Product Safety - Drive Axle Pinion Seal Leak-Replace Seal

The Part Information and Claim Information sections in this bulletin have been revised to include four bolts for the Daewoo G2X, Pontiac Solstice, Saturn SKY and Opel GT vehicles, and a gasket for SRX RHD vehicles. Discard all copies of bulletin 07204C, issued March 2008.

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005-2007 model year Cadillac CTS, CTS-V, SRX, STS; 2006-2007 model year Cadillac STS-V; 2007 model year Daewoo G2X and Opel GT; 2006-2007 model year Pontiac Solstice; and 2007 model year Saturn SKY vehicles. The drive axle differential seal (two on all-wheel drive vehicles) may leak because it does not meet GM's specifications. If a seal is leaking, there will be fluid on the ground where the vehicle is parked. If enough fluid leaks, the differential will become noisier because of reduced lubrication. After about two-thirds of the differential fluid is lost, the bearings may no longer be lubricated and may start to overheat. Damage to the bearings and other differential components could then occur. Damaged bearings will create noise that may be heard by the vehicle occupants. If the vehicle is not repaired and damage progresses, three conditions can occur: (1) When the vehicle is stopped and shifted to reverse, the differential may jam and prevent vehicle movement; (2) the damage can cause drag that will feel like the brake is applied; or (3) the differential could jam and lock the drive wheels while the vehicle is in motion. If (3) occurs, the driver may not be able to control the vehicle and a crash could occur without warning.

Dealers/retailers are to install a new drive axle differential seal (two on all-wheel drive vehicles).

Involved are certain 2005-2007 model year Cadillac CTS, CTS-V, SRX, STS; 2006-2007 model year Cadillac STS-V; 2007 model year Daewoo G2X and Opel GT; 2006-2007 model year Pontiac Solstice; and 2007 model year Saturn SKY vehicles built within these VIN breakpoints:

Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.

For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned.

-- US GM dealers - GM DealerWorld Recall Information

-- Canadian GM/Saturn dealers/retailers - GMinfoNet Recall Reports

-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)

-- Export dealers - sent directly to dealers

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

GM and Saturn Canada Only: Parts required to complete this program are to be obtained from General Motors Service and 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.

Saturn US Only: A pre-shipment of the required parts to perform this repair has been sent to involved Saturn US retailers from Saturn Service Parts Operations (SSPO).

*To avoid pinion seal damage, use the required special tools. Refer to SI for special tool and procedure information. In the event that a pinion seal is damaged during installation, a replacement seal can be obtained by contacting the Product Quality Center at 1-866-654-7654. DO NOT order replacement seals from GMSPO or SSPO.

Important: If the vehicle history or repair or repair orders are not available, refer to Axle Assembly Identification in this bulletin for axle identification information.

Inspection Procedure:

Check the vehicle history for an axle replacementl

Axle Assembly Identification

The axle part number is on an adhesive label on the top side of the axle. It can be read in the vehicle using a small mirror. Another means of identifying an axle that has the new design pinion seal is by referring to Technical Service Bulletin (TSB) 07-04-20-003. A service axle that uses the 2008 production pinion seal can be identified by a casting number that is visible on the pinion cartridge casting immediately behind the yoke. The new design casting number for the rear axle is 6457038590. The new design casting number for the front axle is 6507022390. Refer to TSB 07-04-20-003 for illustrations and more information. Use the "Inspect - New Axle Previously Installed - No Further Action Required", V1794 labor operation code for inspection only claims.

Pinion Seal Replacement

Notice: To avoid pinion seal damage, use the required special tools. Refer to SI for special tool and procedure information.

Important: DO NOT reuse the flange and nut as instructed in the service procedure in SI. Use the new flange and nut provided in the kit.

1. Remove the pinion seal. Refer to the appropriate pinion replacement procedure in SI.
2. Replace the pinion seal. Refer to the appropriate pinion seal replacement procedure in SI.

All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers.

A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter.

Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.

Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by February 28, 2009.

All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

When a customer requests reimbursement, they must provide the following:

Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS.

Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification.

All customer requests for reimbursement for previous repairs for the recall condition are handled by submitting a recall reimbursement claim form directly to Saturn retailers for processing; however, if customers choose, they may file a claim through the Saturn Customer Assistance Center.

A Saturn Customer Reimbursement Procedure and Claim Form are included with the customer letter.

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 program 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. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject

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.

1. To receive credit, submit a claim with the information below:

* The parts allowance should be the sum total of the current SSPO retailer net price plus 40% of all parts required for the repair.

** Administrative allowance

2. Refer to the GM Messenger bulletins SAG20060292/SAG20060295 for Courtesy Transportation guidelines.

*** Customer requests for reimbursement of previously paid repairs to replace the drive axle differential seal.

Customer Reimbursement Claims - Special Attention Required

Customer reimbursement claims must have the date of the (service repair) prior replacement entered into the "repair date" field of the CSO in the "Labor Detail/Comments" screen.

Customer reimbursement claims must have the mileage of the prior repair of the (service repair) entered on the "Service Order Hub" screen in the "miles in" field.

Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer.

Customer reimbursement claims must be submitted on a different CSO than the Recall repair. This is because the repair date and mileage differ between the two repairs.

General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).

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 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 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. A copy of the customer letter is provided in this bulletin for your use in contacting customers. 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, you must 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 a defect that relates to motor vehicle safety exists in certain 2005-2007 model year Cadillac CTS, CTS-V, SRX, STS; 2006-2007 model year Cadillac STS V; 2007 model year Daewoo G2X and Opel GT; 2006-2007 model year Pontiac Solstice; and 2007 model year Saturn SKY vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products.

Important: 

Why is your vehicle being recalled?

The drive axle differential seal (two on all-wheel drive vehicles) may leak because it does not meet GM's specifications. If a seal is leaking, there will be fluid on the ground where the vehicle is parked. If enough fluid leaks, the differential will become noisier because of reduced lubrication. After about two-thirds of the differential fluid is lost, the bearings may no longer be lubricated and may start to overheat. Damage to the bearings and other differential components could then occur. Damaged bearings will create noise that may be heard by the vehicle occupants. If the vehicle is not repaired and damage progresses, three conditions can occur: (1) When the vehicle is stopped and shifted to reverse, the differential may jam and prevent vehicle movement; (2) the damage can cause drag that will feel like the brake is applied; or (3) the differential could jam and lock the drive wheels while the vehicle is in motion. If (3) occurs, the driver may not be able to control the vehicle and a crash could occur without warning.

What will we do?

Your GM dealer/retailer will install a new drive axle differential seal (two on all-wheel drive vehicles). This service will be performed for you at no charge . Because of service scheduling requirements, it is likely that your dealer/retailer will need your vehicle longer than the actual service correction time of approximately 1 hour and 20 minutes to 2 hours and 50 minutes.

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

What should you do?

You should contact your GM dealer/retailer to arrange a service appointment as soon as possible. Bring the enclosed customer reply form with you when you visit your dealer/retailer. The form identifies the repairs required. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us.

Did you already pay for this repair?

The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition.

Do you have questions?

If you have questions or concerns that your dealer/retailer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about this recall can be found at the Owner Center at MyGMLink, http://www.gm.com/recall

If after contacting your dealer/retailer and the Customer Assistance Center, you are still not satisfied 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, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov.

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

Scott Lawson

General Director,

Customer and Relationship Services

Enclosure

07204