Recall - Fuel Tank Shield Installation: Overview
File In Section: Product RecallsBulletin No.: 03002
Date: February, 2003
PRODUCT SAFETY RECALL
SUBJECT:
03002 - MID-FRAME CROSS MEMBER TEAR
MODELS:
2003 CHEVROLET 2500 SERIES AVALANCHE, SUBURBAN
2003 GMC 2500 SERIES YUKON XL
CONDITION
General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2003 model year 2500 Series Chevrolet Avalanche and Suburban, and GMC Yukon XL vehicles. During a 30 degree left angle frontal impact of sufficient severity, a tear could develop in the mid-frame cross member at its attachment to the left frame rail. If the mid-frame cross member tears during frontal impact and produces a sharp edge, contact of the sharp edge with the fuel tank may result in a puncture of the fuel tank and possible fuel leakage. If a sufficient amount of fuel were to leak out and if an ignition source were present, a vehicle fire could occur.
CORRECTION
Dealers are to install a fuel tank shield.
VEHICLES INVOLVED
Involved are certain 2003 model year 2500 Series Chevrolet Avalanche and Suburban, and GMC Yukon XL vehicles built within these VIN breakpoints shown.
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 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 INFORMATION
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.
SERVICE PROCEDURE
The following procedure is for installing a fuel tank shield on involved vehicles. Installation of the shield does NOT require draining or removal of the fuel tank or disconnecting of any fuel lines.
Important
The vehicle must be raised on a hoist that will allow unobstructed access to the bottom of the left frame rail along the entire length of the fuel tank.
1. Raise the vehicle on a suitable hoist and support as necessary.
Important
Read steps 2, 3, and 4 before attempting to install the shield.
2. Position the fuel tank shield under the fuel tank and route the left rear corner of the shield up between the cables and the outboard side of the frame rail.
Important
The illustration shows the shield being positioned under the fuel tank prior to attachment. Only two of the three slots (2) and tabs (1) are shown. The third slot and tab are located further to the rear of the shield.
3. Raise or lower the shield as necessary to hook the slots (2) located along the inboard edge of the shield onto the three metal tabs (1) located on the inboard side of the fuel tank.
4. Raise the outboard side of the shield up to the bottom of the left frame rail and support in place.
5. To attach the shield, install the three bolts through the holes in the shield and into the EXISTING holes in the BOTTOM of the frame rail. Tighten to 12 Nm (106 lb in).
6. Lower the vehicle as necessary to install the fourth bolt through the rear hole in the shield and into the existing hole in the outboard side of the frame rail behind the left rear tire. Tighten to 12 Nm (106 lb in).
7. Lower the vehicle.
8. Install the GM Recall Identification Label.
RECALL IDENTIFICATION LABEL - For US and IPC
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. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall 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 a.m. to 5:00 p.m. EST). Request Item Number S-1015 when ordering.
Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.
RECALL IDENTIFICATION LABEL - For CANADA
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.
COURTESY TRANSPORTATION
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.
CLAIM INFORMATION
Submit a Product Recall Claim with the information indicated.
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission.
CUSTOMER NOTIFICATION - For US and CANADA
Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter included with this bulletin).
CUSTOMER NOTIFICATION - 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 sample letter.
DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions)
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.
DEALER RECALL RESPONSIBILITY - 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, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.
Disclaimer