1997 Chevrolet Venture problems

RACK AND PINION STEERING UNIT FAILURE

MR. DENNIS FIKE OF ELKRIDGE, MD, SUBMITTED A PETITION TO NHTSA BY LETTER DATED JANUARY 13, 2004, ALLEGING THAT A GM DEALER INFORMED HIM THAT HIS VAN WAS NOT INCLUDED IN SAFETY RECALL 02V286 AND CHARGED HIM FOR THE REPLACEMENT OF THE STEERING RACK AND PINION UNIT.MR. FIKE BELIEVES THAT HIS VAN SHOULD HAVE BEEN INCLUDED AND THAT THE REPAIR SHOULD HAVE BEEN PERFORMED WITHOUT CHARGE TO HIM.THE RECALL IN QUESTION ADDRESSED STEERING RACK AND PINION UNIT LOWER PINION BEARING FAILURES ON CERTAIN MY 1996 THROUGH 1998 GM VEHICLES.THE RECALL REMEDY WAS TO INSPECT AND REPLACE THE STEERING GEAR PINION BEAR...

REAR AXLE TRAILING ARM FAILURE

ON NOVEMBER 18, 2002, ODI OPENED A PRELIMINARY EVALUATION (PE02-086) TO EVALUATE ALLEGATIONS OF REAR AXLE TRAILING ARM FAILURES IN THE SUBJECT VEHICLES (U-VAN) WHICH INCLUDED TWO REPORTING CRASHES.ON APRIL 9, 2003, ODI UPGRADED PE02-086 TO AN ENGINEERING ANALYSIS (EA03-005) TO CONTINUE ITS EXAMINATION OF THE ISSUE. THE TRAILING ARM DESIGN IN THESE VEHICLES HAS BEEN USED IN THE U-VAN FROM MY 1997 THROUGH THE PRESENT.THE GM ANALYSIS CONCLUDED THAT THE SUBJECT TRAILING ARMS COULD CRACK OR BUCKLE IF THEY WERE DAMAGED DURING ASSEMBLY, PRE-DELIVERY HANDLING, OR SUBJECTED TO CERTAIN SERVICE RELATED A...

SAFETY BELT ASSEMBLY FAILURE

ODI IDENTIFIED 59 REPORTS WITH THE ALLEGED DEFECT.ODI WAS ABLE TO CONTACT 44 OF THE 59 CONSUMERS IN ORDER TO DETERMINE THE SPECIFIC CAUSE OF THE LATCH PROBLEMS.OF THE 44 OWNERS CONTACTED, ODI DETERMINED THAT FOUR FAILURES WERE DUE TO AN OUT-OF-TOLERANCE LATCH PLATE, AND THAT 23 FAILURES WERE DUE TO A DISPLACED BUCKLE HOUSING COVER.THE REMAINING 17 FAILURES HAD INDETERMINABLE CAUSES.OF THE 59 REPORTS, THERE WERE THREE ALLEGED MINOR INJURIES.NO LEGAL CLAIMS OR LAWSUITS HAVE BEEN FILED WITH REGARD TO THIS ALLEGED DEFECT.BASED ON THE LIMITED NUMBER OF REPORTS, AND A DECLINING REPORT TREND, THIS IN...

POWER RACK AND PINION STEERING FAILURE

THE LOWER PINION BEARING IN THE RACK AND PINION STEERING ASSEMBLY MAY FAIL.GM WILL RECALL 1997-98 GRAND PRIX BUILT BETWEEN 1-MAR-96 AND 31-OCT-97; AND 1996-98 U-VANS/J-CARS BUILT BETWEEN 1-JAN-96 AND 31-OCT-97.SEE ATTACHED SUMMARY.

SHOULDER HARNESS CLIP

STEERING RACK AND PINION

ODI HAS RECEIVED 200 COMPLAINTS FROMT CONSUMERS AND 1,238 FROM GM ALLEGING FAILURE OR LOCKUP OF THE STEERING RACK AND PINION UNIT (R&P).THIS ALLEGED CONDITION CAN RESULT IN THE LOSS OF STEERING CONTROL OF THE VEHICLE AND A CRASH CAN RESULT.GM HAS REPORTED SIX CRASHES IN WHICH EIGHT PEOPLE HAVE SUSTAINED INJURIES RANGING FROM BRUISES, AIRBAG BURN, SEAT BELT ABRASION, FACIAL INJURY, NECK AND BACK PAIN.ALL CRASHES WERE SINGLE VEHICLE CRASHES.GM STATES THAT ONE POSSIBLE FAILURE MODE IS FAILURE OF THE LOWER PINION BEARING IN THE R&P.AN ENGINEERING ANALYSIS HAS BEEN OPENED TO DETERMINE IF A SAFETY D...

