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Switch failure prompts Chevy Malibu Hybrid recall

by Justin King

The high-voltage switch can disconnect while driving, disabling the vehicle.

General Motors has identified a defect that can unexpectedly disable its 2016 Chevrolet Malibu Hybrid.

The vehicles are equipped with a manual service disconnect (MSD) switch that disconnects the high-voltage battery before servicing. In some cases, the MSD switch was not installed properly and may not be locked in position.

"Improperly installed MSDs could become loose and disconnect while driving, which would cut off all high-voltage power to the vehicle," the company warns. "A vehicle stall increases the risk of a crash."

The problem was first identified by a GM quality manager during a scheduled ride, prompting a deeper analysis that identified the assembly error. The company then used OnStar to ping the entire fleet, taking voltage measurements to determine which vehicles left the factory without the switch properly locked.

The campaign affects 534 vehicles sold in the US market.

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