Product Safety - Power Steering Hose Fracture

This bulletin is being revised to address hoses used to service 1991-2006 vehicles. Dealers who ordered these hoses for service are identified in the attachment contained in the Administrative Message (U.S.) or Dealer Communication (Canada).

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles. Some of these vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with hydro-boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur.

Note: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991-2006 vehicles.

Dealers are to inspect the power steering hose(s) for two suspect date codes and replace them if required.

Dealers who have ordered the involved hoses for service (see listing in Administrative Message) are to search their part sales records to determine the name and address of the purchaser(s). If the purchaser is the owner of the vehicle, dealers are to send the owner a copy of the appropriate letter found in this bulletin requesting them to bring their vehicle in for repair. If the purchaser is a body shop, independent repair shop, etc., dealers are to send the shop a copy of the appropriate letter found in this bulletin requesting that they provide the customer's name, address, and telephone number so the dealer can send the owner a copy of the letter.

Involved are certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles built within the VIN breakpoints listed below.

Important: Some of the affected hoses were shipped to dealers by GMSPO between July 25, 2005 and August 24, 2005 and could have been used to service 1991 - 2006 vehicles. Affected dealers have already been issued a Special Return Bulletin to return any shelf stock, refer to Administrative Message VSU20050801 - GMP05 -157.

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

For US and Canada

For dealers involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. Dealers that have ordered involved hoses for service will also be listed in the report contained in the Administrative Message.

For Export

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete vehicle identification number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned.

The Campaign Initiation Detail Report 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.

Less than 10% of the involved vehicles will require hose replacement. If parts are required, order the appropriate hose(s) from General Motors Service Parts Operations (GMSPO). 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.

Inspection Procedure

1. Inspect and record the power steering pressure line for the date code as shown above. The date code is printed on the hose and is repeated approximately every 6 inches (150 mm). Depending on the vehicle configuration, there may be one or two hoses to inspect. Vehicles equipped with the hydro-boost system will have two hoses while others will only have one hose. Removal of conduit may be necessary in order to inspect the date code.



2. Rainier/TrailBlazer/TrailBlazer EXT/Envoy/Envoy XL with 4.2L Engine Power Steering Pressure Hose (1). This pressure line has two hose sections and both must be inspected. Vehicle may need to be lifted to inspect both.



3. Express/Savana Steering Pump to Hydro-Boost Pressure Line (2)



4. Express/Savana Hydro-Boost to Steering Gear Pressure Line (1).



5. Silverado/Tahoe/Sierra/Yukon/Escalade Non Hydro-Boost Pressure Line (3).



6. Silverado/Tahoe/Sierra/Yukon/Escalade Power Steering Pump to Hydro-Boost Pressure Line (1).



7. Silverado/Tahoe/Sierra/Yukon/Escalade Hydro-Boost to Steering Gear Pressure Line (1).



8. Hummer H2 Power Steering Pump to Hydro-Boost Pressure Line.



9. Hummer H2 Hydro-Boost to Steering Gear Pressure Line.



10. Corvette Power Steering Pressure Hose (2). The vehicle will need to be lifted on a hoist for inspection. Removal of the power steering cooler bolts will give increased access to the pressure hose.
11. Compare the date code on the hose(s) to the suspect date codes below.

•	If the date code is one of the codes listed below, the hose(s) must be replaced. Proceed to the Hose Replacement Procedure.

•	If the date code is not one of the codes listed below, then replace the conduit if applicable and no further action is required.

Hose Replacement Procedure

If the inspection reveals that the hose needs to be replaced, follow the instructions in SI. Referenced below are the SI document numbers.

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.

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.

General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). For vehicles with the recalled component installed on their vehicles outside of warranty, dealers are to notify customers of this recall using a copy of the letter contained in 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.

Following this customer letter is another letter for customers identified through dealer search - retype this letter and insert the appropriate information.

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, which relates to motor vehicle safety, exists in certain 2005 Chevrolet Corvette, Silverado; GMC Sierra; and 2006 Buick Rainier; Cadillac Escalade, Chevrolet Corvette, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL, Savana, Sierra, Yukon; and HUMMER H2 vehicles. Some of these vehicles may have been built with a power steering hose that is not to specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with hydro-boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur.

Your GM dealer will inspect the power steering hose(s) for two suspect date codes and replace them if required. This service will be performed for you at no charge .

This inspection and service correction will take approximately 15 minutes to 2-1/2 hours, depending on your vehicle model. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the listed number below. The Customer Assistance Center’s hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

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 40990; 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.

The enclosed customer reply form identifies your vehicle. Presentation of this form 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 form and mailing it back to us.

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.

More information about this recall, including answers to frequently asked questions, can be found at the Owner Center at My GMLink. This free online service offers vehicle and ownership related information along with tools tailored to your specific vehicle. To join, visit www.gm.com/recall and enter your vehicle’s 17-character vehicle identification number (VIN), shown on the enclosed customer reply form.

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

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

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Dear [insert customer name]

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, which relates to motor vehicle safety, exists in certain power steering hoses that were supplied to dealers for use in a number of different 1991 through 2006 vehicles. Some of these hoses may not be to GM specification. Under extreme steering maneuvers, such as turning the steering wheel fully to the left or right while braking, the hose may fracture and leak fluid. If this were to occur, power steering assist would be lost and increased steering effort would be required. On vehicles equipped with hydro-boost power brakes, it could also result in loss of power brake assist and increased braking effort would be required. If the power steering fluid spray were to spray onto hot engine parts, an engine compartment fire could occur.

We installed a power steering hose in your {insert customer's model year and vehicle model} and it could have this condition.

We will inspect the power steering hose for two suspect date codes and replace it, if required. This service will be performed for you at no charge .

This inspection and service correction will take approximately 15 minutes to 2-1/2 hours, depending on your vehicle model. However, due to service scheduling requirements, we may need your vehicle for a longer period of time.

To limit any possible inconvenience, we recommend that you contact the service department as soon as possible to schedule an appointment for this repair. By scheduling an appointment, we can ensure that the necessary parts will be available on your scheduled appointment date. Should we be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the listed number below. The Customer Assistance Center’s hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

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 40990; 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.

If you have already paid for some or all of the cost to replace the power steering hose and you have not received reimbursement under a Vehicle Service Contract, you should contact the appropriate Customer Assistance Center listed in this letter to discuss a possible reimbursement.

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.

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

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.

[insert dealership name]

05086