General Motors, LLC: Safety Recalls in 1996

AN UNDERTORQUED PINCH BOLT CAN RATTLE AND CAUSE LOOSENESS IN THE STEERING SYSTEM. IF THE PINCH BOLT BACKED OUT OF THE JOINT COMPLETELY, ROTATION OF THE STEERING SHAFT AGAINST THE CONNECTOR COULD CAUSE INCREASING LOOSENESS IN THE STEERING SYSTEM AND RESULT IN LOSS OF STEERING AND AN ACCIDENT.

DEALERS WILL INSPECT THE STEERING COLUMN PINCH BOLT FOR CORRECT TORQUE AND, IF NECESSARY, TIGHTEN THE BOLT TO THE SPECIFIED TORQUE.

IF THESE LAMPS WERE NOT FLASHING, OTHER VEHICLES WOULD NOT BE AWARE THAT THIS VEHICLE WAS STOPPED INCREASING THE RISK OF AN ACCIDENT.

DEALERS OR VEHICLE OWNERS WILL INSPECT FOR PROPER FUNCTION OF THE HAZARD WARNING LAMPS. IF NECESSARY, DEALERS WILL REPLACE THE HAZARD LAMP SWITCH.

THIS CONDITION COULD RESULT IN A FRACTURE OF THE WHEEL STUDS CAUSING THE WHEEL TO SEPARATE FROM THE VEHICLE.

DEALERS WILL TIGHTEN THE VEHICLE'S WHEEL LUG NUTS TO THE PROPER SPECIFICATION.

IF AN IGNITION SOURCE IS PRESENT, AND THERE IS A FUEL LEAK, A FIRE COULD OCCUR.

DEALERS WILL INSTALL ADDITIONAL SHIELDING OF THE FUEL TANK. THIS WILL BE ADDED WITHOUT REMOVING OR DISASSEMBLING THE FUEL SYSTEM.

IN THE EVENT OF A VEHICLE COLLISION, UNBELTED OCCUPANTS ARE MORE AT RISK OF INJURY THAN THOSE USING SEAT BELTS.

DEALERS WILL INSPECT THE SEAT BELTS FOR PROPER FRONT SEAT BELT RETRACTOR POSITION. RETRACTORS FOUND TO BE IMPROPERLY POSITIONED WILL BE REINSTALLED CORRECTLY.

IF BOLT FAILURE OCCURS TO THE DRIVER'S SEAT, IT WOULD ALLOW THE SEAT BACK TO SUDDENLY RECLINE, AND COULD RESULT IN LOSS OF VEHICLE CONTROL AND A VEHICLE CRASH WITHOUT PRIOR WARNING.

DEALERS WILL REMOVE THE FOAM AND/OR VINYL FROM BETWEEN THE RECLINER MECHANISM AND THE SEAT FRAME "SOFT" JOINT AND REPLACE THE RECLINER BOLTS.

IN THE EVENT OF A REAR END COLLISION, THE VEHICLE SHEET METAL STRUCTURE WILL NOT PERFORM AS DESIGNED CAUSING UNEXPECTED DAMAGE TO THE FUEL TANK OR FUEL LINES, RESULTING IN FUEL LEAKAGE. IF THIS IS A FUEL LEAK AND AN IGNITION SOURCE, A FIRE COULD OCCUR.

DEALERS WILL INSPECT FOR THE MISSING WELDS AND, IF NECESSARY, PLACE THREE WHELDS BETWEEN THE INVOLVED PANELS APPLYING PRIMER, SEALER AND ANTI-CORROSION MATERIALS.

IN A CRASH, THE FRONT SEAT PASSENGER COULD RECEIVE MORE SEVERE INJURIES IF HE OR SHE CONTACTS A BROKEN REINFORCEMENT OR IF THE SNAGGING AFFECTS THE DEPLOYMENT OF THE AIR BAG.

DEALERS WILL INSPECT THE INSTRUMENT PANEL PADS AND, IF NECESSARY, INSTALL A PLASTIC EDGE PROTECTOR TO THE INSTRUMENT PANEL PAD REINFORCEMENT. ON CERTAIN EARLY-PRODUCTION VEHICLES, THE INSTRUMENT PANEL PAD WILL BE REPLACED.

IF AN IGNITION SOURCE WERE PRESENT, A VEHICLE INTERIOR FIRE CAN OCCUR.

DEALERS WILL REPLACE THE COVERS ON THE FRONT SEAT BACKS, REAR SEAT CUSHION AND REAR SEAT BACK ASSEMBLIES.

THIS CONDITION CAN CAUSE BODY TO CHASSIS MOVEMENT ALLOWING THE STEERING SHAFT TO SEPARATE FROM THE STEERING GEAR WHICH CAN RESULT IN A LOSS OF STEERING CONTROL.

DEALERS WILL RETORQUE THE UPPER AND LOWER BOLTS TO CORRECT SPECIFICATIONS.

