Customer Satisfaction - Hydraulic Steering Pump Shaft Fracture

Certain 2000 model year 2500/3500 Series Chevrolet CK, Silverado, Suburban, and Express, and GMC Sierra, Yukon XL and Savana vehicles may have been built with a driveshaft in the power steering hydraulic pump that can fracture, resulting in loss of hydraulic power assist for steering. On vehicles equipped with Hydro-Boost® power brakes, the same condition can also result in loss of power assist for braking. An inoperative pump can cause increased steering effort, and in Hydro-Boost® equipped vehicle also increased braking effort, but does not eliminate the ability to steer or slow the vehicle.

Dealers are to replace the power steering hydraulic pump.

Involved are certain 2000 model year 2500/3500 Series Chevrolet CK, Silverado, Suburban, and Express vehicles, and GMC Sierra, Yukon XL, and Savana vehicles built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning program 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 Campaign Initiation Detail Report.

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 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 purpose other than follow-up necessary to complete this program 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 required to complete this program are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering requirements. 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.

CK Repair Procedure

Tools Required

1. Place a drain pan below the pump.
2. Remove the hoses.
3. Cap the hoses.



4. Install a 3/8 inch drive wrench on the drive belt tensioner and rotate the arm counterclockwise.
5. Remove the drive belt.
6. Slowly release the tension on the drive belt tensioner.



7. Remove the power steering pump pulley.

7.1.	Install the J 25034-C pulley remover.

7.2.	Be sure the pilot bolt bottoms in the pump shaft by turning the nut to the top of the pilot bolt.

7.3.	Hold the pilot bolt.

7.4.	Turn the nut counterclockwise.




8. Remove the front mounting bolts.
9. Remove the rear mounting nuts from the studs.
10. Remove the electrical connector from the EVO actuator.
11. Remove the pump.
12. Perform the following on EVO equipped pumps only:

12.1.

Mark the orientation of the EVO on the pump.

12.2.

Remove the EVO actuator and discharge fitting from the original pump.

12.3.

Remove the O-ring seal from the EVO actuator and properly discard.

12.4.

Remove the fitting assembly from the replacement pump and carefully remove the O-ring seal before properly discarding the fitting.

12.5.

Lubricate the new O-ring seal removed from the replacement pump fitting with clean power steering fluid and install in correct groove in the EVO actuator.

12.6.

Install the original EVO actuator and discharge fitting on the replacement pump, noting the correct orientation.

Tighten
Tighten the EVO actuator assembly to 50 N·m (37 lb ft).

13. Install the new pump.




Notice: Refer to Fastener Notice in Cautions and Notices.

14. Install the front mounting bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

15. Install the rear mounting nuts to the studs.

Tighten
Tighten the nuts to 50 N·m (37 lb ft).




16. Install the pulley.

16.1.

Place the pulley on the end of the pump shaft.

16.2.

Install the J 25033-C.

16.3.

Be sure the pilot bolt bottoms in the pump shaft by turning the nut to the top of the pilot bolt.

16.4.

Hold the pilot bolt.

16.5.

Turn the nut clockwise.

16.6.

Connect the pulley to the end of the power steering pump shaft.

17. Install the pulley flush with 0.5 mm (0.020 in) play.
18. Route the belt over all the pulleys except the drive belt tensioner.



19. Install a 3/8 inch drive wrench on the drive belt tensioner and rotate the drive belt tensioner arm counterclockwise.
20. Install the belt over the drive belt tensioner pulley.
21. Slowly release the tension no the drive belt tensioner pulley.
22. Confirm that the belt is properly routed.
23. Install the hoses.
24. Install the electrical connector to the EVO actuator.

Important: Hoses touching the frame, body or engine may cause system noise.

25. Verify that the hoses do not touch any other part of the vehicle.

Important: Loose connections may not leak, but could allow air into the steering system.

26. Verify that all hose connections are tight.




Important: Maintain the fluid level throughout the bleed procedure.

27. Remove the pump reservoir cap.

Important: Use clean, new power steering fluid only.

