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Product Safety - Tailgate Support Cable

Subject:04007B -- Tailgate Support Cable

Models:2002-2004 Cadillac Escalade EXT
2000 Chevrolet CK
2000-2004 Chevrolet Silverado
2002-2004 Chevrolet Avalanche
2003-2004 Chevrolet Kodiak
2000-2004 GMC Sierra
2003-2004 GMC TopKick



THIS BULLETIN IS BEING REVISED TO INCLUDE SOME 2003 AND 2004 MODEL YEAR MEDIUM DUTY VEHICLES THAT WERE MODIFIED TO INCLUDE A TAILGATE. PLEASE DISCARD ALL COPIES OF BULLETIN 04007A, ISSUED OCTOBER 2004.


Condition

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2000 model year Chevrolet CK, 2000-2004 model year Chevrolet Silverado and GMC Sierra trucks, and 2002-2004 model year Cadillac Escalade EXT and Chevrolet Avalanche trucks, and 2003-2004 Chevrolet Kodiak and GMC TopKick trucks. On some of these vehicles, the galvanized steel tailgate support cables that retain the tailgate in the full open (horizontal) position may corrode, weaken, and eventually fracture. If one cable fractures, the remaining cable may retain the tailgate in a horizontal position. However, if the remaining cable is sufficiently weakened by corrosion, it could fracture within moments of the first cable fracturing, especially if there is a load on the tailgate. If both cables fracture, the tailgate would suddenly drop and strike the top surface of the rear bumper. Anyone sitting or standing on the tailgate when both cable fracture could be injured by falling from the tailgate. On vehicles that have had the bumper removed, the tailgate may drop even lower. Additionally, if there is cargo on the tailgate, the cargo may become unstable and fall if the support cables fracture.

Correction

Dealers are to replace the galvanized support cables with stainless steel support cables. In addition, dealers are to inspect the tailgate hinge and replace it, if necessary.

Vehicles Involved

Involved are certain 2000 Chevrolet CK, 2000-2004 model year Chevrolet Silverado and GMC Sierra trucks, and 2002-2004 model year Cadillac Escalade EXT and Chevrolet Avalanche trucks, and 2003-2004 Chevrolet Kodiak and GMC TopKick trucks built within these VIN breakpoints:

Year

Division

Model

From

Through

2002

Cadillac

Escalade EXT

2G109185

2G363848

2003

Cadillac

Escalade EXT

3G100002

3G343890

2004

Cadillac

Escalade EXT

4G100005

4G175911

2002

Chevrolet

Avalanche

2G100011

2G363853

2003

Chevrolet

Avalanche

3G100001

3G347428

2004

Chevrolet

Avalanche

4G100011

4G175906

2000

Chevrolet

CK (Classic)

YF416524

YF521040

YR143527

YR230631

2003

Chevrolet

Kodiak

3F507651

3F521614

2004

Chevrolet

Kodiak

4F100150

4F508975

2000

Chevrolet

Silverado

Y1160008

Y1409284

YE195370

YE433962

YZ157610

YZ371943

2001

Chevrolet

Silverado

11100001

11408136

1E100004

1E346660

1F100001

1F213873

1Z100001

1Z335201

2002

Chevrolet

Silverado

21100001

21430587

2E100002

2E306441

2F100002

2F250465

2Z100001

2Z348508

2003

Chevrolet

Silverado

31100001

31412794

3E100001

3E381150

3F100001

3F259060

3Z100001

3Z361857

2004

Chevrolet

Silverado

41100005

41197171

4E100005

4E178445

4F100001

4F145985

4Z100002

4Z178157

2000

GMC

Sierra (Classic)

YF141495

YF521003

YR143530

YR231139

2000

GMC

Sierra

Y1150033

Y1409272

YE194333

YE901599

YZ175180

YZ371915

2001

GMC

Sierra

11100005

11408122

1E100001

1E901535

1F100002

1F213892

1Z100003

1Z335203

2002

GMC

Sierra

21100002

21430585

2E100005

2E306440

2F100001

2F250482

2Z100004

2Z900955

2003

GMC

Sierra

31100002

31412793

3E100009

3E381153

3F100018

3F259040

3Z100004

3Z900320

2004

GMC

Sierra

41100001

41197158

4E100002

4E178436

4F100005

4F145865

4Z100001

4Z178148

2003

GMC

TopKick

3F504306

3F522021

2004

GMC

TopKick

4F500107

4F509433

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

For US

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 will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld.

