Product Safety - Steering Column Intermediate Shaft Undersized

ON FEBRUARY 7, 2003, ALL VEHICLES INVOLVED IN THIS RECALL WERE PLACED ON STOP DELIVERY. AFTER THE RECALL SERVICE PROCEDURE IS COMPLETED, THE VEHICLES MAY BE DELIVERED TO CUSTOMERS.

GENERAL MOTORS IS CONTACTING CUSTOMERS OF INVOLVED VEHICLES VIA TELEPHONE. CUSTOMERS ARE BEING INSTRUCTED TO CALL THEIR SERVICING DEALER TO HAVE THEIR VEHICLE TOWED INTO THE DEALERSHIP. DEALERS ARE TO MAKE ARRANGEMENTS TO HAVE THE VEHICLE TOWED AND ARE TO PROVIDE THE CUSTOMER WITH COURTESY TRANSPORTATION UNTIL THE RECALL CAN BE PERFORMED ON THEIR VEHICLE.

EXISTING PARTS AT GMSPO ARE BEING INSPECTED AND CONFIRMED AS GOOD INVENTORY. ADDITIONAL INVENTORY WILL BE AVAILABLE FOR DEALER ORDERS BY 2/14/03. IN THE RARE CASE THAT A PART IS REQUIRED, PLEASE CONTINUE TO HOLD THE VEHICLE UNTIL A PART CAN BE OBTAINED FROM GMSPO.

THE INVOLVED VIN BREAKPOINTS HAVE BEEN REVISED. SEE TABLE BELOW FOR REVISED BREAKPOINTS.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2003 model year Buick Rendezvous and Pontiac Aztek vehicles. Some of these vehicles have a steering column intermediate shaft that is undersize. The undersize condition could allow the intermediate shaft to spin inside the steering column coupling, resulting in loss of directional control of the vehicle. If this were to happen while the vehicle is moving, a crash could result without prior warning.

Dealers are to inspect, and replace if necessary, the steering column intermediate shaft.

Involved are certain 2003 Buick Rendezvous and Pontiac Aztek model vehicles built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. 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 hard copy of the recall bulletin. Verify vehicle eligibility by using GMVIS, GM Access Screen, or DCS Screen 445, whichever is applicable. 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.

*Important: Due to the small number of vehicles expected to require a replacement, and due to limited INITIAL parts availability, dealers are encouraged not to order recall parts for use as shelf stock. Parts should only be ordered when inspection determines that it is necessary to replace the intermediate steering shaft.

The following procedure provides instructions for inspecting the thickness of the intermediate steering shaft located between the base of the steering column and the steering gear.

Intermediate Steering Shaft Inspection

Important: In cold climates, it will be necessary to allow the vehicle to warm up in order to reposition the seal (boot) located on the intermediate steering shaft. The labor time allowance includes the warm-up time.

Important: The front wheels must be positioned straight ahead when performing this procedure.

1. Start the engine, place the HVAC controls on floor heat with the blower on high, and allow the vehicle to warm up for 10 minutes. After the warm-up is complete, turn the ignition switch to the OFF position.
2. Remove the close-out panel located under the driver's side of the instrument panel (I/P) by pulling down along the rear edge to release the retaining clips.
3. Disconnect the courtesy lamp, unclip the yellow electrical connector, and remove the panel.



4. From underneath the I/P, disconnect the boot (2) that connects to the lower end of the steering column (1).
5. Move the boot down as necessary to expose the intermediate shaft (3).



6. While holding the boot (2) down, using a caliper (3) or micrometer, measure the thickness of the intermediate steering shaft (1) as shown.

•	If the thickness of the intermediate shaft is 16.90 mm (0.6655 in) or MORE, the intermediate shaft does NOT need to be replaced. Proceed to the next step.

•	If the thickness of the intermediate shaft is 16.89 mm (0.6654 in) or LESS, the intermediate shaft MUST BE REPLACED. Proceed to the service procedure titled "Intermediate Steering Shaft Replacement."

7. Reinstall the boot to the base of the steering column.
8. Connect the courtesy lamp and attach the yellow electrical connector to the close-out panel.
9. Position the close-out panel to the underside of the I/P and engage the retaining clips.
10. Install the GM Recall Identification Label.

Intermediate Steering Shaft Replacement

This procedure should only be performed if the intermediate steering shaft inspection results indicate that a replacement is required. For additional information, refer to the appropriate section of the Service Manual. The labor time for performing this procedure includes the time necessary for checking alignment and setting toe-in.

Important: Before installing a NEW replacement intermediate steering shaft, you must inspect the thickness of the shaft as described in the inspection procedure contained in this bulletin. If a replacement part is found to be 16.89 mm (0.6654 in) or LESS, it must NOT be used and should be returned to GMSPO via MR Code 12 and refer to bulletin number.

