McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

Subject-Type Chevrolet Cobalt Ignition

Ignition Switch

DP-E002

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

Subject-Type Chevrolet Cobalt Ignition Switch

DP-E010

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

Subject-Type Chevrolet Cobalt Ignition Switch

DP-E013

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

Subject-Type Chevrolet Cobalt Ignition Switch

DP-E014

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

Subject-Type Chevrolet Cobalt Ignition Switch

DP-E094

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

Subject-Type Chevrolet Cobalt Ignition Switch

DP-E095

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

2005 Chevrolet Cobalt Ignition Switch CT Scan Image

Detent Plunger

Switch Plate with Detent

GM Igniton Switch_Front 0386_Enlarged

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

2005 Chevrolet Cobalt Ignition Switch Radiograph

Detent Plunger

Switch Plate with Detent

RT-E06_RS _cropped

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

New Replacement Chevrolet Cobalt Ignition Switch Radiograph

Detent Plunger

Switch Plate with Detent

RT-E07_RS_cropped

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

2005 Chevrolet Cobalt Ignition Switch

Detent Plunger in Run Detent Position

Approx 2.3 mm

MDP_B-043

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

2005 Chevrolet Cobalt Ignition Switch

Detent Plunger Height

3.68 mm

DP-0649

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

2006 Chevrolet Cobalt Ignition Switch

3.71 mm

Detent Plunger Height

MDP_A-E002

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

2007 Chevrolet Cobalt Ignition Switch (August 2006 Build Date)

3.95 mm

Detent Plunger Height

MDP_A-E004

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

2007 Chevrolet Cobalt Ignition Switch (March 2007 Build Date)

4.77 mm

Detent Plunger Height

MDP_A-E007

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

2008 Chevrolet Cobalt Ignition Switch

5.08 mm

Detent Plunger Height

MDP_A-E010

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

New Chevrolet Cobalt Ignition Switch Service Replacement Part

8.0 mm

Detent Plunger Height

MDP_A-E003

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

Exemplar Chevrolet Cobalt Switch Detent Plungers

5.9 mm

2005 Model Year

9.24 N-cm RUN-to-ACC Torque Value 10.6 mm 12.2 mm

New Service Replacement Part 7.0 mm

17.57 N-cm RUN-to-ACC Torque Value

MDP_A-E001

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

2006 Chevrolet Cobalt Ignition Switch Detent Plunger

Detent Plunger Spring ID: 0.075

MDP_A-E013

McSWAIN ENGINEERING, INC.

PROJECT:

General Motors Ignition Switch

New Replacement Chevrolet Cobalt Ignition Switch Detent Plunger

Detent Plunger Spring ID: 0.070

MDP_A-E015

List of GM Fatalities, Compiled by Democratic Committee Staff 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) (12) (13) Two more in FARS database, not yet determined, involving 2004 Ions

GMX001 Lock Module Detent in RUN

First Design Concept
Detent between lock cover and cam shaft:

GMX001 Lock Module Detent in RUN

Design Evaluation (Engineering and Cost)

The most preferred by supplier

Engineering
Benefits Concerns
No interface tuning required (between lock -A few new components are housing and cylinder) needed - Torque specification needed by supplier

Cost & Timing

Piece Cost Increase Tooling Lead Time
$0.5716 179143 (new About 1 year tooling)

GMX001 Lock Module Detent in RUN

Second Design Concept
Adding a plastic sleeve to the lock housing-lock

cylinder interface:

GMX001 Lock Module Detent in RUN

Design Evaluation

Main concern with trimming of the lock housing to accommodate plastic sleeve

Material thickness creates concern for GMX001 lock hosing

GMT 257 UG Data Shown

GMX001 Lock Module Detent in RUN

Design Evaluation (Engineering and Cost)

Engineering
Benefits
Design cncept already proven to work for GMT257

Cost & Timing

Piece Cost Increase Tooling Lead Time

Concerns
- Not enough material to trim from 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 About 1 year (new tooling)

GMX001 Lock Module Detent in RUN

Other Design Solution Discussed (Ruled out)
Adding spring loaded pins to the lock housing:

Main concern with complexity in warranty.

Ruled out by lock housing supplier 6

GMX001 Lock Module Detent in RUN

Other Design Solution Discussed (Ruled out)
Changing the slot in the key in order to reduce lever

arm and thus the torque:

Key Slot Change

It was determined that the lever arm still present due to the fob ring.

GMX001 Lock Module Detent in RUN

Other Design Solution Discussed (Ruled out)
PK3+ Detent Investigation (Direction from last CPIT meeting) It was determined PK3+ detent is not related to the locking mechanism detent

GMX001 Lock Module Detent in RUN

Conclusion (Best Solutions)
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 Concern with the lock housing-lock cylinder tuning coordination between two suppliers No specification available 9