UNEXPECTED OPENING OF SLIDING DOOR

FINGER CUTTING/PINCHING

ODI HAS RECEIVED THREE REPORTS INDICATING INJURIES OCCURRED TO CONSUMERS WHILE THEY WER FOLDING A SECOND ROW SEAT TO GAIN ACCES TO THE REAR OR THIRD ROW SEATS.WHEN FOLDING THE SEAT A PORTION OF THE SEAT FRAME MOVES IN A SCISSOR ACTION.TWO OF THE CONSUMERS SEVERED THE END OF THEIR FINGER AND THE THIRD SUFFERED A PINCHED FINGER.ALL REQUIRED EMERGENCY ROOM TREATMENT.THIS INVESTIGATION HAS BEEN OPENED TO FURTHER STUDY THIS ISSUE.

STEERING

DORMAN IS RECALLING 979 STEERING KNUCKLES, DORMAN P/NOS. 697-902 AND 697-903, SOLD UNDER DORMAN'S "OE SOLUTIONS<SUP>TM</SUP>" BRAND NAME, AND NAPA P/NOS. 7-8502 AND 7-8503 WHICH WERE SOLD FOR REPLACEMENT USE ON THE VARIOUS VEHICLES LISTED ABOVE. A POTENTIAL MATERIAL OR DESIGN DEFECT COULD RESULT IN THE STEERING KNUCKLE BREAKING IN THE HUB AREA.

Risk: A BROKEN STEERING KNUCKLE COULD RESULT IN LOSS OF STEERING CONTROL AND A POSSIBLE CRASH WITHOUT WARNING.

EXTERIOR LIGHTING:HEADLIGHTS

K2 MOTOR IS RECALLING 1,921 AFTERMARKET HEADLAMPS OF VARIOUS MODELS SOLD FOR USE ON THE ABOVE LISTED VEHICLES. THESE HEADLAMPS ARE MISSING THE AMBER SIDE REFLEX REFLECTOR WHICH FAILS TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."

Risk: WITHOUT THE AMBER SIDE REFLEX REFLECTORS, THE LIGHTING VISIBILITY MAY BE AFFECTED, POSSIBLY RESULTING IN A VEHICLE CRASH.

FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY:PRESSURE RELIEF DEVICES

CERTAIN DELPHI FUEL PRESSURE REGULATORS, P/NOS. FP10020-11B1, FP10026-11B1, AND FP10027-11B1, SOLD AFTER JANUARY 9, 2007, AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES LISTED ABOVE. THE UNIVERSAL PRESSURE REGULATORS (UPR) WERE PRODUCED WITHOUT AN O'RING AND RETAINER.

Risk: FUEL MAY LEAK, POSSIBLY RESULTING IN A FIRE.

LATCHES/LOCKS/LINKAGES:DOORS:LATCH

ON CERTAIN MINIVANS EQUIPPED WITH SECOND-ROW BUCKET SEATS OR CAPTAIN'S CHAIRS AND A POWER SLIDING DOOR ON THE PASSENGER SIDE OF THE VEHICLE, A PASSENGER USING THE INTERIOR HANDLE TO OPEN THE POWER SLIDING DOOR COULD BE INJURED.

Risk: IF A PASSENGER USES THE INTERIOR HANDLE TO OPEN THE POWER SLIDING DOOR AND HOLDS ONTO THE HANDLE WHILE IT IS BEING OPENED BY THE MOTOR, THE PASSENGER'S ARM MAY BE PUSHED INTO THE SEAT BACK OR ARMREST AND A WRIST OR LOWER ARM INJURY MAY RESULT.

STEERING:RACK AND PINION

CERTAIN PASSENGER VEHICLES AND MINI VANS HAVE LOWER PINION BEARINGS IN THE POWER RACK AND PINION ASSEMBLY IN WHICH THE RETAINER TABS WERE NOT CRIMPED PROPERLY. THESE AND SOME OTHER RETAINERS USED IN VEHICLES ASSEMBLED BETWEEN JANUARY 1, 1996 AND OCTOBER 31, 1997, COULD FAIL AND PERMIT THE BALL BEARINGS TO ESCAPE.

