General Motors Ignition Switch Investigation: Key Documents from April 1, 2014 Hearing

On April 1, 2014, the Oversight and Investigations Subcommittee held a hearing titled, "The GM Ignition Switch Recall: Why Did It Take So Long?."  This hearing examined the February and March 2014 General Motors recall of more than two million Chevrolet Cobalt, Chevrolet HHR, Pontiac G5, Pontiac Solstice, Saturn Ion, and Saturn Sky vehicles.  Mary Barra, CEO of General Motors, and The Honorable David Friedman, Acting Administrator of the National Highway Traffic Safety Administration (NHTSA), testified. 

The following documents from General Motors, NHTSA, and Delphi Automotive were used or cited as part of the official hearing record.

GM Component Technical Specification

Delphi Design Records of the Ignition Switch

GM 2001 Problem Resolution Tracking System (PRTS) inquiry of the Saturn Ion, which resulted in pre-production ignition switch design change

GM 2002 Production Part Approval Process Report showing approval of ignition switch (May 3, 2002)

GM Analysis/Development/Validation Plan Report for Suppliers showing torque performance testing of the ignition switch (May 21, 2002)

E-mail from Delphi employee to Ray DeGiorgio regarding short circuit testing in 2002 with attachment, GM Analysis/Development/Validation Plan and Report for Suppliers (November 2002)

GM 2003 Field Performance Report on Ion-Ignition Switch-Column-Intermittent Stall While Driving with no DTCs (2003)

GM 2004 Problem Resolution Tracking System (PRTS) inquiry of the Chevrolet Cobalt to examine inadvertent key turning due to contact with driver’s knee; Closed due to none of the proposed solutions representing an “acceptable business case” (Opened October 2004)

GM GMX001 Lock Module Detent in RUN Presentation from 2004 PRTS

GM 2005 Problem Resolution Tracking System (PRTS) inquiry of the Chevrolet Cobalt to reexamine inadvertent key turn due to contact with driver’s knee. (Opened March 2005)

GM Root Cause Analysis from 2005 PRTS

E-mail between Delphi Employees, Subject: Force displacement curves (June 14, 2005)

New York Times, “Making a Case for Ignitions That Don’t Need Keys” (June 19, 2005)

GM Statement on Chevrolet Cobalt Inadvertent Shutoffs (June 2005)

Cleveland Plain Dealer, “Salamis, key rings and GM’s ongoing sense of humor” (June 26, 2005)

E-mail between GM Employees Steven Kirkman and Ray DeGiorgio, Subject: No new Delta/Kappa ign switch for MY 08 (September 30, 2005)

General Motors Corporation Service Bulletin No: 05-02-35-007 on Information on Inadvertent Turning of Key Cylinder, Loss of Electric System and No DTCs (December 2005)

E-mail between Delphi Employees, Subject: Delta Ignition Samples with New PCB/Plunger (January 9, 2006)

Delphi Change Request Form for New PCB Design and Catera Spring/Plunger for Production in Delta Ignition Switch (January 15, 2006)

Delphi Analysis/Development/Validation Plan and Report showing ignition switch torque testing results  (January 25, 2006)

NHTSA Special Crash Investigation Report on July 2005 Maryland Crash – Calspan Corporation:  Crash Data Research Center On-Site Air Bag Non-Deployment Investigation, Case No: CA05-049 (February 2006)

NHTSA Follow-Up Request for Death Incidents Selected from GM’s 3rd Quarter of 2005 Early Warning Report data (EWR) (March 1, 2006) and GM Response Letter (April 6, 2006)

Delphi Material/Performance Test Results showing ignition switch torque testing results (April 13, 2006)

Delphi Design Failure Mode and Effects Analysis (DFMEA) (Received April 21, 2006)

General Motors Commodity Validation Sign-off, Delta Ignition Switch (April 26, 2006)

Delphi Memo on Delta Torque Angle Data (May 15, 2006)

Delphi Engineering Change Support Information Cover Page, featuring Commodity Validation Sign-off Document (May 27, 2006)

E-mail from Gregory Magno, Office of Defect Investigations, NHTSA on IE07-80, Non-Deployment of Frontal Airbags in the 2003-2006 Cobalt/Ion (September 5, 2006)

Delphi Electronics and Safety Report (September 7, 2006)

General Motors Corporation Service Bulletin No: 05-02-35-007A on Information on Inadvertent Turning of Key Cylinder, Loss of Electric System and No DTCs (October 2006)

NHTSA Special Crash Investigation report on October 2006 Wisconsin Crash – Indiana University Transportation Research Center:  On-Site Air Bag Non-Deployment Investigation, Case No:  In-06-033 (April 2007)

NHTSA Follow-Up Request for Death Incidents Selected from GM’s 4th Quarter of 2006 Early Warning Report (EWR) data and GM Response Letter (June 7, 2007)