1. Turn the ignition switch to the ON position and turn the steering wheel 90 degrees to the right.
2. Turn the ignition switch to the OFF position to lock the steering column.

Important: The steering column must be in the LOCK position before disconnecting the intermediate steering shaft.

3. With the seal (boot) already repositioned, remove the bolt that attaches the intermediate steering shaft to the base of the steering column.
4. Push the intermediate steering shaft down and away from the base of the steering column. If you are unable to remove the intermediate shaft from the steering column, perform the following steps:

•	Insert the tip of a large flat-bladed tool into the intermediate steering shaft end slot.

•	Twist the large flat-bladed tool in order to loosen the intermediate steering shaft.

5. Raise and support the vehicle on a suitable hoist.
6. Remove the left front tire and wheel assembly.
7. Support the rear of the engine frame (cradle) and remove the two rear cradle bolts.
8. Lower the rear of the cradle as necessary to access the intermediate steering shaft where it connects to the steering gear.

Important: It may be necessary to move (steer) the front wheels left or right to allow for access to the bolt in the next step.

9. Release the boot from the steering gear and reposition it to access the bolt attaching the intermediate steering shaft to the steering gear.
10. Remove the bolt attaching the intermediate shaft to the steering gear.
11. Push the intermediate steering shaft upwards to separate it from the steering gear. If you are unable to separate it, perform the following steps.

•	Insert the tip of a large flat-bladed tool into the intermediate steering shaft end slot.

•	Twist the large flat-bladed tool in order to loosen the intermediate steering shaft.

12. Remove the intermediate steering shaft.
13. Install the NEW intermediate steering shaft inside of the boot.
14. Connect it to the steering gear and install the bolt.

Tighten
Tighten the bolt to 48 N·m (35 lb ft).

15. Connect the boot to the steering gear.
16. Install the left front tire and wheel assembly.

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

17. Raise the rear of the cradle and install the two bolts.

Tighten
Tighten the bolts to 165 N·m (122 lb ft).

18. If the front wheels were steered to the left or right to access the lower bolt, return them to their original position.
19. Lower the vehicle.

Important: It may be necessary to slightly align the intermediate steering shaft to the steering column if the front wheels were steered when previously accessing the lower bolt.

20. Connect the intermediate steering shaft to the steering column.
21. Install the bolt.

Tighten
Tighten the bolt to 48 N·m (35 lb ft).

22. Reinstall the boot to the base of the steering column.
23. Connect the courtesy lamp and attach the yellow electrical connector to the close-out panel.
24. Position the close-out panel to the underside of the I/P and engage the retaining clips.
25. Check the alignment and set toe-in as necessary.
26. 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. 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.

Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

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

Dealers in possession of vehicles included in the Stop Delivery are eligible for reimbursement of floor plan expense upon completion of this recall. This reimbursement is limited to the number of days from the Stop Delivery message to receipt of the recall parts and/or repair procedures. Floor plan reimbursement beyond these dates is not allowed. The amount of reimbursement should be charged as a net amount expense using the recall labor operation provided.

Dealers are to provide customers with a comparable rental vehicle until the recall correction can be performed on their vehicle.

Submit a Product Recall Claim with the information indicated below:

Refer to the General Motors WINS Claims 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). In addition, Buick and Pontiac Outbound Calling Centers will be contacting customers of involved vehicles via telephone.

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which 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 to provide 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.

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.

Important: You may have already been contacted regarding this recall by your GM dealer or by the GM Customer Assistance Center. If not, please contact your GM dealer IMMEDIATELY and tell the service department that your vehicle is involved in recall 03009. DO NOT DRIVE YOUR VEHICLE.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2003 model year Buick Rendezvous and Pontiac Aztek vehicles. In some of these vehicles, the diameter of the steering column intermediate shaft is too small. This condition could allow the intermediate shaft to spin inside the steering column coupling, resulting in loss of directional control of the vehicle. If this were to happen while the vehicle is moving, a crash could result without prior warning.

Dealers are to inspect, and replace if necessary, the steering column intermediate shaft. This service will be performed for you at no charge .

The length of time required to perform this inspection is approximately 25 minutes. If the steering column intermediate shaft requires replacement, another hour and 15 minutes will be required. Additional time may be required to schedule and process your vehicle. If you dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed to schedule, process and repair your vehicle.

Please contact your GM dealer immediately to arrange to have your vehicle towed to the dealership. Parts are available and 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.

Your GM dealer will provide you with a comparable rental vehicle while your vehicle is being repaired.

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