Investigation PE04061: 2003–2004 Saturn Ion

Status

CLOSED

Opened

Aug 17, 2004

Closed

Dec 22, 2004

Model years

2003–2004

Subject

Front turn signal/drl failure

Component: Exterior lighting › Turn signal

Summary

On november 16, 2004, gm notified nhtsa that it will conduct a safety recall of 178,798 model year (my) 2003 and 2004 saturn ion sedan vehicles for inoperative front turn signal/drl bulbs.gm stated that temperatures in the lamp assembly exceed the material specification for the bulb sockets and bulb base sleeves, which cause deformation.the deformed sockets can cause loss of bulb and socket contact.the deformed sleeves can cause stress cracks to form on the bulb that can lead to premature bulb failure.the recall remedy is to replace the front turn signal/drl bulbs and inspect for voltage-reducing jumper (which reduces temperature in lamp assembly) and add if not present.see nhtsa recall no. 04v547 for details.the bulbs for the turn signal/drl in the saturn ion sedan and ion coupe are identical in design and made by the same supplier.but the turn signal/drl sockets, wiring and housing are different in design for the sedan and coupe, and were made by different suppliers.gm's data shows a lower operating temperature for the coupe's lamp assembly that does not exceed the material specification for the bulb socket and the bulb base sleeve.complaint and warranty rate is also lower for the coupe.however, gm's warranty data shows a continuing trend for the coupe.this preliminary evaluation has been upgraded to an engineering analysis (ea04-035) for further investigation of the my 2003 and 2004 saturn ion coupe vehicles.

An NHTSA investigation looks into whether a safety defect exists. Opening one is not a finding. Outcomes can include a recall, closure without action, or further inquiry.

Model years covered

• 2004 Saturn Ion898 complaints
• 2003 Saturn Ion758 complaints