Product Safety - Fuel Tank Housing May Contact Frame Side Rail

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2008 model year Chevrolet Express and GMC Savana cutaway vehicles with a 139" wheel base. On some of these vehicles, the frame rail on the driver’s side may be wider than GM’s specification. If the frame rail is wider than GM’s specification, it may contact the fuel tank housing, resulting in a possible fuel leak. If a sufficient amount of fuel were to leak out, and if an ignition source were present, a vehicle fire could occur.

Dealers are to inspect the clearance between the frame side rail and fuel tank housing. If there is sufficient clearance, no further action is required. If the clearance is not sufficient, dealers are to modify the frame side rail.

Involved are certain 2008 model year Chevrolet Express and GMC Savana cutaway vehicles with a 139" wheel base, and built within these VIN breakpoints:

Important:  Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved.

For dealers 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 will not have a report available if they have no involved vehicles currently assigned.

- US dealers - GM DealerWorld Recall Information

- Canadian dealers - GMinfoNet Recall Reports

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.

Parts required to complete this recall 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.

Frame Side Rail Inspection on Driver’s Side of Vehicle

Vehicles without a Body

There are two fuel tank flange access areas located on the driver’s side of the vehicle. Perform the frame side rail inspection at the rear fuel tank flange area (2) only. Do NOT inspect the frame side rail at the front fuel tank flange access area (1). Refer to the illustration to view the tank inspection area (3). The spring perch is near the rear fuel tank flange area.

Important: If the vehicle does not have a body (frame rail only), the frame rail inspection can be performed without removing the fuel tank. Inspect the frame rail from the top of the vehicle in the area outlined in the illustration. Refer to Steps 3-4 in Vehicles with a Body for inspection instructions. Follow Steps 5-15 in Vehicles with a Body if the frame side rail must be reworked.

Vehicles with a Body

Caution: To avoid personal injury, read the following information before performing the frame rail inspection and frame side rail rework service procedure.

•	The fuel tank must be removed before performing the inspection or frame rail rework procedure.

•	Any spilled gasoline must be cleaned up completely.

•	The rework process will generate sparks and all combustibles must be removed from the area.

•	The rework process takes place from the underside of the vehicle and personal protection equipment such as full face shield, gloves, long sleeves, etc., should be used to prevent injury during the repair process.

•	A small grinder with a cut off wheel (or equivalent) needs to be available to remove metal from the frame side rail if the frame side rail does NOT pass inspection.

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
2. Remove the fuel tank from the vehicle. Refer to Fuel Tank Replacement (Cutaway Van Side Tank) in SI.
3. Purchase one piece of steel rod stock 6.35 mm (1/4 in) or 9.52 mm (3/8 in) diameter. Cut the steel rod stock to 76.8 mm (3.023 in) in length. The cut steel rod will be used as an inspection pin for inspecting the width of the top portion of the frame side rail.




Important: There are two fuel tank flange access areas located on the driver’s side of the vehicle. Perform the frame side rail inspection at the rear tank flange area (2) only. Do NOT inspect the frame side rail at the front fuel tank flange access area (1). Refer to the illustration to view the tank inspection area (3). The spring perch is near the rear fuel tank flange area.





Important: Make sure the inspection pin is flat against the frame side rail web and NOT in the radius of the bend. An extra piece of steel stock was welded to the inspection pin to create a handle. This inspection pin handle is not required to perform the inspection.

4. Inspect the width of the frame side rail on the driver’s side of the vehicle, near the rear fuel tank flange access area of the frame side rail. Insert the inspection pin along the width of the frame side rail as shown in the illustration. Inspect the top of the frame side rail (3) only. Do NOT inspect the bottom of the frame side rail (4).

•	If the inspection pin is equal to or longer than the width of the frame side rail (1), then the frame side rail is within the desired specification. Proceed to Step 14.

•	If the inspection pin is shorter than the width of the frame side rail (2), then the frame side rail is too wide and must be reworked to the proper width. Proceed to Step 5.

5. Make sure the fuel filler neck, lines, and harnesses, etc., in the rework area are protected before you perform the rework (i.e., use a welding blanket, metal guard, etc.).



6. Locate the reference slot (6) on the top portion of the frame side rail (4). The reference slot (6) on the frame side rail is located near where the rear fuel tank flange access area was located before removing the fuel tank.
7. Create a side frame rail rework template using masking tape or equivalent. Refer to the illustration.

7.1.	Measure 200 mm (8 in) forward (3) of the reference slot of the top side frame rail (4). Mark the dimension with a piece of tape.

7.2.	Measure 75 mm (3 in) rearward (2) of the reference slot. Mark the dimension with a piece of tape.

7.3.	Measure 5 mm (0.2 in) inward from the outer edge of the top portion of the frame side rail (1). Mark the dimension with a piece of tape. The tape should cover the entire length of the rework area (1).




8. Use a small hand grinder to remove 5 mm (0.2 in) of metal from the width of the frame side rail.
9. Remove sharp edges on the frame side rail in the rework area. Make sure that all of the edges of the frame side rail in the rework area have a similar quality. The upper flange of the frame side rail must have at least 5 mm (0.2 in) radii.



10. Using the inspection pin, ensure the frame side rail width is within the desired specification. If the inspection pin is equal to or longer than the side rail (1), then the side rail is within the desired specification. Make sure that all upper flanges have at least 5 mm (0.2 in) radii (for/aft direction). The minimum upper flange width is 80.1 mm (3.15 in) outside of the frame side rail.
11. Apply anti-corrosion treatment, GM P/N 12378399, (or equivalent), to the bare metal edges of the frame rail rework area.
12. Remove all protection devices, and reinstall the filler neck, lines, harnesses, and surrounding components.
13. Inspect the fuel tank for damage. If the fuel tank is damaged, replace the fuel tank. Wholesale authorization will be required for fuel tank replacement.
14. Install the fuel tank. Refer to Fuel Tank Replacement (Cutaway Van Side Tank) in SI.
15. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.

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).

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 2008 model year Chevrolet Express and GMC Savana cutaway vehicles with a 139" wheel base. 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 frame rail on the driver’s side may be wider than GM’s specification. If the frame rail is wider than GM’s specification, it may contact the fuel tank housing, resulting in a possible fuel leak. If a sufficient amount of fuel were to leak out, and if an ignition source were present, a vehicle fire could occur.

What will we do?

Your GM dealer will inspect the clearance between the frame side rail and the fuel tank housing. If there is sufficient clearance, no further action is required. If the clearance is not sufficient, your GM dealer will modify the frame side rail. This service will be performed for you at no charge . Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual inspection time of approximately 2 hours and 25 minutes. If frame side rail modification is necessary, an additional 45 minutes will be required.

What should you do?

You should contact your GM dealer to arrange a service appointment as soon as possible. Bring the enclosed customer reply form with you when you visit your dealer. 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.

Do you have questions?

If you have questions or concerns that your dealer 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 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

08205