem affecting the rear axle suspension. The Porsche models affected include 2021 Cayenne, Cayenne S, Cayenne Turbo, Cayenne GTS, Cayenne Coupe, Cayenne S Coupe, Cayenne Turbo Coupe, and Cayenne GTS Coupe.

According to the defect report, lock nuts on the trailing arm of the rear axle have not been manufactured according to specifications. The problem could cause a loose thread connection that may allow respective suspension components to move beyond the intended position. If the screw connection fails, the driver could experience a sudden loss of driving stability with a significant change to driving behavior and a loss of vehicle control. Drivers may notice noises and vibrations due to the loosening of the connection, but these warning sings are not guaranteed.

Porsche will instruct owners of affected vehicles to return to their dealers to have the lock nuts replaced. The recall is expected to begin June 2021. Porsche’s number for this recall is AMA9 and the NHTSA campaign number is 21V-271.

2020 Nissan Murano Ball Joint Separation

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Nissan will be asking the owners of certain 2020 Nissan Murano SUVs, to return to their dealerships for a problem that could result in loss of vehicle control. Approximately 15,000 vehicles are affected by this recall.

According to the defect report, an equipment failure at the supplier resulted in improperly formed billets in the transverse links. As a result, the right and left transverse links are out of specification and in rare cases could separate from the ball joint. This could result in loss of vehicle control and an increased chance of an accident.

Owners of affected vehicles will be notified to return to their dealer to have the left and right hand transverse links inspected for the affected LOT codes. If the LOT code is identified, the dealer will replace the links and perform an alignment.

Nissan’s number for this recall is PC797 and the NHTSA campaign number is 21V-170.

Tire Recall Affects Buick, Cadillac, Chevrolet And GMC Vehicles

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General Mortors has decided that a defect affecting vehicle safety exists in some tires installed as original equipment on certain 2018-2021 Buick, Cadillac, Chevrolet and GMC trucks and SUVs.

According to the tire manufacturer, Continental Tires the Americas (CTA), the tires may have been over-cured and could experience an unexpected break in the sidewall. This break could lead to sudden loss of pressure or a belt edge separation that could lead to partial or full tread / belt loss. The problem could increase the risk of loss of vehicle control.

Vehicles Affected Include
2020 Buick Enclave
2020 Cadillac Escalade
2020 Cadillac Escalade ESV
2020 Cadillac XT4
2020 Cadillac XT5
2019-2020 Chevrolet Blazer
2018-2021 Chevrolet Express
2019-2020 Chevrolet Silverado 1500
2020 Chevrolet Suburban
2020 Chevrolet Tahoe
2020 Chevrolet Traverse
2019-2020 GMC Acadia
2018-2021 GMC Savana
2019-2020 GMC Sierra 1500
2020 GMC Yukon
2020 GMC Yukon XL

GM will notify owners and dealers will inspect and replace tires as necessary. The recall is expected to begin April 12, 2021. GM’s number for this recall is N212329050 and the NHTSA campaign number is 21V-115. Approximately 34,000 vehicles are affected.