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Feds open investigation into Chevy Express, Ford Freestar rust issues

'Tis the season... for road salt. And with that, comes rust. And what does rust bring? Well, for Ford and General Motors, a National Highway Traffic Safety Administration investigation. According to The Detroit News, NHTSA is looking into potential recalls issues with Chevrolet Express vans and Ford Freestar minivans.
The feds have received five complaints that rust has caused leaking fuel filler pipes on 2003 Express vans. Separately, seven complaints have been filed over excessive rust in the rear wheel wells of 2004 Ford Freestar and Mercury Monterey minivans. The Freestar and Monterey went out of production in 2007. Neither issue has resulted in any crashes or injuries, according to the report.

Ford Police Interceptors dominate Michigan State Police testing

Once again, Ford Motor Company builds the fastest police vehicles. The Blue Oval touted the news in an official release following Michigan State Police and Los Angeles County Sheriff's Department testing. Ford did very well. Except for one acceleration metric – zero to 10 miles per hour – the Blue Oval's Taurus and Explorer-based cop cars were the quickest, with particular praise coming for the EcoBoost-powered models, which bested Chevrolet and Dodge's V8-powered variants. Dearborn's products also posted the fastest average times around MSP's vehicle dynamics course. But it wasn't all positive for Ford. The only four-cylinder in the contest, the 2.0-liter, EcoBoost Ford SSP Sedan, had both the lowest top speed, 120 mph, and the slowest acceleration figures. It was also the slowest in track testing. Ford's products also failed to match the braking and top speeds of its rivals from Detroit and Auburn Hills – the rear-drive Charger Pursuit posted the best braking stats of the entire test, while the V8-powered Chevrolet Caprice hit the highest top speed, at 155 mph. Ford did score a top speed award, among SUVs, but at 132 mph, the naturally aspirated Police Interceptor Utility had to share its award with the equally fast, rear-drive Chevrolet Tahoe. The LA County Sheriff's timing isn't publicly available, but according to Ford, the EcoBoost-powered police cars put on a similarly impressive show for cops on the West Coast. We've assembled a spreadsheet on Google Docs that offers an easy to browse comparison of the different stats assembled by the Michigan State Police, and divided the vehicles between standard V6-powered sedans, high-performance sedans (EcoBoost and V8 models), and SUVs. You can check it out here. Related Video:

Chevy Volt replacement battery cost varies wildly, up to $34,000

There's a growing hubbub in the plug-in vehicle community over what looks like some ridiculously cheap replacement batteries for the Chevrolet Volt going up for sale. GM Parts Online, for example, is selling a replacement Volt battery with an MSRP of $2,994.64 but, with an online discount, the price comes down to $2,305.88. For the 16-kWh pack in the 2012 Volt, that comes to a very low $144.11 per kilowatt hour (kWH). But is it a real deal? How can it be, when a Chevy dealer may quote you a price of up to $34,000 to replace the pack? For a 16-kWh Volt pack, $2,305.88 comes to a very low $144.11 per kWh. But is it a real deal? Battery packs in alternative propulsion vehicles are usually priced by the kWh and, historically, they've been thought to be in the range of $500-per-kWh for OEM offerings. Since automakers are understandably secretive about their costs, we still don't know what the real number is today, but we do know it varies by automaker. Tesla, for example, has said it pays less than $200-per-kWH at the cell level but, of course, a constructed pack would be more. Whatever is going on, li-ion battery prices are trending downward. So, $144.11 certainly sounds great, but what's the story here? Kevin Kelly, manager of electrification technology communications for General Motors, reminded AutoblogGreen that GM Parts Online is not the official GM parts website and that, "the costs indicated on the site are not what we would charge our dealers or owners for a replacement battery. There would be no cost to the Volt owner if their battery needs replacement or repair while the battery is under the eight year/100,000 mile limited warranty coverage provided by Chevrolet." A single price tag also can't be accurate for everyone, Kelly said. "If the customer needs to have their battery repaired beyond the warranty, the cost to them would vary depending on what needs to be replaced or repaired (i.e. number of modules, which specific internal components need replacement, etc.)." he said. "So, it's hard for us to tell you exactly what the cost would be to the customer because it varies depending on what might need to be repaired/replaced. As a result, the core charge would vary." But, is the $2,300 price even accurate for anyone? Thanks to a reader comment, we see that this similar item on New GM Parts makes it look like the lithium-ion modules that Kelly mentioned – where a lot of the expensive bits are – are not included.