2009 Chevrolet Malibu recalls & problems

Steering

Recall 14E0440007,304 vehicles

Problem

Dorman Products, Inc. (Dorman) is recalling certain replacement intermediate steering shafts sold under the Dorman, OE Solutions, and Solutions brand names, part numbers 425-167, 2425167, and 7-3074, for installation on 2004-2012 Chevrolet Malibu, 2005-2010 Pontiac G6, and 2007-2009 Saturn Aura vehicles. The affected steering shafts may have a yoke that inadequately supports the u-joint bearing resulting in a premature failure.

Risk

A joint bearing that fails prematurely may cause separation of the u-joint resulting in a complete loss of steering control, increasing the risk of a crash.

Fix

Dorman will notify owners, and dealers will refund the purchase price or replace the steering shafts, free of charge. The recall began in September 2014. Owners may contact Dorman customer service at 1-800-523-2492.

Electronic stability control (esc)

Recall 14V2520002,440,524 vehiclesopened after NHTSA action (ODI)

Problem

General Motors LLC (GM) is recalling certain model year 2004-2012 Chevrolet Malibu vehicles manufactured May 16, 2003, through October 11, 2012, 2004-2007 Malibu Maxx vehicles manufactured June 25, 2003, through April 5, 2007, 2005-2010 Pontiac G6 vehicles manufactured May 26, 2004, through January 4, 2010, and 2007-2010 Saturn Aura vehicles manufactured April 24, 2006, through May 26, 2009. In the affected vehicles, increased resistance in the Body Control Module (BCM) connection may result in voltage fluctuations in the Brake Apply Sensor (BAS) circuit. These fluctuations can cause one or more of these conditions: the brake lights to illuminate without the brake pedal being pushed; the brake lights to not illuminate when the pedal is pushed; difficulty disengaging the cruise control; moving the gear shifter out of the 'PARK' position without pushing the brake; and disablement of crash avoidance features such as traction control, electronic stability control, and panic braking assist features.

Risk

Any of the above failure conditions increases the risk of a crash.

Fix

GM will notify owners, and dealers will attach the wiring harness to the BCM with a spacer, apply dielectric lubricant to both the BCM and harness connector and the BAS and harness connector, and will relearn the brake pedal home position, free of charge. The manufacturer distributed an Interim letter to customers on July 14, 2014. The recall began on August 18, 2014. Owners may contact General Motors customer service at 1-800-222-1020 (Chevrolet), 1-800-762-2737 (Pontiac), 1-800-553-6000 (Saturn). GM's number for this recall is 13036.

Components: Electronic stability control (esc); Vehicle speed control › Cruise control; Exterior lighting › Brake lights › Switch; Exterior lighting › Brake lights; Electrical system › Wiring

Electric power assist system

Recall 14V1530001,373,177 vehiclesopened after NHTSA action (ODI)

Problem

General Motors LLC (GM) is recalling certain model year 2004-2006 and 2008-2009 Chevrolet Malibu, 2004-2006 Malibu Maxx, 2009-2010 HHR (non-turbo), 2010 Cobalt, 2008-2009 Saturn Aura and 2004-2007 Ion, and 2005-2009 Pontiac G6. In the affected vehicles, there may be a sudden loss of electric power steering (EPS) assist that could occur at any time while driving.

Risk

If power steering assist is lost, greater driver effort would be required to steer the vehicle at low speeds, increasing the risk of a crash.

Fix

GM will notify owners, and dealers will perform one of four bulletins. Parts are not currently available. GM expects to send an interim notification around May 28, 2014. When parts are available, owners will be mailed a second letter to come in to have the applicable bulletin applied. Bulletin 14115 covers model year 2004-2007 Saturn Ion, 2009-2010 Chevrolet HHR and 2010 Chevrolet Cobalts. Dealers will replace the EPS motor. Bulletin 14116 covers model year 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from March 1, 2008, through June 27, 2008. Dealers will replace the torque sensor assembly. Bulletin 14117 covers model year 2008 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from February 1, 2008, through February 28, 2008. Dealers will replace the torque sensor assembly and EPS motor controller unit. Bulletin 14118 covers model year 2008 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from October 1, 2007, through January 31, 2008. Dealers will replace the EPS motor controller unit. The recall began on July 17, 2014. Owners may contact Chevrolet at 1-800-630-2438, Saturn at 1-800-553-6000, and Pontiac at 1-800-620-7668. GM's number for this recall is N140115. Note: GM bulletin number 14119 will be implemented for model year 2006-2008 and early production of 2009 Chevrolet HHR (non-turbo) and model year 2003 Saturn ION to provide EPS Motor replacement for the life of the vehicle.

