Tag Archives: manufacturing error

GM Repurchases Certain 2022-2023 Chevrolet Malibu For Structural Problems

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General Motors (GM) will be contacting the owners of certain 2022-2023 Chevrolet Malibu’s because of a problem affecting a structural portion of the vehicle frame.

GM first became aware of the problem in August 2022 when a production operator installing parts on a vehicle discovered a section of the motor rail was missing. Further investigation found that the front rail outer panel was cut too short and, as a result, was not completely welded to the front right-hand side of the front impact bar.

The problem was reported to GM’s Speak Up For Safety (SUFS) program which worked with the plant and supplier to identify and contain affected vehicles. Of the 1,875 vehicles that GM contained and inspected, they found none that had an incomplete weld. GM opened an investigation into the subject condition to analyze the potential effects of this condition during a crash. There are no known field incidents related to this condition., but GM has decided to conduct a safety recall.

According to the defect report, the sheet metal blank for the front frame rail outer panel for the 2022-2023 Chevy Malibu was improperly loaded into the die. As a result, the front frame rail was cut 10 millimeters short of its intended design. The shortened frame rail prevented proper welding of the front impact bar to the front frame rail. This defect may be present on the right hand and/or left-hand side of the vehicle.

Owners will be asked to return to their GM dealer to have the right-hand and left-hand sides of the vehicle’s motor rail inspected for incomplete welds. If the condition is found, the vehicle will be repurchased by GM. The NHTSA campaign number for this recall is 22V-923.

Is GM Repurchasing Your Lemon Vehicle?

Under the Lemon Law, if you qualify, you should be able to recover your down payment, (including registration fees, licensing fees, taxes, transportation costs, etc.), plus your total monthly lease or loan payments. The manufacturer will also pay off the balance of your loan or lease. The manufacturer will also pay all or most of your attorney’s fees.

If you have any questions about your rights and the California Lemon Law, please call our office at 1-888-395-3666 and get some great Lemon Law advice!

Chevy Heavy Duty Trucks Steering Instability

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General Motors (GM) will be contacting the owners of certain HD and XD trucks because of a problem affecting the suspension in their vehicles. If the problem is not fixed, it could lead to difficult steering and an increased risk of an accident.

In November 2022, GM received information from one of their suppliers that there was an investigation into a manufacturing quality problem in certain flange lock nuts used in 2021-2022 model year Chevrolet Silverado medium-duty vehicles. After consulting with their supplier, GM’s Safety Field Action Decision Authority (SFADA) decided to conduct a recall.

The vehicles affected include:

2021-2022 Chevrolet 4500HD
2021-2022 Chevrolet 4500XD
2021-2022 Chevrolet 5500HD
2021-2022 Chevrolet 5500XD
2022 Chevrolet 6500HD

According to the defect report, certain hex flange lock nuts used in several locations on the suspension in some HD and XD trucks were not properly formed and heat treated by the supplier. Over time, the nuts could loosen and cause a loss of tension in the suspension joints. Over time, drivers will notice a degradation in vehicle handling.

Parts are not currently available, but when parts are available owners will be asked to return to their dealerships to have the hex flange lock nuts replaced. GM’s number for this recall is N222391080 and the NHTSA campaign number is 22V-874.

Hyundai Issues Seventh Seat Belt Pretensioner Recall

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Hyundai Motor America (Hyundai) has issued a recall (22V-816) affecting certain 2023 Genesis G80 Electric, 2021-2022 Santa Fe Hybrid, and 2022-2023 Santa Fe Plug-In Hybrid vehicles. These vehicles have front driver-side and/or passenger-side seat belt pretensioners that could explode under certain deployment conditions.

This is the seventh recall issued by Hyundai for seat belt pretensioner problems. Hyundai has determined that the subject vehicles were manufactured with driver/passenger pyrotechnic-type seat belt pretensioners that may deploy abnormally in certain crashes due to over pressurization of the pretensioner pipe. The potential of a pretensioner exploding is dependent on vehicle characteristics, pretensioner load limiter specifications, airbag control unit logic, crash duration and severity.

Hyundai first became aware of the problem in September 2021, when they were contacted by the NHTSA’s ODI about an incident involving a 2021 model year Hyundai Elantra. The driver-side seat belt pretensioner allegedly deployed abnormally, causing metal fragments to enter the rear cabin and injuring an occupant’s leg. The NHTSA was notified of the incident by a law firm representing the operator of the incident vehicle.

According to the defect report, the front driver-side and/or passenger-side seat belt pretensioners in the subject vehicles were installed from a suspect production lot containing pyrotechnic-type pretensioners that may deploy abnormally during a crash. At the time, the cause of the abnormal deployment was unknown. Hyundai decided to recall vehicles equipped with pretensioners produced within the same production lot.