For Canada

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 that have no involved vehicles currently assigned will not receive a report with the recall bulletin.

For IPC

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 that have no involved vehicles currently assigned will not receive a report with the recall bulletin.

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 other 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 program.

Parts Information

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.

Part Number

Description

Qty

88980509

Cable, E/Gate (Right)

(New Style Silverado, Sierra Avalanche, Escalade EXT, Kodiak, TopKick)

1 (If Req'd)

88980510

Cable, E/Gate (Left)

(New Style Silverado, Sierra, Avalanche, Escalade EXT, Kodiak, TopKick)

1 (If Req'd)

89045648

Cable, E/Gate (Classic CK, Sierra)

2

15224331

Washer

(New Style Silverado, Sierra, Avalanche, Escalade EXT, Kodiak, TopKick)

1-2 (If Req'd)

15074252*

Hinge, Pubx E/Gate

(New Style Silverado, Sierra, Kodiak, TopKick)

1 (If Req'd)

15080226*

Hinge, E/Gate

(Avalanche, Escalade EXT)

1 (If Req'd)

15691088

Hinge, Pubx E/Gate (Classic CK, Sierra)

1 (If Req'd)

* It is estimated that less than 3% of the vehicles worldwide will require hinge replacement. Please order parts accordingly.

Service Procedure

Classic Silverado and Sierra (GMT400)

The following procedure provides instructions for inspecting, and if necessary, replacing the rear endgate (tailgate) support cables and inspecting the right side tailgate hinge for damage, and replacing if necessary.

Notice: It is recommended that a support be placed under the open tailgate in the next step to prevent the tailgate from being damaged in the event that it drops when disconnecting, inspecting, and replacing the support cables.

Hinge Inspection - Classic CK and Sierra


    Object Number: 1538695  Size: SF
  1. Release (unhook) the RIGHT side tailgate support cable from the pickup box.
  2. With the tailgate (1) completely open as shown in the upper part of the illustration, pull the RIGHT SIDE of the tailgate rearward as shown in the lower illustration. Do not pull on the left side of the tailgate.
  3. • If the tailgate hinge (2) will NOT disengage from the pickup box on the right side, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace both support cables.
    • If the tailgate hinge (3) WILL disengage from the pickup box on the right side, proceed to the next step.

    Object Number: 1553673  Size: SH
  4. With the right side of the tailgate disengaged from the pickup box, inspect the hinge on the right side of the tailgate for damage. The illustration above shows an undamaged hinge (1) and a damaged or bent hinge (2).
  5. • If the hinge is NOT damaged, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace both support cables.
    • If the hinge IS damaged or bent, the hinge needs to be replaced. Proceed to the section titled, "Hinge Replacement" before proceeding with the replacement of the support cables.

Hinge Replacement - Classic CK and Sierra

The following procedure should only be performed if the right side of the tailgate could be disengaged for the pickup truck and the hinge was damaged or bent.

  1. Release (unhook) the left side tailgate support cable from the pickup box.
  2. Remove the tailgate from the vehicle.

  3. Object Number: 1553675  Size: SH
  4. Remove the bolt (1) attaching the right side hinge (2) to the side of the tailgate.

  5. Object Number: 1553677  Size: SH
  6. Locate and drill out the large weld (2) attaching the hinge (1) to the backside of the tailgate bracket (3). Remove the hinge.
  7. Important: Because the new hinge must be welded to the bracket on the tailgate in the next steps, do not pain the hinge until after installation. After welding is complete, the new hinge must be primed and painted in the body color.

  8. Install a new hinge to the tailgate and install the bolt.
  9. Tighten
    Tighten the bolt to 27 N·m (20 lb ft).

  10. Weld the backside of the new hinge to the original bracket on the tailgate.
  11. Tape off the area around the hinge and prime and paint the hinge as required.
  12. Reinstall the tailgate on the vehicle and proceed to the section titled, "Support Cable Replacement."

Support Cable Replacement - Classic CK and Sierra

The following procedure provides instruction for replacing the rear endgate (tailgate) support cables.

  1. Open the rear tailgate and support it as necessary.

  2. Object Number: 1551752  Size: SH
  3. Release (unhook) the right side tailgate support cable from the pickup box.

  4. Object Number: 1551939  Size: SH

    Important: If the support cable (2) has NOT been replaced previously, there will be a toothed nut or plastic nut (1) located between the latch (4) and the tailgate that MAY prevent the bolt (3) from being removed in the next step. The nut is an assembly aid used in teh assembly plant. Do not reinstall or replace the toothed or plastic nut when installing the new support cable.


