Product Safety 00008 - Incorrect Pitman Arm/Drag Link Tapered Hole

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2000 Chevrolet and GMC C3500HD chassis cabs. Some of these vehicles exhibit a condition where the tapered hole in the drag link end that attaches to the pitman-arm tapered ball-stud may be machined too deep causing the hole to be oversized. A drag link with an oversized hole may not "seat" the pitman arm tapered ball stud when assembled. This could cause higher than normal friction between components during operation, and over time, result in joint separation or a broken ball stud. If the joint separated or the ball stud broke while the vehicle was moving, steering control would be lost and a vehicle crash could occur without prior warning.

Dealers are to inspect the steering linkage assembly, and if necessary, replace the drag link and the pitman arm.

Involved are certain 2000 Chevrolet and GMC C3500HD chassis cabs built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC Only) before beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

Parts required to complete this campaign 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.

Important: It is estimated that only 2% of 1,790 (Canada -- 39) involved vehicles will require replacement of the pitman arm and drag link. Please order parts accordingly. If inspection determines part replacement is needed, both kits will be required.

Inspection Procedure

1. With the vehicle wheels in the straight-ahead position, locate the pitman arm ball stud to drag link attachment located forward of the steering gear on the left side of the vehicle.
2. Remove the pitman arm ball stud nut and discard.

-	If the drag link IS seated on the taper of the pitman arm ball stud, no further action is required. Install a new ball stud nut, P/N 11516073, and tighten to 47 N·m (35 lb ft). Install the GM Campaign Identification Label.

-	If the drag link IS NOT seated on the taper of the pitman arm ball stud and the two can be separated, proceed to the Replacement Procedure below.

Replacement Procedure

1. Raise and suitably support the vehicle.

Important: Use the proper tool listed below in order to remove the pitman arm from the steering gear shaft.

•	J 29107-A Universal Pitman Arm Puller OR

•	J 6632-01 Pitman Arm Puller

2. Loosen the outboard drag link adjusting sleeve clamp bolt.
3. Remove and retain the pitman arm nut and the washer that is securing it to the steering gear shaft. Slide the steering gear shaft dust seal upward, providing access for the puller.
4. Noting the position of the pitman arm to the steering gear shaft for assembly purposes, remove the arm from the shaft.

Important: Note the number of turns/rotations required in this step.

5. Disconnect the drag link from the drag link adjusting sleeve, counting the number of turns/rotations required to disengage the link from the sleeve.
6. Assemble the new drag link to the new pitman arm, hand tightening the free running nut contained in the pitman arm kit.
7. Install the new drag link and the pitman arm assembly into the adjusting sleeve the same number of turns/rotations that was required to remove the old drag link and arm assembly, as noted in Step 5.
8. Position the new drag link and pitman arm assembly in the location noted in Step 4 and assemble the pitman arm to the steering gear shaft.
9. Install the pitman arm washer and nut.

Tighten
Tighten the nut to 250 N·m (184 lb ft).

10. Slide the steering gear shaft dust seal downward against the pitman arm until it is in contact with the pitman arm.
11. Tighten the pitman arm ball stud free spinning nut and then remove the nut and discard.

Tighten
Tighten the nut to 62 N·m (46 lb ft).

12. Install the torque prevailing pitman arm ball stud contained in the pitman arm kit.

Tighten
Tighten the nut to 47 N·m (35 lb ft).

13. Tighten the drag link adjusting sleeve clamp bolt.

Tighten
Tighten the bolt to 68 N·m (50 lb ft).

14. Lubricate the pitman arm ball stud.
15. Lower the vehicle.
16. Install the GM Campaign Identification Label.

FOR US AND IPC

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels for US dealers can be obtained from Dealer Support Material by calling 1-888-414-6322 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Additional Campaign Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

FOR CANADA

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering.

Submit a Product Campaign Claim with the information indicated below:

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

FOR US AND CANADA

Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin).

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 suggested dealer letter.

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 campaign 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 campaign notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the campaign is not completed within a reasonable time.

FOR ALL

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

Dealers are to service all vehicles subject to this campaign 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. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign 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 campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2000 Chevrolet and GMC C3500HD chassis cabs. Some of these vehicles exhibit a condition where the tapered hole in the drag link end that attaches to the pitman-arm tapered ball-stud may be machined too deep causing the hole to be oversized. A drag link with an oversized hole may not "seat" the pitman arm tapered ball stud when assembled. This could cause higher than normal friction between components during operation, and over time, result in joint separation or a broken ball stud. If the joint separated or the ball stud broke while the vehicle was moving, steering control would be lost and a vehicle crash could occur without prior warning.

Your dealer will inspect the steering linkage assembly, and if necessary, replace the drag link and the pitman arm. This service will be performed for you at no charge .

You may be contacted by a dealer other than the dealer who sold or is currently servicing your vehicle. Please be advised that you may take your vehicle to the General Motors dealership of your choice to have the recall service work completed. Please contact your dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department

General Motors of Canada Limited