2000 Saturn LS suspension problems

“THE WHOLE SUBFRAME ON MY 2000 SATURN LS IS ROTTED SO BAD THAT I CAN'T EVEN DRIVE THE VEHICLE. IT STARTED WITH MY CAR NOT STARTING AND PUTTING IT UP ON A LIFT TO SEE WHAT THE PROBLEM WAS. THAT NOT STARTING PROBLEM IS A BAD RESONATOR, BUT IN THE PROCESS THE SUBFRAME WAS FOUND TO BE SERIOUSLY ROTTED AWAY. *TR”

“TOOK CAR TO HAVE STRUTS REPLACED AND WAS TOLD THE SUB FRAME HAD RUSTED AWAY TO MAKE THE CAR UNSAFE TO DRIVE,ALWAYS CHECKED THE BODY AND FRAME YEARLY FOR RUST ON CHASSIS AND UNI BODY SO THERE WOULD NOT BE ANY POTENTIAL PROBLEM S. I LIVE IN THE NORTHEAST PART OF THE USA.. THE PROBLEM WITH THE SUB FRAME IS IT RUSTS FROM THE INSIDE OUT SO IT MAKES INSPECTION EXTREMELY HARD TO SEE. *TR”

“DRIVING DOWN THE ROAD THE VEHICLE STARTED MAKING NOISE AND STEERING WAS UNCONTROLLABLE. I TRAILERED THE VEHICLE BACK HOME. CLOSER INSPECTION REVEALED THE FRONT SUBFRAME/ENGINE CRADLE WAS COMPLETELY RUSTED THROUGH IN MULTIPLE SPOTS, VERY DANGEROUS!!! I CONTACTED THE DEALER TO GET A NEW SUBFRAME AND I WAS ADVISED THE SUBFRAME IS NO LONGER AVAILABLE AND TO TRY FINDING ONE IN A SALVAGE YARD. I CONTACTED A SALVAGE YARD AND THEY SAID THEY HAD A FEW AND IT WOULD BE NO PROBLEM TO PULL ONE. I GOT THE CALL TODAY SAYING THEY WERE SORRY BUT ALL OF THE FRONT SUBFRAMES ON THE SATURN L SERIES THEY HAVE ARE RUSTED THROUGH AND ARE NOT USABLE. I CONTACTED OTHER YARDS WITH THE SAME RESPONSE. I ENDED UP HAVING TO FIND A SALVAGE YARD DOWN SOUTH THAT HAD A USABLE SUBFRAME. I WENT ONLINE TO FIND NUMEROUS FORUM POSTS DISCUSSING THIS TOPIC AND I'M FINDING IT IS VERY COMMON ON THIS VEHICLE. WHY WAS THERE NEVER A RECALL FOR THIS WITH SUCH A WIDESPREAD SAFETY HAZARD? FROM WHAT I CAN TELL IT HAPPENS ON ALL MODEL YEARS OF THE L SERIES. THE IRONY IS THE REST OF THE CAR IS VERY CLEAN, NO RUST ON THE REST OF THE UNDERCARRIAGE. THERE IS NO CLEAR EXPLANATION WHY THE SUBFRAME WOULD HAVE CORROSION…”

“THIS HAPPENED VERY SUDDENLY. I APPLIED THE BRAKE TO ENTER THE RAMP TO THE HIGHWAY AND THE CAR PULLED TO THE LEFT AND MADE A NOISE. I THOUGHT IT MAY BE A BEARING OR BRAKE PROBLEM BUT I HAD NOT HAD ANY ISSUES BEFORE THAT SO I WENT ON SINCE IT SEAMED TO BE DRIVING OK. WHILE I WAS ON THE INTERSTATE I WENT TO GO INTO THE LEFT LANE AND REALIZED THERE WAS A SERIOUS PROBLEM WITH THE STEERING. I SLOWED DOWN AND GOT OFF THE HIGHWAY TO THE SHOP. I WAS TOLD THERE THE K FRAME HAD LESS THAN 1/2" BEFORE BREAKING COMPLETELY AND COULD HAVE BEEN A SERIOUS ACCIDENT SINCE IT HAS TO DO WITH STEERING. I HAVE REGULAR MAINT ON THE CAR AND THERE WAS NO INDICATION THAT THIS MIGHT HAPPEN. THE UNDERSIDE IS IN VERY GOOD SHAPE. I HAD THE FRAME REPLACED. I FEEL IT WAS A DEFECT IN THE FRAME. I'M SURE IM NOT THE ONLY ONE THIS HAS HAPPENED TOO. *KB”

“VEHICLE PULLED WHEN BRAKING. SYMPTOMS STARTED ON A MONDAY AS A LIGHT PULL. MORE NOTICEABLE ABOVE 50 MPH, AND NOT NOTICEABLE BELOW 35. BY THURSDAY MORNING, PULL WAS SEVERE ABOVE 50MPH. STAYED TILL AFTER 6:00 AT NIGHT TO AVOID TRAFFIC. RIDE HOME WAS "ENTERTAINING" AS STEERING WHEEL DID NOT ALWAYS GO BACK TO "CENTER" WHEN GOING STRAIGHT. I THOUGHT I NEEDED A STEERING RACK UNTIL I INSPECTED THE VEHICLE ON SATURDAY. MY INSPECTION SHOWED THAT FRONT SUBFRAME (A.K.A. ENGINE CRADLE) FAILED WHERE THE "PASSENGER SIDE LOWER CONTROL ARM REAR BUSHING WAS ATTACHED". A SIZABLE PIECE OF FRAME RIPPED OUT, WITH BUSHING STILL ATTACHED TO LOWER CONTROL ARM. RUSTED PERFORATIONS IN SUBFRAME VISIBLE APPROXIMATELY 6" BEHIND WHERE FRAME FAILED. TWO SETS OF RIMS (SUMMER AND WINTER) WITH NO "DINGS" TESTIFIES THAT VEHICLE NEVER EVEN HIT A CURB IN 170,000 MILES. 4 CYLINDER, SO NO EXHAUST NEARBY TO "WEAKEN STEEL". BAD CHOICE OF CORROSION PROTECTION IN A CRITICAL PART OF THE FRAME, AND/OR UNDERSIZING OF STEEL THICKNESS TO ACCOMMODATE FOR CORROSION IS MY ESTIMATE OF "FAILURE MODE". CONTACTED DEALER AND NO REPLACEMENT PARTS AVAILABLE. WELL MAINTAINED VEHICLE, VERY DISAPPOINTED IT FAILED THIS…”

“CUSTOMER HAS SEVERAL QUESTIONS ABOUT HIS SATURN INCLUDING IGNITION AND TIRE REPLACEMENT**CC THE CRANK SENSOR WAS REPLACED, THE SHIFT LIGHT INDICATOR IN THE DRIVE POSITION WENT OUT WHILE THE HEADLIGHTS WERE ON. THE AC WAS NOT COOLING WHEN THE VEHICLE WAS IN IDLE. THE TIRES HAD SEVER CUPPING FOLLOWING FOUR CROSS ROTATIONS DUE TO A BAD REAR WHEEL ALIGNMENT. THE IGNITION WOULD NOT UNLOCK. *JB”