Product Safety - Power Steering Hose Contact

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2003-2005 4500/5500 Series Chevrolet Kodiak, school bus chassis, and GMC TopKick vehicles; and 2003-2004 GMC school bus chassis vehicles equipped with an 8.1L engine (L18) and Hydromax brake system. Some of these vehicles have a clearance condition in which the power steering hose may come into contact with a portion of the intermediate steering shaft. If the hose contacts the intermediate steering shaft, a hole could be worn in the hose and a loss of hydraulic fluid would occur. This loss of hydraulic fluid would be accompanied by a hissing sound. If there is a sufficient amount of fluid loss, the driver will hear noise from the power steering pump, the brake warning light and warning tone will activate, and increased effort may be required for steering and braking, increasing the risk of a crash.

Dealers are to reroute the power steering hose. If the steel braiding of the hose is exposed, dealers are to replace the hose.

Involved are certain 2003-2005 4500/550 Series Chevrolet Kodiak, school bus chassis, and GMC TopKick vehicles; and 2003-2004 GMC school bus chassis vehicles equipped with an 8.1L engine (L18) and Hydromax brake system and built within these VIN breakpoints:

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 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 (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned.

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.

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.

1. Open the hood.



2. Inspect the power steering pump to steering gear hose for signs of abrasion near the steering intermediate shaft.

•	If there are no signs of abrasion or the abrasion has not worn through to the steel braiding underneath, then reposition the 90° power steering hose adapter in the steering gear to 45 degrees.

•	If there are signs of abrasion exposing the steel braid, the hose and both adapters must be replaced. Proceed to the section titled, Hose Replacement Procedure.

3. Place a wrench on the 90° adapter on the steering gear and loosen the jam nut about one turn.



4. Carefully turn the adapter up 45 degrees.
5. While holding the adapter in place, tighten the jam nut.
6. Ensure that the power steering hose does not contact the steering intermediate shaft.
7. Close the hood.

Hose Replacement Procedure

Tools Required

J 42971 Quick Disconnect Tool

1. Install a drain pan under the vehicle.
2. Using J 42971, Quick Disconnect Tool, disconnect the power steering hose from the pump and the steering gear. Refer to Power Steering Hose Quick Connect Fitting in SI (Document ID #627559).
3. Remove the power steering hose from the vehicle.
4. Using J 42971, disconnect the steering gear outlet hose from the steering gear. Refer to Power Steering Hose Quick Connect Fitting in SI (Document ID #627559).
5. Remove the straight fitting from the power steering gear outlet and save for re-installation.
6. Remove the 90° fitting from the power steering gear inlet.
7. Install the new 90° fitting to the power steering gear inlet.



8. Carefully turn the fitting up 45 degrees.
9. While holding the adapter in place, tighten the jam nut.
10. Re-install the straight fitting to the power steering gear outlet.
11. Reconnect the steering gear outlet hose to the steering gear.
12. Remove the straight adapter from the power steering pump.
13. Using J 42971, disconnect the power steering suction hose from the pump. Refer to Power Steering Hose Quick Connect Fitting in SI (Document ID# 627559).
14. Loosen the jam nut for the suction line 90° fitting.
15. Rotate the suction line fitting counter clockwise 25 degrees, towards the front of the vehicle.
16. While holding the adapter in place, tighten the jam nut.
17. Route the suction line under the radiator support and reconnect it to the pump.



18. Install the new 45° fitting to the pump for the pressure line. Orient the new 45° fitting horizontally pointing toward the rear of the vehicle.
19. While holding the adapter in place, tighten the jam nut.
20. Route the new hose under the power steering suction line, and connect it at the steering pump and at the steering gear. Refer to Power Steering Hose Quick Connect Fitting in SI (Document ID# 627559).
21. Ensure that the power steering hoses do not contact the steering intermediate shaft.
22. Bleed the system. Refer to Bleeding the Power Steering System in SI (Document ID #814238, Manual or Document ID #804697, Vacuum).
23. Close the hood.

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 requests for reimbursement of previously paid repairs to correct the recall condition are to be submitted by July 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:

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.

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).

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, which relates to motor vehicle safety, exists in certain 2003-2005 4500/5500 Series Chevrolet Kodiak and GMC TopKick vehicles equipped with an 8.1L engine (L18) and Hydromax brake system. Some of these vehicles have a clearance condition in which the power steering hose may come into contact with a portion of the intermediate steering shaft. If the hose contacts the intermediate steering shaft, a hole could be worn in the hose and a loss of hydraulic fluid would occur. This loss of hydraulic fluid would be accompanied by a hissing sound. If there is a sufficient amount of fluid loss, the driver will hear noise from the power steering pump, the brake warning light and warning tone will activate, and increased effort may be required for steering and braking, increasing the risk of a crash.

Your dealer will reroute the power steering hose. If the steel braiding of the hose is exposed, your dealer will replace it. This service will be performed for you at no charge .

This inspection will take approximately 15 minutes. If the power steering hose requires replacement, an additional 1 hour and 15 minutes will be needed. 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 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 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 20590 or call 1-888-327-4236.

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.

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

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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