Product Safety - Tie Rod End Nut Under-Torqued

General Motors is contacting customers of involved vehicles via telephone. Customers are being instructed to call their dealer to have their vehicle towed into the dealership. Dealers are to make arrangements to have the vehicle towed and are to provide the customer with courtesy transportation until the recall can be performed on their vehicle.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2003 model year Chevrolet Express and GMC Savana vehicles. These vehicles have a condition where the right-hand tie rod end nut may not be torqued to specification. A tie rod end nut that is not torqued to specification can loosen, resulting in separation of the tie rod from the steering knuckle. Separation of a tie rod can cause unexpected steering input in some maneuvers and could cause a crash without prior warning.

Dealers are to torque the tie rod end nut to the proper specification, and if necessary, replace the tie rod end.

Involved are certain 2003 model year Chevrolet Express and GMC Savana vehicles built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall 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 recall bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this recall. Any dealer not receiving a computer listing with the recall 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 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.

Important: Due to the very small number of vehicles that are expected to require tie rod ends, dealers are asked to order only after inspection determines that a part is required.

The following service procedure is for inspecting the nut that attaches the RIGHT side outer tie rod end to the steering knuckle. The procedure also instructs you to verify the left side torque specification. See the Steering section of the Service Manual if additional information is needed.

1. Raise the vehicle on a suitable hoist and support.
2. Visually inspect the nut on the RIGHT outer tie rod end at the steering knuckle.

•	If the RIGHT tie rod end nut is MISSING, or if the threads are NOT visible on the top side of the tie rod end nut, then replace the tie rod end. Proceed to Step 3 if tie rod end replacement is necessary.

•

If the nut is present and some of the threads on the tie rod end stud are visible on the top side of the nut, verify that it has been tightened to 63 N·m (47 lb ft) by using a torque wrench. At this time, verify that the nut attaching the left side tie rod end to that knuckle has been tightened to the same specification. Proceed to the last step of this procedure and install the GM Recall Identification Label.

3. Remove the nut, if present, from the tie rod end and separate the tie rod stud from the steering knuckle.

Important: Retain the removed tie rod end in the next step until you receive a return request from the Warranty Parts Center.

4. Loosen the adjuster nut approximately one turn and unscrew the tie rod end from the steering gear.
5. Screw the new tie rod end on the steering gear until it is approximately one thread away from contacting the adjuster nut.
6. Install the tie rod end stud in the steering knuckle and install the new attaching nut. Tighten the nut to 63 N·m (47 lb ft). At this time, verify that the nut attaching the left side tie rod end to the knuckle has been tightened to the same specification.
7. Tighten the adjuster nut to 68 N·m (50 lb ft).
8. If the new tie rod end has a grease fitting, apply grease as necessary.
9. Lower the vehicle.
10. Check the alignment and set toe-in as necessary.
11. Install the GM Recall Identification Label.

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

Put the Program 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 Program Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Program Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Request Item Number S-1015 when ordering.

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

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

Put the Recall 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 Recall 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 GMP91 when ordering.

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.

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.

Dealers are requested to notify customers of this recall and arrange to have the vehicle towed to the dealership. General Motors will also contact customers and notify them of this recall on their vehicles by telephone and letter (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 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.

FOR 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. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. 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.

Dear General Motors Customer:

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

Important: You may have already been contacted regarding this recall campaign by your GM dealer or by the GM Customer Assistance Center, but this letter is to inform you to contact your GM dealer immediately and arrange to have your vehicle towed to the dealership.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2003 model year Chevrolet Express and GMC Savana vehicles. These vehicles have a condition where the right-hand tie rod end nut may not be torqued to specification. A tie rod end nut that is not torqued to specification can loosen, resulting in separation of the tie rod from the steering knuckle. Separation of a tie rod can cause unexpected steering input in some maneuvers and could cause a crash without prior warning.

Your GM dealer will torque the tie rod end nut to the proper specification, and if necessary, replace the tie rod end. This service will be performed for you at no charge .

The length of time required to perform this service correction is approximately 15 minutes to torque the tie rod end nuts, and if necessary, another 55 minutes to replace the tie rod end. Additional time may be required to schedule and process your vehicle. If you dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed to schedule, process and repair your vehicle.

Please contact your GM dealer as soon as possible to arrange a service date. Parts are available and instructions for making this correction have been sent to your dealer.

Your GM dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. 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:

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 attached customer reply card identifies your vehicle. Presentation of this card 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 attached and mailing it in the postage paid envelope.

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.

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