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Why an independent rear suspension for GM's new, full-sized SUVs wasn't easy

A Motor Trend report last month laid out how Cadillac's 4.2-lier twin-turbo Blackwing V8 could be an orphan due to cost concerns in the GM empire. Last-minute chassis changes to Cadillac's new sedans and XT6 crossover led to engine bays that couldn't fit the Blackwing. On the SUV side, according to the report, the new independent rear suspension for big people haulers cost so much to implement that GM ruled out reworking the Escalade to accept the Blackwing. At least one commenter rightly asked how could a suspension swallow that much money. A new piece in Motor Trend has the answer. The excellent Alissa Priddle spoke to Tim Herrick, GM's executive chief engineer for full-size trucks, about why the clean-sheet IRS cost "multimillions of dollars."  First, GM would need to build a new body shop at the Arlington, Texas plant that assembles the automaker's big SUVs to stamp the numerous wholly new parts and panels accommodating an IRS. Then GM would need to design and pay for a new assembly process. On top of those up-front costs, there was the incremental cost of the four-link IRS components being more expensive than those in the trucks' former leaf-sprung solid axles. Herrick endured so many rejections for so long that he remembers the date and time when he got approval for the new unit. He said it came down to a meeting where he told a higher-up, "I'll make you a deal: If we get to the reveal, or if we launch this and you think this was a dumb idea, I'll hand you my badge and let you walk me out." Head to Motor Trend to read the full story. Based on Herrick being on stage to help present the new SUVs to the press, and on our First Ride in the new Chevrolet Tahoe and Suburban at GM's Milford Proving Grounds, it appears this will have a happy ending for all involved. Furthermore, since Herrick worked on the T1 platform that supports the big SUVs as well as the light- and heavy-duty pickups, he understood the demands on the commercial side, too. That could be why when Roadshow asked Tim Asoklis, chief engineer of the Tahoe and Suburban, if the new IRS could endure life in the Chevrolet Silverado and GMC Sierra, Asoklis answered, "Oh, absolutely." Related Video:    

Mysterious white powder discovered at GM Orion Assembly

Workers at General Motors Orion Assembly Plant in Orion Township, MI uncovered a mysterious white powder in two different parts of the factory earlier this week, raising concerns about worker safety. "We can confirm that an unknown substance (white powder) was found on the floor outside of Gate 6 at Orion Assembly on Monday, August 29. On Tuesday, August 30, we had a second report of a bottle containing a similar substance found inside the plant," GM spokesperson Dayna Hart told The Oakland Press via email. GM stressed that incident didn't disrupt operations at the plant, and that the company was taking steps to ensure the safety of the sprawling factory's workers. That did include, an anonymous worker told The Oakland Press, closing off parts of the factory for two full days, as drug-sniffing dogs and crews in haz-mat suits descended on the area. "A sample of the substance has been sent to a laboratory for identification and results are expected later this week," Hart said. "All findings and actions have been shared with our employees." Orion Assembly currently builds the Chevrolet Sonic and Buick Verano, and will eventually be responsible for production of the new, all-electric Chevy Bolt early next year. Related Video:

Worldwide, Nissan Leaf has outsold next two competitors combined

Nissan may not be meeting some of the more optimistic prognostications with sales of its Leaf electric vehicle, but it's certainly kicking the competition's butt. EV Sales is tracking global sales of plug-in vehicle models and estimates that Nissan has sold almost 172,000 units of the Leaf worldwide. That's more than the two next-best-selling plug-ins combined. Globally, EV Sales estimates, the Chevrolet Volt extended-range plug-in has moved about 88,000 units, while Toyota has sold about 71,000 of its Prius Plug-in Hybrid vehicles worldwide. Fourth-place Tesla Model S is close behind at about 66,000 units. Among automakers, Nissan is also by far the lead dog, but Mitsubishi has leapfrogged Chevrolet among plug-in vehicle makers, as the Outlander Plug-in Hybrid continues to sell well. Impressively, the relatively new BMW i3 has moved almost 23,000 units since its debut in Germany last year. As for Nissan, company chief Carlos Ghosn said at the New York Auto Show earlier this month that the company could sell as many as 50,000 units a year of the Leaf in the US, provided that charging infrastructure throughout the country improves. Earlier this year, cumulative US Leaf sales moved past 75,000 units since its late-2010 launch. Related Videos: Featured Gallery 2013 Nissan Leaf View 55 Photos News Source: EV Sales Green Chevrolet Nissan Electric volt