[Federal Register Volume 66, Number 215 (Tuesday, November 6, 2001)]
[Notices]
[Pages 56145-56146]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 01-27869]


-----------------------------------------------------------------------

DEPARTMENT OF TRANSPORTATION

National Highway Traffic Safety Administration


Denial of Motor Vehicle Defect Petition, DP00-008

AGENCY: National Highway Traffic Safety Administration (NHTSA), 
Department of Transportation.

ACTION: Denial of petition for a defect investigation.

-----------------------------------------------------------------------

SUMMARY: This notice sets forth the reasons for the denial of a 
petition submitted to NHTSA under 49 U.S.C. 30162, requesting that the 
agency commence an investigation into an alleged defect in the water 
pump in model year (MY) 1994-1998 Saab 900S motor vehicles.

FOR FURTHER INFORMATION CONTACT: Ms. Jennifer Russert, Office of 
Defects Investigation (ODI), NHTSA, 400 Seventh Street SW., Washington, 
DC 20590. Telephone: (202) 366-1869.

SUPPLEMENTARY INFORMATION: On September 18, 2000, Mr. Avery B. Goodman 
submitted a petition requesting NHTSA to open an investigation into an 
alleged defect in MY 1994-1998 Saab 900S vehicles. In April 1997, Saab 
Automotive AB (Saab) had issued Customer Satisfaction Campaign 10445, 
which referred to the replacement of the water pumps in MY 1994-1996 
Saab 900 vehicles with four-cylinder engines. Saab stated that load 
variations in the belt circuit could cause the water pump pulley to 
crack at the hub center, subsequently causing the drive belt to jump 
off the pulley. In the event of a failure, there would be a loss of 
belt tension, causing loss of power steering, as well as other belt 
driven functions. The petitioner alleged a safety-related defect in his 
MY 1994 Saab 900, stating that the water pump pulley broke off at the 
weld to the pulley shaft. The petitioner was concerned that the water 
pump pulley failure resulted in the loss of power steering, air 
conditioning, and engine cooling systems.
    The MY 1994 Saab 900 was a new vehicle design (with the exception 
of the convertible, which carried over the previous generation design 
until the 1995 model year). Engine positioning was changed, and a new 
accessory drive design was implemented. The new drive design featured a 
water pump with the drive belt pulley welded onto the pump shaft. In 
December 1994, Saab became aware of problems with cracking of the water 
pump pulley and subsequent loss of drive power to the air conditioning 
compressor, alternator, and power steering pump through warranty claim 
data.
    Upon analysis, Saab discovered weld fatigue cracks at the water 
pump/pulley junction. Saab determined that the root cause was the 
center of the drive belt not being aligned with the center of the water 
pump pulley attachment. This induced rotational bending of the pulley 
at the weld joint to the water pump shaft, in line with applied drive 
belt load. Continual bending as the pulley rotated under normal engine 
drive conditions subsequently caused fatigue cracks in the weld.
    Cracking of the water pump pulley center hub can result in the 
pulley separating from the water pump shaft, causing the drive belt to 
jump off of the pulley, and subsequently cause loss of drive belt 
tension. Loss of belt tension would cause a loss of power drive to the 
following components: Air conditioning compressor, engine water coolant 
pump, alternator, and power steering pump
    Testing of a bolted pulley demonstrated the added strength of the 
bolted pulley design and no signs or potential for fatigue cracking. 
The bolted pulley design was implemented into vehicle production early 
in MY 1996 and Saab subsequently decided to implement Customer 
Satisfaction Campaign 10445 worldwide. Under that campaign, dealers 
were to inspect the water pump belt pulley. If there was no yellow 
identification mark, indicating that a newly designed water pump had 
been installed, and the pulley was not attached to the pump by bolts, 
dealers were to replace the pump.
    There have been 4 complaints (including that of the petitioner) to 
NHTSA of problems with the power steering assist, water pump, water 
pump pulley, or similar concerns on MY 1994-1996 Saab 900 vehicles. One 
occurred on a new MY 1995 vehicle, the other three, including the 
petitioner's, occurred on MY 1994 vehicles in 1999. Saab reported an 
additional 5 complaints (Saab had a total of 8 complaints, but 3 
duplicated ODI complaints) of similar water pump pulley failures on MY 
1994-1996 vehicles since the initiation of Campaign 10445. There have 
been no reports of problems with the power steering assist, water pump, 
water pump pulley, or similar concerns on MY 1996, 1997 and 1998 Saab 
900 vehicles.
    If the pulley fails, engine cooling, power steering assist, 
generator charging ability, and the air conditioning would all fail. 
The petitioner expressed concern with the loss of power steering and 
alleged he had difficulty controlling his vehicle on the freeway. 
Although he did not mention his speed, he said he was slowing and 
attempting to exit the freeway. In a study conducted by Saab in October 
1993, unrelated to this petition, loss of power steering assistance was 
analyzed to determine what effect it could have on a driver's ability 
to maintain steering control. Saab concluded that without the variable 
power assist, subject vehicles could be controlled safely at highway 
speeds. The agency's experience supports Saab's conclusion that 
vehicles can be controlled at highway speeds despite a loss of power 
steering. With a loss of power steering at low speeds, it is still 
possible to complete a turn or a parking maneuver, although it 
typically takes more effort on the part of the driver to turn the 
steering wheel. While slowly

[[Page 56146]]

turning a corner, or parking, loss of power steering does not pose a 
significant risk to traffic safety. The loss of drive to the generator 
prevents the vehicle's battery from being charged, but is a progressive 
loss of battery power and does not represent a safety concern. Loss of 
engine cooling could cause the vehicle to overheat, typically resulting 
in coolant overflow at the radiator or a burst cooling system hose, 
however, there have been no reports of such incidences. Air 
conditioning is an auxiliary function, the loss of which does not 
affect the safe operation of the vehicle.
    In view of the foregoing, it is unlikely that NHTSA would issue an 
order for the notification and remedy of the alleged safety-related 
defect as defined by the petitioner in the subject vehicles at the 
conclusion of the investigation requested in the petition. Therefore, 
in view of the need to allocate and prioritize NHTSA's limited 
resources to best accomplish the agency's safety mission, the petition 
is denied.

    Authority: 49 U.S.C. 30162(d); delegations of authority at CFR 
1.50 and 501.8.

    Issued on: November 1, 2001.
Kathleen C. DeMeter,
Director, Office of Defects Investigation, Safety Assurance.
[FR Doc. 01-27869 Filed 11-5-01; 8:45 am]
BILLING CODE 4910-59-P