Cadillac CTS Investigations

3 ODI actions on file.

• OTHEREQ11001CLOSEDOpened 2/7/2011
  IEE Passenger Sensing System Mats
  AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE-INACTIVE

  On December 17, 2010, General Motors (GM) notified the NHTSA that it had decided certain 2005 - 2007 model year Cadillac CTS vehicles contain a safety related defect.GM stated that certain CTS vehicles contain a passenger sensing system mat, manufactured by IEE, in the front passenger seat that may flex causing the mat to kink, bend or fold.If this flexing causes the connections in the mat to break, the passenger airbag could become disabled.Non-deployment of the front passenger air bag in the event of a crash necessitating that air bag's deployment may reduce protection of the passenger and increase the risk or severity of injury to them.This issue was assigned recall number 10V-644.On February 8, 2011, RMD mailed an information request (IR) letter to IEE requesting a list of purchasers for any company that was sold the same or similar defective mats.RMD also requested IEE supply the year, make and models of compatible vehicles for each of the mats it listed in its response.IEE responded on February 15, 2011, reporting that the mats recalled in GM recall 10V-644 were developed specifically for the 2005-2007 Cadillac CTS.IEE noted that, ...the CTS Sensor Mat is not the same or similar to any other sensor mat manufactured by IEE.IEE further explained that the sensor mats were sold to Lear Corp. (Lear), for incorporation into seat assemblies, with the seat assemblies finally being sold to GM.Also, some sensor mats were sold to Integrated Manufacturing and Assembly, LLC (IMA) who would then re-sell the mats to GM to use as service parts.Ultimately, these parts were all sold to GM for use in the 2005-2007 Cadillac CTS vehicles.According to its 10V-644 Defect Report, GM reported that some vehicles outside the recall population have ...significantly lower incident rates and will be provided a special coverage.This special coverage includes a free repair should the same issue occur to non-recalled 2005-2007 Cadillac CTS vehicles up to 10 years or 120,000 miles.On April 7, 2011, RMD mailed an IR letter to GM to gather more information on GM's decision to only recall a portion of the vehicles that contained the subject IEE mats.RMD also requested that GM provide updated to current warranty claims, field reports, and other field information for CTS vehicles both recalled and those under the special coverage.On May 19, 2011, GM responded with a letter and several CD attachments that were submitted to NHTSA's Office of the Chief Counsel along with a request for confidentiality.GM confirmed that the IEE mats recalled in 10V-644 were only used in the 2005-2007 Cadillac CTS.GM also explained its reasoning in only recalling a portion of the CTS vehicles containing IEE mats.Due to various production phases, error detections, and false corrections, certain vehicles were more prone to mat failures than other vehicles.GM identified 4 distinct seat assembly production periods and chose to recall CTS vehicles depending on which seat assembly each vehicle received.Examining the data submitted in regards to warranty claims, field reports, and incidents, the CTS vehicles that were included in the safety recall were responsible for about 80% of the overall claims.CTS vehicles included in the special coverage (essentially an extended warranty), those with seat assemblies from other identified production phases, were responsible for about 20% of the overall claims.As GM has provided clear data to support its recall decision and since no other manufacturer has installed these same or similar passenger sensing system mats / seat assemblies in their vehicles, this Equipment Query is satisfied.This EQ is cl