28. Fill the pump reservoir with fluid to the FULL COLD level.



29. Attach the J 43485 to the J 35555 or equivalent.
30. Place the J 43485 on or in the pump reservoir filler neck.
31. Apply a vacuum of 68 kPa (20 in Hg) maximum.
32. Wait 1 minute.
33. Remove the J 43485 and the J 35555.
34. Reinstall the pump reservoir cap.
35. Start the engine. Allow the engine to idle.
36. Turn the steering wheel 180-360 degrees in both directions 5 times.
37. Switch the ignition off.
38. Verify the fluid level.

G Van Repair Procedure

Tools Required

1. Place a drain pan below the pump.
2. Loosen the air cleaner duct clamp.
3. Remove the air cleaner assembly bolts.
4. Remove the air cleaner assembly.
5. Drain coolant from the recovery reservoir.
6. Remove the coolant recovery reservoir-retaining bolt.
7. Remove the coolant recovery reservoir hose clamp and the hose at the radiator fitting.
8. Remove the coolant recovery reservoir from the cowl tabs and the vehicle.
9. Remove the dipstick bracket bolt at the generator.
10. Remove the engine oil and transmission fluid dipsticks.
11. Remove the upper fan shroud retaining bolts from the top of the radiator.
12. Remove the upper to lower fan shroud retaining bolts.
13. Remove the upper fan shroud from the vehicle.
14. Remove the fan and clutch assembly.



15. Install a 3/8 inch drive wrench on the drive belt tensioner and rotate the arm counterclockwise.
16. Remove the drive belt.
17. Slowly release the tension on the drive belt tensioner.



18. Remove the power steering pump pulley.

18.1.

Install the J 25034-C pulley remover.

18.2.

Be sure the pilot bolt bottoms in the pump shaft by turning the nut to the top of the pilot bolt.

18.3.

Hold the pilot bolt.

18.4.

Turn the nut counterclockwise.

19. Remove the air conditioning compressor mounting bolts and support compressor with wire.
20. Remove upper radiator hose support bracket.



21. Remove power steering pump bolts (5).
22. Remove power steering pump bracket (1).
23. Remove the reservoir hose from the pump.
24. Loosen adjusting nuts (4).
25. Remove pressure line from pump and raise it to prevent drainage.
26. Remove the return line from the pump and raise it to prevent drainage.
27. Cap the ends of the hoses to prevent entry of dirt.
28. Remove the electrical connector from EVO actuator, if equipped.
29. Remove the pump.
30. Perform the following on EVO equipped pumps only:

30.1.

Mark the orientation of the EVO on the pump.

30.2.

Remove the EVO actuator and discharge fitting from the original pump.

30.3.

Remove the O-ring seal from the EVO actuator and properly discard.

30.4.

Remove the fitting assembly from the replacement pump and carefully remove the O-ring seal before properly discarding the fitting.

30.5.

Lubricate new O-ring seal removed from the replacement pump fitting with clean power steering fluid and install in correct groove in the EVO actuator.

30.6.

Install the original EVO actuator and discharge fitting on the replacement pump noting the correct orientation.

Tighten
Tighten the EVO actuator assembly to 50 N·m (37 lb ft).

31. Transfer rear bracket to replacement pump.
32. Install the new pump on the rear mounting studs.




Notice: Refer to Fastener Notice in Cautions and Notices.

33. Install the pressure line to the pump.
34. Tighten the fitting.

Tighten
Tighten to 27 N·m (20 lb ft).

35. Install the return line to the pump.
36. Install reservoir hose to the pump.
37. Install the power steering pump bracket.



38. Install bracket bolts and nut and finger tighten.



39. Install power steering pump bolts and finger tighten.
40. Tighten bracket bolts and nut.

Tighten
Tighten to 41 N·m (30 lb ft).

41. Tighten power steering pump bolts and nuts.

Tighten
Tighten to 50 N·m (37 lb ft).




42. Install air conditioning compressor and bolts.

Tighten
Tighten to 50 N·m (37 lb ft).

43. Install upper radiator hose support bracket.



44. Install the pulley.

44.1.

Place the pulley on the end of the pump shaft.

44.2.

Install the J 25033-C.

44.3.

Be sure the pilot bolt bottoms in the pump shaft by turning the nut to the top of the pilot bolt.

44.4.

Hold the pilot bolt.

44.5.

Turn the nut clockwise.

44.6.

Connect the pulley to the end of the power steering pump shaft.

