Special Coverage Adjustment - Steering Idler Arm Attaching Bracket Fracture

Some customers of 2003-2006 Chevrolet Express and GMC Savana 2WD 2500/3500 series vehicles may comment about free play in the steering, a clunking noise in the front end, a "binding" feel, and/or off-center steering wheel position. This may be caused by a fracture of the steering idler arm attaching bracket.

This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the customer.

For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after May 24, 2007, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to May 24, 2007, must be submitted to the Service Contract provider.

Involved are certain 2003-2006 Chevrolet Express and GMC Savana 2WD 2500/3500 series vehicles built within the following VIN breakpoints:

Parts required to complete this special coverage are to be obtained from General Motors Service and Parts Operations (GMSPO).

* A special tool is required for this repair. To obtain the tool on loan, contact the Technical Assistance Center. Do not order brackets for shelf stock.

General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly).

Idler Arm Bracket Replacement

Tools Required

CH 48093 A - Alignment Tool

Important: CH 48093 A, Alignment Tool, is required for this repair. Contact Technical Assistance to review the service procedure and make arrangements to obtain the required tool on a loan basis.

1. Open the hood.
2. Disconnect the negative battery cable.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
4. Remove the plastic deflector shield.
5. Remove the stabilizer shaft insulator clamps and lower the shaft for better access. Refer to Stabilizer Shaft Replacement in SI.
6. Remove the two bolts that retain the idler arm to the bracket and swing the arm out of the way.
7. Remove the ground strap, which is next to the idler arm bracket on the frame.
8. Remove the rust proofing from the frame and bracket.
9. Use a die grinder with a cut off wheel reciprocating saw to cut the bracket in half between the two retaining nuts. Cut the bracket from the cross member. Cut along the weld on the bracket to the frame. The front part of the bracket can be removed making it easy to remove the rear portion of the bracket.
10. Grind off the weld and prep the area.



11. Install the new idler arm bracket (1) to the alignment tool (CH-48093-1A) (2) and then to the frame.
12. With a MIG welder weld the new bracket to the frame.
13. Apply wax-based anti-corrosion compound to the repair.
14. Reinstall the ground strap.
15. Reinstall the idler arm to the bracket and tighten the bolts.

Tighten
Tighten the idler arm to bracket bolts to 150 N·m (111 lb ft).

16. Reinstall the stabilizer shaft. Refer to Stabilizer Shaft Replacement in SI.

Tighten
Tighten the stabilizer shaft bolts to 25 N·m (18 lb ft).

17. Reinstall the plastic deflector shield.

Tighten
Tighten the plastic deflector shield bolts to 14 N·m (10 lb-ft).

18. Lower the vehicle.
19. Reinstall the negative battery cable.
20. Check the wheel alignment. Refer to Measuring Wheel Alignment.

For vehicles repaired under the terms of this special coverage, submit a claim with the information indicated below:

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

A General Motors Customer Reimbursement Procedure and Claim 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 described in this bulletin are to be submitted to the dealer prior to or by May 31, 2008. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000 km (120,000 miles) whichever occurs first.

When a customer requests reimbursement, they must provide the following:

If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership.

Dear Genral Motors Customer:

As the owner of a 2003, 2004, 2005, or 2006 model year Chevrolet Express or GMC Savana two wheel drive, 2500 or 3500 series vehicle, your satisfaction with our product is very important to us.

This letter is intended to make you aware that we have received a few comments from customers about free play in the steering, a clunking noise in the front end of the vehicle, a "binding" feel, and/or off-center steering wheel position. This may be caused by a fracture of the steering idler arm attaching bracket.

Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above.

What We Have Done: General Motors is providing owners with additional protection to cover a fracture of the steering idler arm attaching bracket. If this condition occurs on your 2003, 2004, 2005, or 2006 model year Chevrolet Express or GMC Savana two wheel drive, 2500 or 3500 series vehicle within 10 years of the date your vehicle was originally placed in service or 193,000 km (120,000 miles), whichever occurs first, the condition will be repaired for you at no charge.

What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to call the service department at your dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts. Keep this letter with your other important glove box literature for future reference.

Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage 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.

We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products.

General Motors Corporation

Enclosure

07103