    Object Number: 1551755  Size: SH
  5. Loosen the bolt (3) that attaches the opposite end of the support cable to the latch assembly (2).
  6. • If the toothed or plastic nut IS present, you will only be able to loosen the bolt partially from the latch. If this condition is encountered, proceed to the next step.
    • If the toothed or plastic nut is NOT present, proceed to Step 8.

    Important: DO NOT loosen the other bolt completely in the next step. Leave two or three threads of the bolt engaged in the tailgate. Removing this bolt completely may allow the linkage inside the tailgate to separate from the latch.

  7. If the toothed or plastic nut is present, loosen the other two bolts (1) attaching the latch (2) to the tailgate. DO NOT remove these bolts.
  8. Finish loosening the bolt that attaches the support cable. The bolt will NOT be removable even though the threads are completely out.

  9. Object Number: 1551940  Size: SH
  10. Place an interior trim removal type tool (2) between the support cable end (3) and the latch (1), and pry the two apart. As the two spread apart, the toothed or plastic nut on the other side of the latch will begin to move towards the end of the bolt.
  11. Once the toothed or plastic nut has moved away from the backside of the latch, use long nose pliers to grasp and twist it off of the bolt. Discard the toothed nut.
  12. Remove the bolt and support cable.
  13. Important: Do not reinstall the toothed or plastic nut when installing the new support cable. Also, the support cables used on these vehicles are interchangeable from side to side, and no washers are to be isntalled like those used on the new style trucks (GMT800).

  14. Install the new support cable to the latch and reinstall the original bolt.
  15. Tighten
    Tighten the bolt to 30 N·m (22 lb ft).

  16. If the other bolts were loosened earlier,
  17. Tighten
    Tighten the other loose bolts to 30 N·m (22 lb ft).

  18. Attach the opposite end of the support cable to the pickup box.
  19. Repeat this procedure on the other support cable.
  20. Important: Depending on the condition of the tailgate and related parts, one of the two new support cables (either left or right) may NOT be tight (taut) when the tailgate is fully open. This condition may be caused by several factors including a damaged hinge, pickup box, or the tailgate itself may be slightly bent due to overloading at some previous time. Replacing either or both support cables a second time will NOT correct this condition. Replacement of any additional parts to correct this condition will NOT be covered under this recall.

  21. Remove the tailgate support, close, open and re-close the tailgate. Verify that the support cables fold properly.

Escalade EXT, Avalanche, New Style Silverado and Sierra (GMT800), Kodiak, TopKick

The following procedures provides instructions for inspecting, and if necessary, replacing the rear endgate (tailgate) support cables and inspecting the right side tailgate hinge for damage, and replacing if necessary.

Notice: It is recommended that a support be placed under the open tailgate in the next step to prevent the tailgate from being damaged in the event that it drops when disconnecting, inspecting, and replacing the support cables.

Support Cable Inspection -- Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick

  1. Open the rear tailgate and support it as necessary.

  2. Object Number: 1537874  Size: SH
  3. Release (unhook) the right side tailgate support cable from the pickup box.

  4. Object Number: 1545570  Size: SH

    Important: In the above illustration, the clear sealant (1) is shown as black in color. This was done for illustration purposes only. If sealant is present on the support cables it will be clear or hazy (cloudy) in appearance.

  5. Inspect the end (eyelet) of the support cable that attaches to the tailgate for sealant covering the end of the cable strands.
  6. • If there IS a clear type sealant (1) over the end of the cable strands, the support cable needs to be replaced. Reconnect the support cable to the pickup box and perform this same inspection on the left support cable. After inspecting both cables, proceed to the section titled "Hinge Inspection."
    • If there IS NOT a clear type sealant (2) over the end of the cable strands, that support cable does NOT need to be replaced. Reconnect the support cable to the pickup box and perform this same inspection on the left support cable. After inspecting both cables, proceed to the section titled "Hinge Inspection."

Hinge Inspection - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick


    Object Number: 1538695  Size: SF
  1. Release (unhook) the RIGHT side tailgate support cable from the pickup box again.
  2. With the tailgate (1) completely open as shown in the upper part of the illustration, pull the RIGHT SIDE of the tailgate rearward as shown in the lower illustration. Do not pull on the left side of the tailgate.
  3. • If the tailgate hinge (2) will NOT disengage from the pickup box on the right side, no repair is needed to the hinge. Proceed to the section titled "Support Cable Replacement" and replace any support cable that HAD sealant in the earlier inspection. If neither of the support cables requires replacement, no further action is required.
    • If the tailgate hinge (3) will disengage from the pickup box on the right side, proceed to the next step.

