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Why an independent rear suspension for GM's new, full-sized SUVs wasn't easy

A Motor Trend report last month laid out how Cadillac's 4.2-lier twin-turbo Blackwing V8 could be an orphan due to cost concerns in the GM empire. Last-minute chassis changes to Cadillac's new sedans and XT6 crossover led to engine bays that couldn't fit the Blackwing. On the SUV side, according to the report, the new independent rear suspension for big people haulers cost so much to implement that GM ruled out reworking the Escalade to accept the Blackwing. At least one commenter rightly asked how could a suspension swallow that much money. A new piece in Motor Trend has the answer. The excellent Alissa Priddle spoke to Tim Herrick, GM's executive chief engineer for full-size trucks, about why the clean-sheet IRS cost "multimillions of dollars."  First, GM would need to build a new body shop at the Arlington, Texas plant that assembles the automaker's big SUVs to stamp the numerous wholly new parts and panels accommodating an IRS. Then GM would need to design and pay for a new assembly process. On top of those up-front costs, there was the incremental cost of the four-link IRS components being more expensive than those in the trucks' former leaf-sprung solid axles. Herrick endured so many rejections for so long that he remembers the date and time when he got approval for the new unit. He said it came down to a meeting where he told a higher-up, "I'll make you a deal: If we get to the reveal, or if we launch this and you think this was a dumb idea, I'll hand you my badge and let you walk me out." Head to Motor Trend to read the full story. Based on Herrick being on stage to help present the new SUVs to the press, and on our First Ride in the new Chevrolet Tahoe and Suburban at GM's Milford Proving Grounds, it appears this will have a happy ending for all involved. Furthermore, since Herrick worked on the T1 platform that supports the big SUVs as well as the light- and heavy-duty pickups, he understood the demands on the commercial side, too. That could be why when Roadshow asked Tim Asoklis, chief engineer of the Tahoe and Suburban, if the new IRS could endure life in the Chevrolet Silverado and GMC Sierra, Asoklis answered, "Oh, absolutely." Related Video:    

GM re-recalls 11k SUVs

General Motors is recalling a bunch of previously recalled SUVs because, well, they still aren't quite fixed. The latest repairs are necessary on 10,974 SUVs in North America, including 9,932 in only the US. Affected models include the 2006-2007 Buick Rainier, Chevrolet Trailblazer, and GMC Envoy; plus the 2006 Trailblazer EXT and Envoy XL. While not listed by NHTSA, a statement by GM to Autoblog says the 2006-2007 Saab 9-7X and Isuzu Ascender are also affected. In these SUVs, it's possible that liquid could get into the driver's door master power window switch module and cause a short circuit. This could potentially lead to a fire, and owners are urged to park the vehicles outside until repaired. GM has been trying to fix this issue for years. It started as an investigation into fires, and that led to a recall for about 250,000 vehicles in cold-weather states. A nationwide campaign came in 2013 for 193,000 of them in the US. Last year, the automaker decided to replace the whole module as a repair. However in a recent investigation of these recalls, GM discovered that this latest group of SUVs never received the new part. According to documents submitted to NHTSA (as a PDF), "Some dealers incorrectly used the labor code associated with module replacement when, instead of replacing the module, they only added a protective coating to the module." To fix things this time, the models finally get the correct component. Related Video: GM Statement General Motors is recalling 9,932 older midsize SUVs in the U.S. because they were mistakenly excluded from an earlier recall. Certain 2006 Chevrolet TrailBlazer EXT and GMC Envoy XL, and 2006-2007 TrailBlazer, Envoy, Buick Rainier, Saab 9-7X and Isuzu Ascender vehicles may continue to have a condition in which the printed circuit board inside the driver's door may corrode and short if exposed to certain fluids such as melted snow containing road salt. GM is aware of four fires but no crashes, injuries or fatalities associated with the expanded recall. The total number of vehicles being recalled, including Canada, Mexico and exports is 10.974. Customers are urged to park these vehicles outside until repairs have been made. GM reported this recall to the NHTSA on September 23.

Chevrolet Bolt EV Concept foreshadows an affordable, 200-mile EV future [w/videos]

Confirming numerous reports and rumors, Chevrolet introduced the Bolt EV Concept, "a vision" of a 200-mile EV with an entry price of around $30,000. Those lofty promises ride atop a funky crossover that made its global debut at the 2015 Detroit Auto Show. The orange five door features a spacious greenhouse, complemented by a glass roof and thin D-pillar. A narrow grille and slim LED headlights crown a high fascia that leaves little ahead of its front axle. It's a similar story in back, as General Motors' design boss Ed Welburn sought to limit overhangs and maintain the Bolt's small footprint. "Form and function have never meshed so well together," Welburn said. "No compromises were made when it came to aesthetics and the elements that contribute to the Bolt EV concept's range, resulting in a unique proportion that's sleek, efficient and obviously a Chevrolet." The cabin is not unlike current Chevrolet compacts, with the MyLink touchscreen and a detached instrument cluster dominating the sparse dash. Unlike cars like the Sonic, which features a similar design for its instrument cluster, A Volt-like display is found over the steering column. "The Bolt EV concept is a game-changing electric vehicle designed for attainability, not exclusivity," CEO Mary Barra said. "Chevrolet believes electrification is a pillar of future transportation and needs to be affordable for a wider segment of customers." Take a look at both the official gallery of Bolt images, as well as our live shots. And then scroll on down for more comments from GM brass, in the official press release. Chevrolet Bolt EV Concept Signals Brand's EV Strategy Affordable, long-range concept builds on brand's electrification leadership 2015-01-12 DETROIT – Chevrolet today made a significant statement on its commitment to electrification with the introduction of the Bolt EV concept – a vision for an affordable, long-range all-electric vehicle designed to offer more than 200 miles of range starting around $30,000. "The Bolt EV concept is a game-changing electric vehicle designed for attainability, not exclusivity," said General Motors CEO Mary Barra. "Chevrolet believes electrification is a pillar of future transportation and needs to be affordable for a wider segment of customers." Leveraging the electrification prowess established by Volt and Spark EV, the Bolt EV concept is designed to offer long-range performance in all 50 states and many global markets.