F/CMVSS Noncompliance - Right Rear Brake Hose Fitting

General Motors has decided that certain 2004 model year Pontiac Grand Prix vehicles fail to conform to Federal/Canada Motor Vehicle Safety Standard 135, "Passenger Car Braking Systems." On some of these vehicles, the right rear brake hose fitting may not be tightened properly and a brake fluid leak could occur. If the brake fluid level in the master cylinder reservoir dropped to the indicator limit, the brake system warning light would be activated. If enough additional fluid leaks, the brake pedal will be lower than normal and stopping distances will be longer. If this occurs when stopping distance is limited, a crash could occur.

Dealers are to tighten the right rear brake hose fitting to the proper torque specification, and add brake fluid if necessary.

Involved are certain 2004 model year Pontiac Grand Prix vehicles built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall.

Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

The following procedure provides instructions for inspecting the bolt that attaches the RIGHT rear brake hose to the brake caliper, and if necessary, bleeding the right rear brake.

Inspection

1. Raise the vehicle on a suitable hoist and support as necessary.
2. Remove the RIGHT rear tire and wheel assembly.




Important: The left rear brake caliper and hose is being shown for reference purposes only. The right rear caliper and hose that is being inspected in this recall is similar.

3. Carefully inspect the bolt that attaches the right rear brake hose to the brake caliper for leaking brake fluid.

•

If there is NO indication of brake fluid leakage where the bolt and hose attach to the brake caliper, hold the brake hose fitting firmly in position at the caliper and verify that the bolt is tightened to 48 N·m (35 lb ft). Reinstall the tire and wheel. Tighten the wheel nuts to 140 N·m (103 lb ft). Lower the vehicle. Install the GM Recall Identification Label.

•	If there is brake fluid leaking where the bolt and hose attach to the brake caliper, hold the brake hose fitting firmly in position at the caliper and tighten the bolt to 48 N·m (35 lb ft). Proceed to the Right Rear Brake Bleeding Procedure below.

Right Rear Brake Bleeding Procedure

This bleeding procedure should only be performed if the results of the Inspection Procedure indicated that there was a brake fluid leak. Bleeding the hydraulic system is done using a pressure bleeder and is limited to the right rear brake. This pressure bleeding procedure is a shortened version of the full-vehicle procedure found in the Service Manual. As a result, the labor time included in this recall for bleeding the brake system is less than the published time found in the LTG.

Tools Required

Important: 

1. Lower the vehicle as necessary to allow for manual bleeding of the right rear brake assembly.

Caution: Refer to the Brake Fluid Irritant Caution in the Cautions and Notices section of the appropriate Service Manual.

Notice: Refer to the Brake Fluid Effects on Paint and Electrical Components Notice in the Cautions and Notices section of the appropriate Service Manual.

Notice: When adding fluid to the brake master cylinder reservoir, use only DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination, which could result in damage to the internal rubber seals and/or rubber linings of the hydraulic brake system components.

2. Open the hood.
3. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Fill the brake master cylinder reservoir as necessary with Delco Supreme 11®, GM U.S. P/N 12377967, GM Canadian P/N 89021320, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
4. Install the J 35589-A to the brake master cylinder reservoir.
5. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme 11®, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point.
6. Connect the J 29532, or equivalent to the J 35589-A.
7. Charge the J 29532, or equivalent, air tank to 175-205 kPa (25-30 psi).
8. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system.
9. Wait approximately 30 seconds, and then inspect the right rear brake hose to brake caliper-attaching bolt for signs of leakage. Any brake fluid leak identified must be repaired prior to completing this bleed procedure.
10. Install a proper size box-end wrench onto the right rear wheel hydraulic circuit bleeder valve (screw) located on the brake caliper.
11. Install a transparent hose over the end of the bleeder valve.
12. Submerge the open end of the transparent hose into a transparent container partially filled with DOT-3 brake fluid with a clean, sealed brake fluid container.
13. Loosen the bleeder valve to purge the air fro the right rear wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, and then tighten the bleed valve.
14. Close the J 29532, or equivalent, fluid tank valve, and then disconnect the J 29532 or equivalent, from the J 35589-A.
15. Remove the J 35589-A from the brake master cylinder reservoir.
16. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
17. Connect a Tech 2 to the vehicle's diagnostic link connector (DLC) and perform the automatic bleed procedure.
18. After completion of the automatic bleed procedure, slowly depress the brake pedal and verify that if feels firm. Release the pedal.
19. Verify that the fluid in the master cylinder reservoir is at the maximum-fill level.
20. Install the tire and wheel assembly.

Tighten
Tighten the wheel nuts to 140 N·m (103 lb ft).

21. Install the GM Recall Identification Label.

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle.

For US

When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

For Canada

Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering.

The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

Refer to the General Motors WINS Claim Processing Manual for details on Product Recall Claim Submission.

Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter included with this bulletin).

FOR US (US States, Territories, and Possessions)

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale.

ALL

All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

General Motors has decided that certain 2004 model year Pontiac Grand Prix vehicles fail to conform to Federal/Canada Motor Vehicle Safety Standard 135, "Passenger Car Braking Systems." On some of these vehicles, the right rear brake hose fitting may not be tightened properly and a brake fluid leak could occur. If the brake fluid level in the master cylinder reservoir dropped to the indicator limit, the brake system warning light would be activated (see your Owner's Manual for more information). If enough additional fluid leaks, the brake pedal will be lower than normal and stopping distances will be longer. If this occurs when stopping distance is limited, a crash could occur.

Your GM dealer will tighten the right rear brake hose fitting to the proper torque specification, and add brake fluid if necessary. This service will be performed for you at no charge .

It will take approximately 20 minutes to tighten the right rear brake hose fitting. If the addition of brake fluid is necessary, an additional 20 minutes will be required. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

Please contact your GM dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer.

Your GM dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the number listed below:

If, after contacting the appropriate customer assistance center, you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street SW, Washington, DC 20590 or call 1-888-327-4236.

The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the attached and mailing it in the postage paid envelope.

If your vehicle is within the New Vehicle Limited Warranty your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products.

General Motors Corporation

Enclosure