    Object Number: 1538698  Size: SF
  4. With the right side of the tailgate disengaged from the pickup box, inspect the hinge on the right side of the tailgate for damage. The illustration above shows an undamaged hinge (1) and a damaged or bent hinge (2).
  5. • If the hinge is NOT damaged, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace any support cables that HAD sealant in the earlier inspection. If neither of the support cables require replacement, no further action is required.
    • If the hinge IS damaged or bent, the hinge needs to be replaced. Proceed to the section titled, "Hinge Replacement."

Hinge Replacement - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick

The following procedure should only be performed if the right side of the tailgate could be disengaged from the pickup box.

  1. Release (unhook) the left side tailgate support cable from the pickup box.
  2. Remove the tailgate from the vehicle.

  3. Object Number: 1538803  Size: SH
  4. Remove the two bolts attaching the right side hinge to the tailgate.
  5. Important: On Chevrolet Silverado and GMC Sierra models, the NEW hinge being installed must be primed and painted in the body color prior to installation. New hinges for the Chevrolet Avalanche and Cadillac Escalade EXT come pre-painted in a glossy black primer, these hinges must still be painted black.

  6. Install a NEW hinge to the tailgate and install the two bolts.
  7. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  8. Reinstall the tailgate on the vehicle. If one or both tailgate support cables require replacement, proceed to the section titled "Support Cable Replacement". If neither support cables require replacement, no further action is required.

Support Cable Replacement - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick

The following procedure should only be performed if sealant was found in one or both support cables in the earlier inspection.


Object Number: 1466543  Size: SH

Important: If the support cable (2) has NOT been replaced previously, there will be a toothed nut (1) located between the latch (4) and the tailgate that will prevent the bolt (3) from being removed in the next step. The nut is an assembly aid used in the assembly plant. The nut does NOT need to be reinstalled or replaced when installing a new support cable in this recall.


    Object Number: 1537875  Size: SH
  1. Loosen the bolt (1) that attaches the opposite end of the support cable to the latch assembly (2).
  2. • If the toothed nut is present, you will only be able to loosen the bolt partially from the latch. If this condition is encountered, proceed to the next step.
    • If the toothed nut is not present, proceed to Step 6.

    Important: DO NOT loosen the other bolt completely in the next step. Leave two or three threads of the bolt engaged in the tailgate. Removing this bolt completely may allow the linkage inside the tailgate to separate from the latch.

  3. If the toothed nut is present, loosen the other bolt (3) attaching the latch to the tailgate. DO NOT remove this bolt.
  4. Finish loosening the bolt that attaches the support cable. The bolt will NOT be removable even though the threads are completely out.

  5. Object Number: 1537876  Size: SH
  6. Place an interior trim removal type tool (2), or equivalent, between the support cable end (3) and the latch (1), and pry the two apart. As the two spread apart, the toothed nut on the other side of the latch will begin to move towards the end of the bolt.
  7. Once the toothed nut has moved away from the backside of the latch, use long nose pliers to grasp and twist it off of the bolt. Discard the toothed nut.
  8. Remove the bolt and support cable.
  9. Notice: Due to manufacturing variation in the thickness of the latch, support cable end, and the shoulder on the bolt, a spacer (flat washer) must be used when installing the new cable. The washer will act as an extension to the shoulder on the bolt, and the outside diameter of the washer will allow it to fit inside of the opening in the cable end. This will allow the cable end to rotate freely on the bolt/latch when the tailgate is closed and prevent the support cable from getting pinched between the tailgate and the pickup box. The washer does part number listed in this bulletin MUST BE used when installing the new support cables. Its dimensions are critical for correct cable positioning when closing the tailgate and it has the corrosion protection specified by GM. DO NOT use any other washer in place of the one listed in this recall.

    Important: The washer does NOT replace the toothed nut removed earlier and is NOT to be installed between the latch and the tailgate.

    Notice: When installing the new support cable, make sure that the left side (LS) is installed on the left (driver's) side of the vehicle, and the right side (RS) is installed on the right (passenger) side. The support cables are marked with an LS or RS on the end of the cable that attaches to the tailgate. Installing a support cable on the incorrect side of the vehicle may result in the cable getting damaged when the tailgate is closed.