Automatic transmission › Gear position indication (prndl)

Recall 12V460000426,240 vehicles

Problem

General Motors (GM) is recalling certain model year 2007-2010 Saturn Aura and model year 2008-2010 Chevrolet Malibu and Pontiac G6 vehicles, equipped with a 4-speed automatic transmission. On these vehicles, the tabs on the transmission shift cable end may fracture and separate.

Risk

If the tabs were to fracture and separate, the shift lever and the actual position of the transmission gear may not match. The driver would be able to move the shifter to 'PARK' and remove the ignition key, but the transmission gear may not be in 'PARK.' The vehicle may not be able to be restarted and the vehicle could roll away after the driver has exited the vehicle, resulting in a possible crash without prior warning.

Fix

GM will notify owners, and dealers will install a retainer over the cable end or replace the shift cable as necessary. This service will be performed free of charge. Notification to owners began on on November 9, 2012. Owners were instructed to not bring their vehicles for repair until January 2013. Owners may contact General Motors at 1-800-521-7300.

Automatic transmission › Lever and linkage › Column shift

Recall 09V073000276,729 vehicles

Problem

GENERAL MOTORS IS RECALLING 276,729 MY 2009 BUICK ENCLAVE, CHEVROLET COBALT, HHR, MALIBU, TRAVERSE, GMC ACADIA, PONTIAC G5, G6 AND SATURN AURA AND OUTLOOK PASSENGER VEHICLES. THESE VEHICLES FAIL TO COMPLY WITH FEDERAL MOTOR VEHICLES SAFETY STANDARD 102, "TRANSMISSION SHIFT POSITION SEQUENCE, STARTER INTERLOCK, AND TRANSMISSION BRAKING EFFECT", AND FMVSS 114, "THEFT PROTECTION AND ROLLAWAY PREVENTION". ON SOME OF THESE VEHICLES, THE TRANSMISSION SHIFT CABLE ADJUSTMENT CLIP MAY NOT BE FULLY ENGAGED. IF THE CLIP IS NOT FULLY ENGAGED, THE SHIFT LEVER AND THE ACTUAL POSITION OF THE TRANSMISSION GEAR MAY NOT MATCH. WITH THIS CONDITION, THE DRIVE COULD MOVE THE SHIFTER TO "PARK" AND REMOVE THE IGNITION KEY, BUT THE TRANSMISSION GEAR MAY NOT BE IN "PARK".

Risk

THE DRIVER MAY NOT BE ABLE TO RESTART THE VEHICLE AND THE VEHICLE COULD ROLL AWAY AFTER THE DRIVER HAS EXITED THE VEHICLE, RESULTING IN A POSSIBLE CRASH WITHOUT PRIOR WARNING.

Fix

DEALERS WILL INSPECT AND ENSURE THAT THE SHIFT CABLE ADJUSTMENT CLIP IS FULLY ENGAGED. IN THE EVENT THAT THE CLIP DOES NOT ENGAGE, THE SHIFT CABLE WILL BE REPLACED FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN ON OR BEFORE MARCH 24, 2009. OWNERS MAY CONTACT BUICK AT 1-866-608-8080, CHEVROLET AT 1-800-630-2438, GMC AT 1-866-996-9463, PONTIAC AT 1-800-620-7668 AND SATURN AT 1-800-972-8876 OR AT WWW.GMOWNERCENTER.COM.

Defroster/defogger/hvac system

Recall 08V63400077 vehicles

Problem

GM IS RECALLING 77 MY 2009 CHEVROLET MALIBU HYBRID VEHICLES FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 103, "WINDSHIELD DEFROSTING AND DEFOGGING SYSTEM." THE HEATING, VENTILATION, AND AIRCONDITIONING (HVAC) SYSTEM MAY BECOME INOPERATIVE. IF THIS WERE TO OCCUR, THE BLOWER WOULD NOT FUNCTION PROPERLY AND THE MODE SELECTOR WOULD REMAIN IN THE LAST KNOWN SETTING.

Risk

IF THE WINDSHIELD BEGAN TO FOG OR FROST, THERE MAY NOT BE ENOUGH AIRFLOW TO CLEAR THE WINDSHIELD, RESULTING IN REDUCED DRIVER VISIBILITY AND A POSSIBLE CRASH WITHOUT PRIOR WARNING.

Fix

DEALERS WILL REPROGRAM THE HVAC CONTROL HEAD MODULE. THE RECALL IS EXPECTED TO BEGIN ON DECEMBER 17, 2008. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 OR THROUGH THEIR WEBSITE AT <A HREF=HTTP://WWW.GMOWNERCENTER.COM>HTTP://WWW.GMOWNERCENTER.COM</A> .