Siemens VDO Automotive Corporation Field Event Analysis Report provided to GM based on sensing and diagnostic module (SDM) readout in 2005 Cobalt crash (August 16, 2007)

NHTSA Defects Assessment Division Panel Presentation (November 15, 2007)

Continental Automotive Systems US, Inc. Field Event Analysis Report (May 11, 2009)

NHTSA Special Crash Investigation report on April 2009 Pennsylvania Crash – Calspan Corporation:  Crash Data Research Center On-Site Air Bag Non-Deployment Investigation, Case No: CA09-022 (February 2010)

E-mail between GM Employees Terry Woychowski and Mary Barra, Subject:  NYT on ION Upgrade (October 3, 2011)

Chart created for internal GM use plotting Torque to Rotate from Run to Accessory across model years (May 2012)

E-mail between GM Employees Peter Judis, Brian Stouffer, John Sprague, John Zuzelski, and Terrence Connolly; Subject: Cobalt Key Cylinder Issue – History of Steering Column Changes Attached (June 28, 2012)

E-mail between GM Employees, Subject: Red X Assistance Requested Cobalt 2007 vs. 2008 (September 6, 2012)

E-mails between GM Employees Ray DeGiorgio, Brian Stouffer, Brian Thompson, and David DeFrain, Subject: 2005-07 Cobalt Ignition Switch Effort (October 5, 2012)

McSwain Engineering, Inc. Photos of General Motors Ignition Switch (October 2012)

Excerpt from Deposition of Ray DeGiorgio, GM Project Engineer for the ignition switch, during the Melton litigation (April 29, 2013)

Excerpt from Deposition of Brian Stouffer, GM Field Performance Evaluation/Assessment Engineer, during the Melton litigation (May 1, 2013)

E-mail between GM Employees Michael J. Robinson to Gay P. Kent, Subject: Confidential: NHTSA Email Outlining Concerns about Recent GM Actions (July 24, 2013)

E-mails between GM and Delphi Employees, Subject: Request for Information Chevrolet Cobalt Ignition Switch P/N 10392423 (October 2013)

GM-Requested Exponent Report (2013)

Charts for GM Executive Field Action Decision Committee (EFADC) Presentation

GM Executive Field Action Decision Committee (EFADC) Presentation on Frontal Airbag Non-Deployment (December 17, 2013)

E-mails between GM Employees Brian Stouffer and John Murawa, Subject:  Cobalt Airbag Chronology (December 18, 2013)

GM Executive Field Action Decision Committee (EFADC) Presentation on Ignition Switch (January 31, 2014)

GM Preventive Action Documentation (N-130454) 2005-2007 Cobalt/Pursuit/G5 Ignition Switch

Letter from Carmen Benavides, Director, Product Investigations and Safety Regulations, General Motors, to Nancy Lewis, Associate Administrator for Enforcement, National Highway Traffic Safety Administration, to notify NHTSA of the 2005-2007 Chevrolet Cobalt and 2007 Pontiac G5 ignition switch recall (February 7, 2014)

Letter from Jennifer Timian, Chief, Recall Management Division, Office of Defects Investigation, NHTSA to Carmen Benavides, Director, Product Investigations and Safety Regulations, General Motors, to acknowledge NHTSA’s receipt of GM’s notification of a safety recall  (February 14, 2014)

Letter from Carmen Benavides, Director, Product Investigations and Safety Regulations, General Motors, to Nancy Lewis, Associate Administrator for Enforcement, National Highway Traffic Safety Administration, to provide a chronology of GM’s recall decision (February 24, 2014)

GM Executive Field Action Decision Committee (EFADC) Presentation on Ignition Switch Unintended Rotation (February 24, 2014)

Letter from Carmen Benavides, Director, Product Investigations and Safety Regulations, General Motors, to Nancy Lewis, Associate Administrator for Enforcement, National Highway Traffic Safety Administration, to notify NHTSA of the expanded ignition switch recall (February 25, 2014)

Letter from Carmen Benavides, Director, Product Investigations and Safety Regulations, General Motors, to Nancy Lewis, Associate Administrator for Enforcement, National Highway Traffic Safety Administration, to provide an updated chronology for the expanded recall (March 11, 2014)

GM Customer Care and After Sales Notice of Upcoming Safety Recalls 13454 and 14063 to All General Motors Dealers (March 17, 2014)

Class Action Complaint against General Motors, Case No:  14-CV-01339-JSW (March 24, 2014)

GM Press Release, “GM Moves to Secure Recalled Ignition Switches” (March 28, 2014)

Letter from Carmen Benavides, Director, Product Investigations and Safety Regulations, General Motors, to Nancy Lewis, Associate Administrator for Enforcement, National Highway Traffic Safety Administration, to notify NHTSA of a second expansion to the ignition switch recall (March 28, 2014)

List of GM-recognized fatalities resulting from the ignition switch defect, prepared by Democratic Committee Staff