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PROJECT:

Subject-Type Chevrolet Cobalt Ignition

General Motors Ignition Switch

DP-E002

Ignition Switch

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PROJECT:

Subject-Type Chevrolet Cobalt Ignition Switch

General Motors Ignition Switch

DP-E010

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PROJECT:

Subject-Type Chevrolet Cobalt Ignition Switch

General Motors Ignition Switch

DP-E013

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PROJECT:

Subject-Type Chevrolet Cobalt Ignition Switch

General Motors Ignition Switch

DP-E014

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PROJECT:

Subject-Type Chevrolet Cobalt Ignition Switch

General Motors Ignition Switch

DP-E094

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PROJECT:

Subject-Type Chevrolet Cobalt Ignition Switch

General Motors Ignition Switch

DP-E095

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PROJECT:

2005 Chevrolet Cobalt Ignition Switch CT Scan Image

GM Igniton Switch_Front 0386_Enlarged

General Motors Ignition Switch

Detent Plunger

Switch Plate

with Detent

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PROJECT:

2005 Chevrolet Cobalt Ignition Switch Radiograph

RT-E06_RS _cropped

General Motors Ignition Switch

Detent Plunger

Switch Plate

with Detent

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PROJECT:

New Replacement Chevrolet Cobalt Ignition Switch Radiograph

RT-E07_RS_cropped

General Motors Ignition Switch

Detent Plunger

Switch Plate

with Detent

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PROJECT:

2005 Chevrolet Cobalt Ignition Switch

MDP_B-043

General Motors Ignition Switch

Detent Plunger in

Run DetentPosition

Approx 2.3 mm

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PROJECT:

2005 Chevrolet Cobalt Ignition Switch

DP-0649

3.68 mm

Detent Plunger

Height

General Motors Ignition Switch

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PROJECT:

2006 Chevrolet Cobalt Ignition Switch

MDP_A-E002

3.71 mmDetent Plunger

Height

General Motors Ignition Switch

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PROJECT:

2007 Chevrolet Cobalt Ignition Switch (August 2006 Build Date)

MDP_A-E004

3.95 mmDetent Plunger

Height

General Motors Ignition Switch

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PROJECT:

2007 Chevrolet Cobalt Ignition Switch (March 2007 Build Date)

MDP_A-E007

4.77 mmDetent Plunger

Height

General Motors Ignition Switch

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PROJECT:

2008 Chevrolet Cobalt Ignition Switch

MDP_A-E010

5.08 mmDetent Plunger

Height

General Motors Ignition Switch

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McSWAIN ENGINEERING, INC.

PROJECT:

New Chevrolet Cobalt Ignition Switch Service Replacement Part

MDP_A-E003

Detent Plunger

Height8.0 mm

General Motors Ignition Switch

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McSWAIN ENGINEERING, INC.

PROJECT:

Exemplar Chevrolet Cobalt Switch Detent Plungers

MDP_A-E001

5.9 mm

10.6 mm

12.2 mm

7.0 mm

2005Model Year

New ServiceReplacement

Part

9.24 N-cm

RUN-to-ACCTorque Value

17.57 N-cmRUN-to-ACC

Torque Value

General Motors Ignition Switch

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McSWAIN ENGINEERING, INC.

PROJECT:

2006 Chevrolet Cobalt Ignition Switch Detent Plunger

MDP_A-E013

Detent Plunger Spring ID: 0.075

General Motors Ignition Switch

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McSWAIN ENGINEERING, INC.

PROJECT:

New Replacement Chevrolet Cobalt Ignition Switch Detent Plunger

MDP_A-E015

Detent Plunger Spring ID: 0.070

General Motors Ignition Switch

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List of GM Fatalities, Compiled by Democratic Committee Staff

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Total (13)

Cobalt (9)

(1) July 2005 in Dentsville, Maryland (Amber Marie Rose, 15)(2) October 2006 in St. Croix County, Wis. (Natasha Weigel, 18, and Amy Rademaker, 15) -- Note:

According to Auto News, GM is only counting one of these. Unclear why.

(3) October 2007 in Lyndhurst, Ohio (42-year-old woman)(4) September 2008 in Berrien County, Mich. (Zachary Schoenbach, 19)(5) September 2008 in Berrien County, Mich. (Joseph Harding, Jr., 19)(6) April 2009 near Knox, Pa. (Esther Matthews, 73)(7) April 2009 near Knox, Pa. (her granddaughter, Grace Elliott, 13)(8) December 2009 near Murfreesboro, Tenn. (Hasaya Chansuthus, 25)(9) June 2013 in Quebec, Canada (1 death, unknown)

Ion (4)

(10) November 2004 in Texas (1 death, unknown)(11) February 2009 in Missouri (1 death, unknown)

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GMX001 Lock Module Detent in RUN

F irst Design Concept

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Detent between lock cover and cam shaft:

1

Design Evaluation (Engineering and Cost)

GMX001 Lock Module Detent in RUN

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Benefits Concerns Piece Cost Increase Tooling Lead TimeNo interface tuning required (between lockhousing and cylinder)

-A few new components are

needed

- Torque specification needed by

supplier

$0.5716179143 (new

tooling)About 1 year

Eng ineering Cos t & Tim ing

The most preferred by supplier

2

Second Design Concept

GMX001 Lock Module Detent in RUN

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Adding a plastic sleeve to the lock housing-lockcylinder interface:

3

Design Evaluation

GMX001 Lock Module Detent in RUN

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Main concern with trimming of the lock housing toaccommodate plastic sleeve

GMT 257 UG Data Shown

Material thicknesscreates concern for

GMX001 lock hosing

4

Design Evaluation (Engineering and Cost)

GMX001 Lock Module Detent in RUN

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Benefits Concerns Piece Cost Increase Tooling Lead Time

Design cncept already proven to work forGMT257

- Not enough material to trimfrom the lock housing in order to

accommodate sleve.

- Simultaneous tuning effort from

lock cylinder engineering and

lock housing supplier

- No specification available

$0.2758$152,145

(new tooling)About 1 year

Eng ineering Cos t & Tim ing

5

Other Design Solution Discussed (Ruled out)

GMX001 Lock Module Detent in RUN

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Adding spring loaded pins to the lock housing:

Main concern with complexity in warranty.

Ruled out by lock housing supplier 6

Other Design Solution Discussed (Ruled out)

GMX001 Lock Module Detent in RUN

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Changing the slot in the key in order to reduce leverarm and thus the torque:

It was determined that the lever arm still present due to the

fob ring.

Key Slot Change

7

Other Design Solution Discussed (Ruled out)

GMX001 Lock Module Detent in RUN

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PK3+ Detent Investigation (Direction from last CPIT meeting)

It was determined PK3+ detent is not related to the locking

mechanism detent

8

Conclusion (Best Solutions)

GMX001 Lock Module Detent in RUN

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Modification of the lock housing cam shaft seems to be the

most feasible and the preferred one by supplier.

Concern with the higher price increase

Concern with lack of specification

Adding a plastic sleeve to the lock housing -to-cylinder

interface.

Concern with the material thickness of the lock housing