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NHTSA could add 1M cars to GM recall

The Detroit Free Press is reporting that the National Highway Traffic Safety Administration may expand a recall campaign for faulty brake lamps. The agency is currently looking into complaints that certain 2004-2011 Chevrolet Malibu models as well as some 2007-2009 Saturn Aura sedans may have brake lights that do not illuminate when the driver presses the pedal. Alternatively, the lamps may also illuminate without input from the driver. General Motors recalled 8,000 Pontiac G6 models from the 2005 model year for the same problem, and NHTSA is currently investigating whether to add 550,000 more G6 models built between 2005 and 2009 to the list for the same issue.
In addition, investigators are currently examining 97 complaints from Malibu and Aura owners with the same trouble. If NHTSA adds those models to the recall campaign, more than one million units could be covered. GM, meanwhile, says there have been no accidents or injuries as a result of the problem.

2015 Chevy Spark will have lighter, smaller battery

As General Motors gets ready to release the 2015 Chevy Spark EV, it is retooling the Brownstown Battery Assembly to build a new battery system for the chirpy little electric car. The new Spark will lose a few pounds and kWh from its lithium-ion pack, but it will keep all of it's performance specs. The current Spark EV uses a 21-kWh lithium-ion battery pack with bits made by A123 Systems (known as B456 Systems during bankruptcy). For the 2015 model, GM is going to build a 19-kWh battery system in-house that will use 192 LG Chem cells. Losing a bit of energy capacity means that the battery system for the 2015 Spark EV will be 86 pounds lighter but it will keep the EPA-rated 82-mile range and 119 MPGe. The 2015 Spark EV also keeps its $26,685 (plus destination) starting price from the 2014 model. The car will once again qualify for a federal tax credit of up to $7,500. LG Chem also supplies the cells for GM's other plug-in vehicles from its facility in Western Michigan. The Brownstown production line currently builds the battery packs for the Chevy Volt, the Opel Ampera and the Cadillac ELR. You can read our first drive of the 2014 Chevy Spark here. Brownstown Battery Assembly Expands Capabilities Will build battery system for 2015 Chevrolet Spark EV 2014-05-14 DETROIT – General Motors will bring all its electric vehicle battery building capabilities in-house with production of battery systems for the 2015 Chevrolet Spark EV at its battery assembly plant in Brownstown, Mich. "Using our in-house engineering and manufacturing expertise enabled us to deliver a battery system that is more efficient and lighter than the 2014 Spark EV without sacrificing range," said Larry Nitz, executive director of GM global transmission and electrification engineering. "Our successful working relationship with LG Chem has allowed us to deliver a new battery system for the Spark EV that helps us to better leverage our economies of scale." A newly designed battery system features an overall storage capacity of 19 kWh and uses 192 lithium ion cells. The cells are produced at LG Chem's plant in Holland, Mich. The battery system weight of 474 lbs. is 86 pounds lighter than the system in the 2014 Spark EV. The Spark EV battery is built on a dedicated production line at Brownstown, which also manufactures complete battery packs for the Chevrolet Volt, Opel Ampera and Cadillac ELR.

Vert-A-Pac train cars kept your Chevy Vega's price in check

Our apologies to those who've seen this before, but for the rest of the class, how awesome are these pictures of the Vert-A-Pac shipping system General Motors came up with to ship the Chevrolet Vega back in the 1970s? Developed along with Southern Pacific Railroad, GM was able to double the amount of Vega models it could ship by packing them into the unique storage cars vertically.
At the time, rail cars could fit 15 vehicles each, but Chevrolet was able to lower shipping costs by making it possible to ship 30 Vegas per rail car, in turn allowing the price of the Vega to remain as low as possible. Each rail car had 30 doors that would fold down so that a Vega could be strapped on, and then a forklift would come along and lift the door into place. All the cars were positioned nose down, and since they were shipped with all of their required fluids, certain aspects had to be designed specifically for this type of shipping, including an oil baffle in the engine, a special battery and even a repositioned windshield washer reservoir. See for yourself in our image gallery above.