Risk: IF THIS OCCURS, THE PINION SHAFT CAN BE FORCED UPWARD DURING LEFT TURNS AND BACK DOWN AS THE STEERING WHEEL IS MOVED BACK AND TO THE RIGHT. IF THE PINION SHAFT MOVES FURTHER, THE DRIVER WILL NEED TO EXERT MORE EFFORT TO TURN THE STEERING WHEEL, SIMILAR TO A VEHICLE WITHOUT POWER ASSISTED STEERING. IF THE PINION SHAFT MOVES EVEN FURTHER, THE DRIVER WILL REQUIRE MUCH HIGHER EFFORT TO TURN LEFT AND MAY NOT BE ABLE TO TURN THE WHEEL AS MUCH AS INTENDED. WITH THE MAXIMUM PINION SHAFT MOVEMENT, WHICH REQUIRES INTERNAL GEAR COMPONENT DAMAGE, THE DRIVER CAN ENCOUNTER HIGH RESISTANCE TO TURNING LEFT, FOLLOWED BY UNINTENDED POWER ASSIST TO THE RIGHT. IN ANY OF THESE CONDITIONS, A CRASH COULD OCCUR.

LATCHES/LOCKS/LINKAGES:DOORS:LATCH

VEHICLE DESCRIPTION: 1997-2001 CHEVROLET VENTURE, PONTIAC MONTANA/TRANSPORT, AND OLDSMOBILE SILHOUETTE MINI VANS EQUIPPED WITH PASSENGER SIDE POWER SLIDING DOORS THAT WERE SERVICED IN CAMPAIGN 01013 (01V-067) FROM APRIL TO AUGUST 2001. ALSO 2001 CHEVROLET VENTURE, PONTIAC MONTANA, AND OLDSMOBILE SILHOUETTE MINI VANS EQUIPPED WITH PASSENGER SIDE POWER SLIDING DOORS ASSEMBLED IN JANUARY THROUGH APRIL 2001. THESE VEHICLES HAVE INADEQUATE FRONT WELDS. IF A FRONT WELD FAILS, THE ACTUATOR CAN JAM IN THE UNLATCHED POSITION AND, WHEN THE SLIDING DOOR CLOSES, IT WILL NOT BE LATCHED.

Risk: IF THIS HAPPENS, THE POWER SLIDING DOOR CAN OPEN WHILE THE VEHICLE IS IN MOTION, PARTICULARLY WHEN THE VEHICLE ASCENDS A HILL, MAKES A TURN, OR TRAVELS OVER A ROUGH ROAD SURFACE. AN UNRESTRAINED OCCUPANT COULD FALL OUT OF THE VAN AND BE INJURED.

LATCHES/LOCKS/LINKAGES:DOORS:LATCH

VEHICLE DESCRIPTION: MINIVANS EQUIPPED WITH PASSENGER SIDE POWER SLIDING DOORS. THE DOOR CLOSES BUT MAY NOT BE LATCHED. IF THIS HAPPENS, THE POWER SLIDING DOOR CAN OPEN WHILE THE VEHICLE IS IN MOTION, PARTICULARLY WHEN THE VEHICLE ASCENDS A HILL, MAKES A TURN, OR TRAVELS OVER A ROUGH ROAD SURFACE.

Risk: AN UNRESTRAINED OCCUPANT COULD FALL OUT OF THE VAN AND BE INJURED.

SEATS:FRONT ASSEMBLY:RECLINER

VEHICLE DESCRIPTION: PASSENGER MINI VANS EQUIPPED WITH BUCKET SEATS OR A SPLIT BENCH SEAT IN THE SECOND (MIDDLE) OR THIRD (BACK) ROW. THE SEAT LATCH MECHANISMS ON BUCKET SEATS AND ON THE 40% PORTION OF THE SPLIT BENCH SEAT IN THE SECOND AND THIRD ROWS DO NOT HAVE PROTECTIVE COVERS.

Risk: WHEN ACTIVATING THE RELEASE MECHANISM TO ROLL A BUCKET SEAT FORWARD, A CUSTOMER'S FINGER(S) COULD BE SEVERELY INJURED OR SEVERED IN THEY ARE NOT KEPT CLEAR OF THE MECHANISM.

Other

On certain vehicles equipped with second-row bucket seats or captain's chairs and power sliding door on the passenger side, if a passenger uses the interior handle to open the power sliding door and holds onto the handle while it is being opened by the motor, the passenger's arm may be pushed into the seat back or armrest and a wrist or lower arm injury may result. Correction: Dealers will replace the original interior power sliding door handle. The original handles are offset from the door panel and a passenger can wrap his or her fingers around them. The replacement door handles are essentially flush with the door trim, preventing a passenger from gripping them in the same fashion.