Recall 21V-796 vehicles affected include:

2021 Hyundai Elantra
2021 Hyundai Elantra HEV
2021 Hyundai Venue
2022 Genesis GV70
2021 Genesis GV80

Recall 22V-069 vehicles affected include:

2020-2021 Hyundai Accent

Recall 22V-123 vehicles affected include:

2022 Hyundai Elantra
2022 Hyundai Elantra HEV

Recall 22V-218 vehicles affected include:

2020 Hyundai Accent
2021-2022 Hyundai Elantra

Recall 22V-354 vehicles affected include:

2020-2022 Hyundai Accent
2021-2022 Hyundai Elantra
2021-2022 Hyundai Elantra HEV

Recall 22V-458 vehicles affected include:

2020-2022 Hyundai Venue

Owners receiving notices will be asked to return to their Hyundai dealer to have the seat belt pretensioners secured with a cap. Hyundai’s number for this recall is 238/011G.

GMC Hummer EV High Voltage Battery Leak

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General Motors (GM) has decided that a battery defect exists in certain 2022-2023 GMC Hummer EVs and 2022 BrightDrop EV600s. While GM works to develop a fix for this condition, owners will receive interim notifications alerting them of the problem. Once a remedy becomes available, GM will send a second notification with a time frame for repairs.

GM first became aware of the problem in July 2022 after receiving Speak Up For Safety (SUFS) submissions relating to potential electrocoating and urethane sealing issues in certain Hummer EV battery packs. After further investigation, two manufacturing errors were identified.

  1. Under cured electrocoating along certain portions of the battery tray.
  2. Improper urethane seal repair could result in poor urethane seal adhesion in battery packs built during specific build windows.

According to the defect report, flanges on the battery pack enclosure may have been improperly primed or electrocoated, inhibiting proper adhesion of the urethane sealant. If water enters the battery pack enclosure and causes a battery pack malfunction, one or more malfunction indicator lamps may illuminate and the driver information center will display a warning message.

GM is aware of two field reports and a relevant report involving a GM test vehicle. All three vehicles had water leaks at urethane seals that had been repaired by the battery pack supplier during pack assembly. Water inside the battery packs triggered the vehicles’ onboard diagnostics, and the drivers received notification of a battery-pack malfunction.

GM is not aware of any accidents, injuries, or fires related to this condition. GM’s Safety Field Action Decision Authority (SFADA) decided to conduct a safety recall on vehicles containing packs with potentially improperly repaired urethane seals.

The remedy is currently under development. Interim letters notifying owners of the safety risk are expected to be mailed on November 28, 2022. Second letters will be sent once the remedy is available. GM’s number for this recall is N222380031 and the NHTSA campaign number is 22V-771.

Hyundai And Kia Loss Of Drive Power – Transmission Oil Pump Malfunction

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Hyundai and Kia will be contacting the owners of certain 2021-2023 vehicles because of an internal fault affecting the electric oil pump in their transmissions. These automobiles are equipped with 2.5L turbocharged gasoline direct injection (T-GDI) engines and 8-speed dual-clutch transmissions (DCT)

Hyundai first became aware of the problem in September 2022 when the NHTSA’s ODI contacted them about a 2022 Hyundai Santa Cruz allegedly experiencing a loss of motive power while driving at various speeds. An investigation into the problem identified an internal fault with the DCT’s high-pressure electric oil pump as the likely cause of the vehicle entering “fail-safe” driving. Based on the information received, Hyundai decided to conduct a recall for affected vehicles. Because the same components are used on certain Kia vehicles, Kia also decided to conduct a recall.

The vehicles affected include:

2022 Hyundai Elantra N
2022 Hyundai Kona N
2022 Hyundai Santa Cruz
2021-2022 Hyundai Santa Fe
2021-2022 Hyundai Sonata
2021-2022 Hyundai Veloster N
2021-2023 Kia K5
2021-2022 Kia Sorento

According to the defect report, “The electric oil pump within the 8-speed dual-clutch transmission (DCT) may experience an internal fault due to insufficient soldering of a component of the electric oil pump circuit board. As a result, the subject vehicles may set a diagnostic trouble code with warnings and allow the vehicle to be driven normally for 20-30 seconds, followed by complete loss of motive power due to disengagement of the transmission drive gears.” If this happens, drivers will hear an audible warning chime, the message “stop safely immediately” on the instrument cluster and an illuminated malfunction indicator light (MIL).

Hyundai has received 229 unique incidents in the US related to this problem. Kia has identified 36 alleged incidents of loss of motive power due to an internal fault with the electric oil pump. Hyundai’s number for this recall is 236 and the NHTSA campaign number is 22V-746. Kia’s number for this recall is SC250 and the NHTSA campaign number is 22V-760.

2023 Kia Sportage Risk Of Electrical Fire

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Certain Kia Sportage SUVs manufactured between January 12, 2022, through August 8, 2022, may experience an electrical surge that could stall the engine and result in a vehicle fire.