45. Install the pulley flush with 0.5 mm (0.020 in) play.
46. Route the belt over all the pulleys except the drive belt tensioner.



47. Install a 3/8 inch drive wrench on the drive belt tensioner and rotate the drive belt tensioner arm counterclockwise.
48. Install the belt over the drive belt tensioner pulley.
49. Slowly release the tension on the drive belt tensioner.
50. Confirm that the belt is properly routed.
51. Install the electrical connector to the EVO actuator, if equipped.
52. Install cooling fan and clutch assembly.

Tighten

•	All except 7.4L - Tighten to 57 N·m (42 lb ft).

•	7.4L only - Tighten to 24 N·m(18 lb ft).

53. Install upper fan shroud into the vehicle.
54. Install the upper fan shroud retaining bolts.

Tighten
Tighten the bolts to 8 N·m (71 lb in).

55. Install the dipstick tube bracket bolt at the generator.
56. Install coolant reservoir hose and clamp.
57. Install coolant reservoir to cowl.
58. Install coolant reservoir bolt.

Tighten
Tighten to 11 N·m (97 lb in).

59. Install the engine oil and transmission fluid dipsticks.
60. Install the air cleaner assembly.
61. Install the air cleaner assembly bolts.

Tighten
Tighten to 18 N·m (13 lb ft).

62. Refill coolant reservoir to the proper mark.

Important: Hoses touching the frame, body or engine may cause system noise.

63. Verify that the hoses do not touch any other part of the vehicle.

Important: Loose connections may not leak, but could allow air into the steering system.

64. Verify that all hose connections are tight.




Important: Maintain the fluid level throughout the bleed procedure.

65. Remove the pump reservoir cap.

Important: Use clean, new power steering fluid only.

66. Fill the pump reservoir with fluid to the FULL COLD level.



67. Attach the J 43485 to the J 35555 or equivalent.
68. Place the J 43485 on or in the pump reservoir filler neck.
69. Apply a vacuum of 68 kPa (20 in Hg) maximum.
70. Wait 1 minute.
71. Remove the J 43485 and the J 35555.
72. Reinstall the pump reservoir cap.

Important: Do not turn steering wheel to lock.

73. Start the engine. Allow the engine to idle.
74. Turn the steering wheel 180-360 degrees in both directions 5 times.
75. Switch the ignition off.
76. Verify the fluid level.

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

A General Motors Product Program 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 condition in this program are to be submitted by February 28, 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.

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

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

General Motors will notify customers of this program 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.

All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles.

Dealers are to service all vehicles subject to this program 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. Program 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 program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle.

If you have paid to have this condition corrected prior to 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:

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 Chevrolet Customer Assistance Center at 1-800-630-2438/GMC Customer Assistance Center at 1-866-996-9463. The deaf, hearing impaired, or speech impaired should call 1-800-833-2438 (Chevrolet) or 1-800-462-8583 (GMC) (Utilizes Telecommunication Devices for the Deaf/Text Telephones, TDD/TTY).

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.

Dear General Motors Customer:

General Motors has decided to conduct a recall to address an issue that relates to motor vehicle safety in certain 2000 model year 2500 and 3500 series Chevrolet CK Pickup, Silverado, Suburban, and Express vehicles; GMC Sierra, Yukon XL, and Savana vehicles.

Some of these vehicles have been built with a driveshaft in the power steering hydraulic pump that can fracture, resulting in loss of hydraulic power assist for steering. On vehicles equipped with Hydro-Boost® equipped power brakes, the same condition can also result in loss of power assist for braking. An inoperative pump can cause increased steering effort, and in Hydro-Boost® equipped vehicles, also increased braking effort, but does not completely eliminate the ability to steer or slow the vehicle.

To prevent this condition from occurring, your dealer will replace the hydraulic pump. This service will be performed for you at no charge .

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. Presenting the enclosed customer reply form to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please check the appropriate box and provide the new owner information, if available.

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 this condition.

If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. The Customer Assistance Center’s hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

This free online service offers vehicle and ownership related information and tools tailored to your specific vehicle. To get the most personalized information for your vehicle, visit www.mygmlink.com , and enter your vehicle's 17-character vehicle identification number (VIN) shown on the enclosed customer reply form to get the most personalized information for your vehicle.

We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving.

General Motors Corporation

Enclosure

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