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Saturn Vue ignition issue was discussed three times before recall, new documents reveal

Despite the tens of millions of recalled vehicles this year, it's somewhat rare that we get a glimpse into what goes into deciding when to conduct one of these safety campaigns. New documents published by General Motors and the National Highway Traffic Safety Administration are giving us an interesting opportunity to see how the sausage is made and show the number of meetings it takes to declare a recall.
In early August, GM added about another 269,000 vehicles to its 2014 recall tally in the US when it announced a slew of new safety campaigns. Among them was a fix for the 2002-2004 Saturn Vue that covered 202,155 of them in the US. The problem was that the key could be removed from the ignition even when it wasn't in the "OFF" position, and that had caused two crashes and one injury, according to the automaker.
Where we start to see behind the veil is in the defect notice freshly released by NHTSA. It shows that GM began investigating more widely for ignition switches in April, shortly after the company expanded its ignition switch recall to a variety of Saturn products, among others, according to Automotive News. The automaker found 152 reports in the 2002-2004 Vue of vehicles rolling away or the key being removed out of a total population of 215,243 units worldwide.

Saturn Vue ignition switch leads to new group of GM recalls totaling 312k

General Motors has another spate of recalls to announce. This time they cover 312,280 vehicles worldwide, including 269,041 of in the US, in a total of six campaigns. In 2014, the automaker has recalled 29,079,765 vehicles worldwide, with 25,754,356 of those in the US.
The largest among them covers 215,243 units of the Saturn Vue from 2002-2004 model years worldwide, 202,115 in the US. It's possible for the for the key to be removed even when the ignition isn't in the OFF position. The company knows of two crashes and one injury caused by this problem. Dealers are checking the parts and replacing the ignition cylinder and key set, if necessary.
Next is 72,826 models worldwide (48,059 vehicles in the US) of the 2013 Cadillac ATS four-door sedan, 2013 Buick Encore and 2013 Chevy Trax in Canada. It's possible that the for lap belt pretensioner to retract but not to lock, which could increase occupant movement during a crash. Both front, outboard lap belt pretensioners are being replaced, and a stop-sale is in effect on unsold models until the problem is repaired. There are no known crashes or injuries, though.

Report: GM temporarily restarts Saturn Outlook, Hummer H3 production

Saturn Outlook - Click above for high-res image gallery
Even though both the Saturn and Hummer brands are being phased out, General Motors has reportedly revived production of both the Outlook crossover and H3 SUV to meet consumer demands.
Last month, GM assembled 1,037 Outlooks at its Lansing, Michigan facility, which is where the crossover's Lamda platform stablemates (Buick Enclave, Chevrolet Traverse and GMC Acadia) are built. A spokesperson for GM states that production was reinstated to utilize the rest of the Saturn-specific material at the facility, and that the automaker will continue to assemble the Outlook for a few more weeks.