• EAEA07017CLOSEDOpened 12/7/2007
  REAR DRIVETRAIN COMPONENT FAILURE
  POWER TRAIN:DRIVELINE:DIFFERENTIAL UNIT

  IN JULY OF 2007 THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED PE07-037 TO INVESTIGATE ALLEGATIONS THAT THE REAR DIFFERENTIAL MAY FAIL CAUSING A LOSS OF MOTIVE POWER, AND IN SOME INSTANCES A LOSS OF CONTROL, IN MODEL YEAR (MY) 2004 THROUGH 2006 CADILLAC CTS, CTS-V, AND STS VEHICLES.AS A RESULT OF THAT INVESTIGATION GM ISSUED RECALL 07V-589 TO CORRECT A LEAKING PINION SEAL PROBLEM.EA07-017 WAS OPENED TO INVESTIGATE COMPLAINTS OF FRACTURED REAR DIFFERENTIAL HOUSINGS OR REAR HALF SHAFTS IN HIGH PERFORMANCE CADILLAC CTS-V VEHICLES.ACCORDING TO GM, THESE FAILURES RESULTED FROM THE CUMULATIVE DAMAGE FROM MULTIPLE POWER HOP EVENTS THAT CAN OCCUR DURING VERY AGGRESSIVE DRIVING. IN FEBRUARY 2008 INVESTIGATORS FROM ODI MET WITH GM REPRESENTATIVES TO CONDUCT TESTING OF THE SUBJECT CTS-V VEHICLES.DURING THE TESTING THE SUBJECT VEHICLES WERE SUBJECTED TO CONSIDERABLE TORSIONAL FORCES FROM STANDING STARTS AND WHILE DRIVING.POWER HOP OCCURRED DURING SOME OF THE MOST AGGRESSIVE DRIVING MANEUVERS.THE TESTING DID NOT RESULT IN FAILURE OF ANY REAR DRIVETRAIN COMPONENTS.THE ENGINEERING DESIGN AND TESTING DATA SUPPLIED TO ODI BY GM AND THE RESULTS OF THE TESTING CONDUCTED BY ODI TEND TO SUPPORT GM'S POSITION THAT THE DIFFERENTIAL DESIGN IS NOT DEFECTIVE. COMPLAINTS LISTED IN THE FAILURE REPORT DO NOT INCLUDE THOSE INDICATIVE OF FAILURE OF THE REAR PINION SEAL IN CTS-V VEHICLES COVERED BY RECALL 07V-589. FURTHER INVESTIGATION IN THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.SEE ATTACHED CLOSING REPORT FOR FURTHER DETAILS.

• PEPE07037RECALLOpened 7/17/2007
  FAILURE OF THE REAR DIFFERENTIAL
  POWER TRAIN:DRIVELINE:DIFFERENTIAL UNIT

  ODI EVALUATED TWO DIFFERENT ALLEGED DEFECTS INVOLVING REAR DRIVETRAIN COMPONENTS DURING THIS PRELIMINARY EVALUATION.GM IS CONDUCTING A RECALL TO ADDRESS ONE OF THE DEFECT CONDITIONS AND ODI HAS OPENED AN ENGINEERING ANALYSIS TO CONTINUE ITS INVESTIGATION OF THE OTHER ALLEGED DEFECT. ON DECEMBER 19, 2007, GM SUBMITTED A DEFECT INFORMATION REPORT TO NHTSA CONCERNING DEFECTIVE REAR AXLE PINION SEALS IN APPROXIMATELY 275,936 MODEL YEAR (MY) 2005-07 CADILLAC CTS, STS AND SRX VEHICLES AS WELL AS MY 2006-07 PONTIAC SOLSTICE AND MY 2007 SATURN SKY VEHICLES (RECALL 07V-589).ON STS AND SRX VEHICLES WITH ALL WHEEL DRIVE, THE FRONT AXLE PINION SEAL ALSO DOES NOT MEET ALL OF GM'S SPECIFICATIONS AND MAY EXPERIENCE A FLUID LEAK.GM INDICATED THAT THE SEAL SUPPLIER MADE AN UNAUTHORIZED CHANGE TO THE PINION SEAL MATERIAL.LEAKING PINION SEALS COULD RESULT IN LOSS OF REAR DIFFERENTIAL LUBRICATION WHICH COULD RESULT IN REAR WHEEL LOCK-UP AND LOSS OF VEHICLE CONTROL. ON DECEMBER 7, 2007, ODI OPENED AN ENGINEERING ANALYSIS (EA07-017) TO INVESTIGATE COMPLAINTS OF REAR DRIVETRAIN COMPONENT FAILURE (E.G., FRACTURED REAR DIFFERENTIAL CARRIER HOUSING OR REAR AXLE HALF SHAFTS) WHILE DRIVING IN APPROXIMATELY 7,600 MY 2004 THROUGH 2006 CADILLAC CTS-V VEHICLES.THIS CONDITION MAY RESULT IN A LOSS OF MOTIVE POWER AND VEHICLE DISABLEMENT AND IS NOT ADDRESSED BY RECALL 07V-589.ODI IDENTIFIED 35 COMPLAINTS (16 TO ODI AND 19 TO GM) AND 128 WARRANTY CLAIMS POTENTIALLY RELATED TO THIS CONDITION (SEE EA07-017 OPENING RESUME).THESE COMPLAINTS ARE NOT INCLUDED IN THE FAILURE REPORT SUMMARY OF THIS CLOSING RESUME. THE COMPLAINTS AND WARRANTY FIGURES GIVEN IN THIS RESUME ARE LIMITED TO THOSE THAT (A) ARE MOST LIKELY CAUSED BY A LEAKING REAR PINION SEAL; AND (B) RESULTED IN AN ALLEGATION OF A REAR DIFFERENTIAL FAILURE WHILE DRIVING.THE DATA DO NOT INCLUDE ALL REPORTS OF SEAL LEAKAGE.