Kia became aware of the problem in May 2022 when they received their first customer complaint of a no-start condition in a 2023 Sportage. An inspection of the vehicle found a loose alternator cable with thermal damage to the alternator, the wire harness, and the intake manifold. The affected parts were collected and sent for further inspection. In August, Kia received a second alternator collected from another incident that had localized melting around a broken alternator battery positive (B+) terminal due to electrical arcing. After inspection of the collected parts and a review of vehicle production records, Kia decided to initiate a recall.

According to the defect report, the alternator battery positive (B+) terminal nut may not have been properly torqued by the supplier during assembly. If the terminal nut is not properly torqued, it can loosen over time and may result in an engine stall. In the worst case, arching at the positive terminal could result in a vehicle fire. Drivers may be alerted of a problem through an illuminated Charging System Warning Light.

Owners receiving notices will be asked to return to their dealers to have the alternator battery positive terminal nut inspected and tightened as necessary. Kia’s number for this recall is SC248 and the NHTSA campaign number is 22V-651.

Earlier this month Kia issued a recall that included certain Kia Sportage vehicles that could catch fire. In this recall (22V-703) the car tow hitch harness could catch fire even when the car is parked. As part of the vehicle recall owners are asked not to park indoors or near structures.

Are you experiencing problems with your Kia vehicle? It could be a Lemon. Know your Lemon Law Rights. If you have any questions about your rights and the California Lemon Law, please call our office at 1-888-395-3666 and get some great Lemon Law advice!

Chevy Equinox And GMC Terrain Driver Seat Squeaks And Rattles

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General Motors (GM) will be contacting the owners of certain 2022-2023 Chevrolet Equinox and 2022 GMC Terrain SUVs because the driver’s seat in these vehicles may have a defect that could affect the drivers safety. The vehicles involved are equipped with powerd driver seats without the memory function.

GM became aware of the problem in July 2022 during noise testing at their assembly plant, after a driver seat frame height adjust pivot bolt was discovered on the floor of one of the test vehicles. The problem was brought to the attention of GM’s Speak Up For Safety program and inspections of vehicles at GM assembly plants and parts returned to the supplier was initiated. GM identified several stripped or loose pivot bolts in power seat frames produced by the supplier between June 30, 2022 and July 15, 2022, and decided to conduct a safety recall.

According to the defect report, the seat frame supplier assembly process did not detect improperly torqued bolts. As a result, the driver seats in these vehicles may have a stripped or loose bolt at the seat frame height adjust pivot. If the seat frame height adjust pivot bolt comes out of the pivot joint, the seat structure may not properly restrain the occupant during an accident and could increase the risk of injury. Vehicle occupants may hear squeaks or rattles coming from the driver’s seat, and/or the seat may feel loose.

Owners will be asked to return to their dealers to have the driver’s seat inspected and replace the seat cushion frame, if necessary. GMC’s number for this recall is N222377890 and the NHTSA campaign number is 22V-724.

If your vehicle is experiencing repeated problems, it could be a Lemon. Know your Lemon Law Rights. If you have any questions about your rights and the California Lemon Law, please call our office at 1-888-395-3666 and get some great Lemon Law advice!

2022 Ford Mustang Mach-E Half Shaft Replacement

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Ford will be contacting a small number of 2022 Ford Mustang Mach-E owners regarding a defect affecting the half-shaft in their cars. Some Mach-E vehicles may have been manufactured with a right rear half-shaft that could break under load.

Ford’s Critical Concern Review Group became aware that there was a problem in July 2022, when product engineering identified two vehicles with broken rear right half-shafts. One broken half-shaft was found during a squeak and rattle validation, and a second just before it was being loaded for transport.

Further investigation found that improper placement during the green turning in the lathe caused too much material to be removed, exceeding the specified minimum wall thickness of 9.1mm. Supplier records showed that inspection of the bottom wall thickness of the rear right half-shaft outer race had been suspended for a period of time which allowed non-compliant parts to pass inspection and be installed in finished rear right half-shaft assemblies. Ford’s team reviewed supplier maintenance records to determine the population of affected parts to have been produced between 07/18/2022 and 07/29/2022.

A broken half-shaft will result in loss of transmission torque to the rear wheels, necessary for motive power and for the transmission to hold the vehicle in park. If the electronic parking brake (EPB) is not manually applied, the loss of the primary park torque will allow the vehicle to roll with the transmission in park.

Owners receiving notifications will be instructed to take their vehicle to a Ford or Lincoln dealer. Dealers will photograph the label on the right rear half-shaft to confirm the suspect serial number(s). If the serial number matches, the dealer will replace the right rear half-shaft. Customers will be advised to manually apply the parking brake until the inspection and repair is completed. Ford’s number for this recall is 22S55 and the NHTSA campaign number is 22V-646.