  10. Install one new flat washer on the bolt followed by a new support cable. The end of the support cable should go over the washer and onto the shoulder of the bolt.
  11. Install the bolt, flat washer, and cable assembly into the latch and tailgate.
  12. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  13. If the other bolt was loosened earlier,
  14. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  15. Verify that the support cable end rotates freely on the bolt.
  16. Attach the opposite end of the support cable to the pickup box.
  17. Repeat the procedure on the other support cable.
  18. Important: Depending on the condition of the tailgate and related parts, one of the two new support cables (either left or right) may NOT be tight (taut) when the tailgate is fully open. This condition may be caused by several factors including a damaged hinge, pickup box, or the tailgate itself may be slightly bent due to overloading at some previous time. Replacing either or both support cables a second time will NOT correct this condition. Replacement of any additional parts to correct this condition will NOT be covered under this recall.

  19. Remove the tailgate support, close, open and re-close the tailgate. Verify that the support cables fold properly.

Customer Reimbursement - For US

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

A General Motors Product Recall Customer Reimbursement Procedure Form is included with the customer letter.

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

Customer Reimbursement - For Canada

Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006..

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:

    • Proof of ownership at time of repair.
    • Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair.

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 1.6.2, for specific procedures regarding customer reimbursement verification.

Courtesy Transportation

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.

Claim Information

Submit a Product Recall Claim with the information indicated below:

Repair Performed

Part Count

Part No.

Parts Allow

CC-FC

Labor Op

Labor Hours

Net Item

Inspect Tailgate Support Cables (No Replacement Req'd) AND Inspect Hinge (Inc. Hinge Replacement, If Req'd) - New Style Silverado, Sierra, Avalanche, Escalade EXT, Kodiak, TopKick

0-1

--

*

MA-96

V1241

0.2

N/A

Add: Paint Time

 

 

 

 

 

0.2

***

$4.50 USD

$12.12 CAD

Inspect & Replace Tailgate Support Cables (Inc. Hinge Replacement If Req'd) - New Style Silverado, Sierra, Avalanche, Escalade EXT, Kodiak, TopKick

2-5

--

**

MA-96

V1242

0.3

N/A

Add: Paint Time

 

 

 

 

 

0.2

***

$4.50 USD

$12.12 CAD

Inspect Hinge and Replace Tailgate Support Cables - Classic CK, Sierra

2

--

*

MA-96

V1239

0.3

N/A

Add: Replace, Prime and Paint Hinge

1

 

 

 

 

0.4

***

$4.50 USD

$12.12 (CAD)

Courtesy Transportation

N/A

N/A

N/A

MA-96

****

N/A

*****

Customer Reimbursement (Canadian and Export Dealers/US CAC)

N/A

N/A

N/A

MA-96

V1243

0.2

******

* -- The "Parts Allowance" should be the sum total of the current GMSPO Dealer net price plus applicable Mark-Up or Landed Cost Mark-Up (for IPC) for the hinge (if required) needed to complete the repair.

** -- The "Parts Allowance" should be the sum total of the current GMSPO Dealer net price plus applicable Mark-Up or Landed Cost Mark-Up (for IPC) for the tailgate support cable(s), and if required, the hinge needed to complete the repair.

*** -- The amount identified in the "Net Item" column represents the material allowance for the aerosol spray paint used on the hinge, if replaced.

**** -- Submit courtesy transportation using normal labor operations for courtesy transportation as indicated in the GM Service Policies and Procedures Manual.

***** -- The amount identified in the "Net Item" column should represent the actual dollar amount for courtesy transportation.

****** -- The amount identified in the "Net Item" column should represent the dollar amount reimbursed to the customer.

Note: Canadian dealers should refer to the Canadian distribution of the bulletin for detailed claim information.

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

Customer Notification -- For US and Canada

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

Customer Notification -- For IPC

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.

Dealer Recall Responsibility -- For US and IPC (US States, Territories, and Possessions)

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.

Dealer Recall Responsibility -- 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. 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, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE

If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement.

Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

Your claim will be acted upon within 60 days of receipt.

If your claim is:

    • Approved, you will receive a check from General Motors.
    • Denied, you will receive a letter from General Motors with the reason(s) for the denial, or
    • Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available.