Steering

On certain vehicles, the lower pinion bearings retainer tabs were not crimped properly. These and some other retainers used in vehicles assembled between January 1, 1996 and October 31, 1997 may fail and permit the ball bearings to escape. If the problem were to occur, the driver would have to exert more effort to turn the steering wheel. Correction: Dealers are to inspect the condition of the lower bearing, and replace the lower pinion bearing or the rack and pinion steering gear assembly, if necessary.

Other

Certain 1997-2001 Chevrolet Venture, Pontiac Montana/ Trans Sport, and Oldsmobile Silhouette mini vans equipped with passenger side power sliding doors that were serviced in campaign 01013 (01v-067) from April to August 2001. Also 2001 Chevrolet Venture, Pontiac Montana, and Oldsmobile Silhouette mini vans equipped with passenger side power sliding doors assembled in January through April 2001. These vehicles have inadequate front welds. If a front weld fails, the actuator can jam in the unlatched position and, when the sliding door closes, it will not be latched. If this happens, the power sliding door can open while the vehicle is in motion, particularly when the vehicle ascends a hill, makes a turn, or travels over a rough road surface. An unrestrained occupant could fall out of the van and be injured. Correction: dealers will inspect the actuators for certain date codes and, if necessary, replace the actuators.

Structure

Certain vehicles may exhibit a condition in which the power sliding door closes, but is not latched, If this happens the power sliding door can open while the vehicle is in motion, particularly when the vehicle ascends a hill, makes a turn, or travels over a rough road surface. An unrestrained occupant could fall out of the vehicle and be injured. Correction: Dealers will install a new power sliding door un-latch actuator assembly.

Accessories

On certain vehicles operated in areas of high salt use, the spare tire hoist cable may corrode and eventually break. This would allow the spare tire to fall off the vehicle possibly resulting in a road hazard for other vehicles. Correction: A letter will be sent to owners of affected vehicles with maintenance and inspection instructions for spare tire hoist cable assemblies. Additionally, the letter will advise the owner that, if the cable breaks during that inspection, their dealer will repair the assembly. This policy will be in effect until December 31, 2002.

Brakes

On certain vehicles, ice may accumulate on the rear brake pipes located approximately under the driver's side floor mat. If a large amount of ice accumulates on the brake pipes, the weight of the buildup may pull the pipes away from the underbody of the vehicle which could cause the pipes to drag on the ground and be damaged. Damaged brake pipes could result in loss of brake fluid and reduced brake effectiveness. Correction: A brake pipe retainer clip will be installed to the underbody.

Seats And Restraints

NOTE: VEHICLES EQUIPPED WITH BUCKET SEATS OR A SPLIT BENCH SEAT IN THE MIDDLE OR BACK ROW. THE SEAT LATCH RELEASE MECHANISMS ON BUCKET SEATS AND ON THE 40% PORTION OF THE SPLIT BENCH SEAT IN THE SECOND AND THIRD ROWS DO NOT HAVE PROTECTIVE COVERS. WHEN ACTIVATING THE RELEASE MECHANISM TO ROLL A BUCKET SEAT FORWARD, AN OPERATOR'S FINGERS MAY BE SEVERELY INJURED OR SEVERED IF THEY ARE NOT KEPT CLEAR OF THE MECHANISM. CORRECTION: DEALERS WILL INSTALL A PROTECTIVE COVER OVER THE RELEASE MECHANISM.

Brakes

NOTE: VEHICLES EQUIPPED WITH TRACTION CONTROL. WHEN THE WINDSHIELD WIPERS ARE TURNED ON, THE WINDSHIELD WIPER LINKAGE ARM MAY CONTACT A BRAKE LINE CONNECTED TO THE TRACTION CONTROL SYSTEM (TCS) MODULATOR. THIS COULD RESULT IN BRAKE FLUID LEAKAGE, REDUCED BRAKING EFFECTIVENESS AND INCREASED STOPPING DISTANCES. CORRECTION: A BRAKE LINE CLIP WILL BE INSTALLED WHICH WILL ASSURE PROPER CLEARANCE. ADDITIONALLY, VEHICLES WILL BE INSPECTED FOR BRAKE LINE DAMAGE CAUSED BY THIS CONDITION AND DAMAGED BRAKE LINES WILL BE REPLACED.