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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:    

The real costs of keeping a Chevy Volt on the road

The release of the new, 2016 Chevy Volt is sure to bring a surge of used electric vehicles to the market as early adopters trade their older models in. Many of these cars are selling for a fraction of their original price, thanks in part to federal and state incentives that lowered the initial cost to the first owner, which opens these cars up to a whole new class of consumers. While the prices are getting attractive, potential buyers are still hesitant to buy a used EV due to uncertainty about service and repair costs, but there may be some good news on the horizon. The Chevy Volt comes with a battery warranty that is good for at least 8 years and 100,000 miles, but many of the Volts popping up on the market have passed that 100,000-mile mark. The threat of needing a new battery can be a deterrent, especially with some dealers quoting prices as high as $34,000 for a full "drive motor battery replacement." That sum is more than the MSRP of a 2016 model. Some of the fear of EV maintenance and repair comes from the mystery of the individual pieces that make up the drivetrain and charging system. If we take a look at the Volt in terms of analogs to a traditional internal-combustion vehicle, the outlook becomes a little more friendly. The Volt battery pack consists of three lithium-ion modules in a T-shaped arrangement, each of which can be serviced individually. Module 1 is made up of 90 cells and corresponds to GM part number 22954462, which retails for $3,258.33; module 2 is made up of 72 cells and corresponds to GM part number 22954463, which retails for $2,930.00; lastly, module 3 is made up of 125 cells and corresponds to GM part number 22954464, and retails for $4,933.33. These part numbers have been added to the dealer order systems but have not shown up in the distribution centers at this time. Although all three of the modules add up to a fairly large $11,121.66 total and are still on hold for dealer ordering, the good news is that in most cases these battery cell modules do not need to be replaced. There are many other individual pieces mounted on the battery pack that are serviceable, such as the Battery Energy Control Modules (BECM) and the Battery Interface Control Modules (BICM). These modules control and monitor the battery packs and charging system and have been known to fail while the lithium-ion battery cells are not at fault. Some have been replaced under warranty, but if you are stuck buying one they run about $255 a piece for the part.

Battery Show 2015: Genovation GXE Corvette EV designed for the 'Ring

The Genovation GXE all-electric Corvette has broken cover. At the Battery Show 2015 in Novi, MI, this week, the converted C6 Z06 Corvette that we first heard about back in August was tucked into a booth along the back wall. Don't let the demure location fool you. This is a muscle-y electric vehicle, ready to roar into the limited-run, expensive EV game. The Genovation GXE Corvette can go from 0-60 miles per hour in three seconds and has a top speed of 200 mph. The powertrain was designed and built in the US, and offers over 700 horsepower and over 600 pound-feet or torque. With a near 50/50 weight distribution, this is "a real driver's car," Genovation CEO Andrew Saul told AutoblogGreen. Saul said that the GXE was designed to do two hard laps at Nurburgring thanks to a 44-kWh battery pack uses the same sort of cylindrical 18650 cells that you can find in a Tesla. That translates to about 40-50 miles of fast, on-road driving, Saul said, or 150 miles on the New York City test cycle. That particular test, "simulates low speed urban driving with frequent stops," according to DieselNet. The car also has a 6-kW charger and a six-speed manual transmission and the adjustable regenerative braking levels can be controlled by paddles on the steering wheel. Of course, none of those performance figures have been proven yet because the GXE hasn't had a chance to hit the road. Saul said that it will take another three-to-four weeks to finish the build and then, finally, there will be a few weeks of road testing. This will include a quarter-mile run on a track as well as a trip to Nevada to do a several-mile top speed test. If all of that sounds like something you're interested in, then get ready to open your wallet wide and wait. Saul said that buying one will set you back $330,000 (just $290,000 if you bring your own C6 Z06). Genovation also won't be making all that many. Saul said he expects to put the GXE into limited production of under 200 units, starting off at maybe five or 10 a year. Featured Gallery Battery Show 2015: Genovation GXE All-Electric Corvette View 14 Photos Green Chevrolet AutoblogGreen Exclusive Electric exclusive corvette genovation