Please follow the instructions on the Claim Form provided on the reverse side to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number listed below. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday

Division

Number

Text Telephones (TTY)

Cadillac

1-866-982-2339

1-800-833-2622

Chevrolet

1-800-630-2438

1-800-833-2622

GMC

1-866-996-9463

1-800-462-8583

Puerto Rico - English

1-800-496-9992

 

Puerto Rico - Español

1-800-496-9993

 

Virgin Islands

1-800-496-9994

 

GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT CLAIM FORM

THIS SECTION TO BE COMPLETED BY CLAIMANT

Date Claim Submitted:

 

Vehicle Identification Number (VIN):

 

Mileage at Time of Repair:

 

Date of Repair:

 

Claimant Name (please print):

 

Street Address or PO Box Number:

 

City, State, ZIP Code:

 

Daytime Telephone Number (include Area Code):

 

Evening Telephone Number (include Area Code):

 

Amount of Reimbursement Requested: $

 

 

THE FOLLOWING DOCUMENTATION MUST ACCOMPANY THIS CLAIM FORM

Original or clear copy of all receipts, invoices and/or repair orders that show:

    • The name and address of the person who paid for the repair.
    • The Vehicle Identification Number (VIN) of the vehicle that was repaired.
    • What problem occurred, what repair was done, when it was done and who did it.
    • The total cost of the repair expense that is being claimed.
    • Payment for the repair in question and the date of payment.
        (copy of front and back of cancelled check, or copy or credit card receipt.)

My signature to this document attests that all attached documents are genuine and I request reimbursement for the expense I incurred for the repair covered by this special policy.

Claimant's Signature:

 

Please mail this claim form and the required documents to:

General Motors Corporation

P.O. Box 33170

Detroit, MI 48232-5170

All recall reimbursement questions should be directed to the following number: 1-800-204-0261.

September 2004

Dear General Motors Customer:

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

You may have already been contacted regarding this recall, but this letter is to inform you that parts are available to service your vehicle.

Reason For This Recall

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2000 model year Chevrolet CK, 2000-2004 model year Chevrolet Silverado and GMC Sierra trucks, and 2002-2004 model year Cadillac Escalade EXT and Chevrolet Avalanche trucks, and 2003-2004 Chevrolet Kodiak and GMC TopKick trucks. On some of these vehicles, the galvanized steel tailgate support cables that retain the tailgate in the full open (horizontal) position may corrode, weaken, and eventually fracture. If one cable fractures, the remaining cable may retain the tailgate in a horizontal position. However, if the remaining cable is sufficiently weakened by corrosion, it could fracture within moments of the first cable fracturing, especially if there is a load on the tailgate. If both cables fracture, the tailgate would suddenly drop and strike the top surface of the rear bumper. Anyone sitting or standing on the tailgate when both cable fracture could be injured by falling from the tailgate. On vehicles that have had the bumper removed, the tailgate may drop even lower. Additionally, if there is cargo on the tailgate, the cargo may become unstable and fall if the support cables fracture.

What Will Be Done

Your GM dealer will replace the galvanized support cables with stainless steel support cables. In addition, the tailgate hinge will be inspected and replaced, if necessary. This service will be performed for you at no charge .

Until stainless steel support cables can be installed on your vehicle, do not stand, sit, or apply loads directly onto the tailgate when it's in the full open (horizontal) position. This will reduce the potential of personal injury and damage to the outer panel of your tailgate. Additionally, when loading or unloading cargo from the pickup box, the tailgate should be removed. Please see your Owner's Manual for tailgate removal instructions.

How Long Will The Repair Take?

This service correction will take approximately 20 to 30 minutes. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

Contacting Your Dealer

To limit any possible inconvenience, we recommend that you contact your GM 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 number listed below. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday.

Division

Number

Text Telephones (TTY)

Cadillac

1-866-982-2339

1-800-833-2622

Chevrolet

1-800-630-2438

1-800-833-2622

GMC

1-866-996-9463

1-800-462-8583

Puerto Rico - English

1-800-496-9992

 

Puerto Rico - Español

1-800-496-9993

 

Virgin Islands

1-800-496-9994

 

GMICT

1-800-862-4389

 

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.

Customer Reply Card

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.

Customer Reimbursement

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

Courtesy Transportation

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.

Recall Information Online

More information about this recall (including frequently asked questions) is available online at the Owner Center at My GMLink. This free online service offers vehicle and ownership-related information and tools tailored to your specific vehicle. To join, visit www.mygmlink.com and enter your Vehicle Identification Number (VIN) shown on the enclosed form, to get the most personalized information for your vehicle.

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

04007