IF A VEHICLE CRASH WERE TO OCCUR, FUEL LEAKAGE COULD RESULT. IF AN IGNITION SOURCE WERE PRESENT, THIS CONDITION COULD RESULT IN A VEHICLE FIRE.

GENERAL MOTORS IS WORKING IN CONJUNCTION WITH CARPENTER, THOMAS BUILT AND U.S. BUS IN PROVIDING THE OWNER NOTIFICATION AND REMEDY CAMPAIGN FOR THIS RECALL. DEALERS WILL INSTALL NEW SHIELDING FOR THE FUEL TANK, NEW FILL PIPE AND VENT HOSES, AND IF REQUIRED, ADD ADDITIONAL ATTACHMENTS TO SECURE THE SCHOOL BUS BODY TO THE CHASSIS.

THE TAPERED STUD CAN LOOSEN AND THE DRIVER WOULD NOTICE A LAG IN THE RESPONSIVENESS TO STEERING WHEEL INPUTS. EVENTUALLY THE RELAY ROD STUD CAN FRACTURE RESULTING LOSS OF STEERING CONTROL.

DEALERS WILL REMOVE THE EXISTING CRIMPED NUT AND INSTALL A NEW NUT TORQUED TO SPECIFICATIONS.

THIS CONDITION CAN CAUSE AN ELECTRICAL SHORT LEADING TO IGNITION AND COMBUSION OF THE PLASTICS IN THE ELECTRICAL COMPONENTS OF THE VEHICLE RESULTING IN A VEHICLE FIRE.

DEALERS WILL REPLACE THE 25 AMP CIRCUIT BREAKERS WITH 25 AMP FUSES IN THE FUSE BLOCK; REMOVE A TEMPORARY PAPER FUSE-BLOCK COVER; INSTALL A PLASTIC SHIELD OVER THE FUSE BLOCK; REPLACE AND REORIENT THE POWER DOOR LOCK RELAY (IF EQUIPPED); INSPECT THE REMOTE KEYLESS ENTRY MODULE (IF EQUIPPED) FOR SIGNS OF CORROSION, REPLACE IF CORRODED, AND REORIENT IT; AND APPLY ADDITIONAL BODY SEALER IN KEY AREAS.

THE AREA AND PATTERN WIPED ON THE WINDSHIELD WILL BE REDUCED AND COULD AFFECT THE DRIVER'S VIEW IN WET WEATHER INCREASING THE RISK OF A VEHICLE ACCIDENT.

DEALERS WILL INSPECT FOR THE CORRECT WIPER BLADE ASSEMBLY AND INSTALL A CORRECT LENGTH WIPER BLADE ASSEMBLY.

THIS CONDITION COULD RESULT IN SEAT MOVEMENT WITH A BELTED OCCUPANT DURING A MODERATE TO SEVERE FRONTAL IMPACT.

DEALERS WILL INSPECT AND REPLACE THE PASSENGER SEAT INBOARD FORE/AFT ADJUSTER.

THE REAR BELTS MAY NOT HOLD AN OCCUPANT IN THE EVENT OF A VEHICLE ACCIDENT INCREASING THE RISK OF PESONAL INJURY.

DEALERS WILL REPLACE THE THREE REAR-SEAT BELT BUCKLES (ONE ASSEMBLY) WITH A NEW, REVISED DESIGN.

CONSEQUENCE OF NON-COMPLIANCE: IF AN IGNITION SOURCE WAS PRESENT, FUEL LEAKAGE RESULTING FROM THIS PUNCTURE COULD RESULT IN A POST-CRASH FIRE.

DEALERS WILL INSTALL TWO NEW SHIELD GUSSETS BETWEEN THE FUEL TANK AND ATTACHMENT BRACKETS TO PREVENT THE REINFORCEMENT FROM PUNCTURING THE FUEL TANK WALL.

IF THIS CONDITION WERE PRESENT IN A SITUATION WHERE STOPPING DISTANCES WERE SMALL, A VEHICLE CRASH COULD OCCUR.

DEALERS WILL INSPECT FOR PROPER BOOSTER INSTALLATION. BOOSTERS FOUND TO BE IMPROPERLY LOCATED WILL BE REMOVED AND REINSTALLED PROPERLY.

THIS DAMAGE TO THE TIRE REINFORCING STRUCTURE IN THE BEAD "TOE" AREA CAUSES A BULGE IN THE SIDEWALL AFTER THE TIRE IS INFLATED. THIS CONDITION WILL RESULT IN A SLOW AIR LOSS CAUSING THE TIRE TO GO FLAT. HOWEVER, IT IS POSSIBLE FOR THE DAMAGE TO RESULT IN A RAPID AIR LOSS CAUSING INJURIES TO ANYONE IF THEY WERE HANDLING THE TIRE WHEN THIS OCCURRED.

DEALERS WILL DEMOUNT EACH TIRE AND INSPECT FOR BEAD DAMAGE. IF BEAD DAMAGE IS FOUND, THE TIRE WILL BE REPLACED.

THIS CONDITION CAN CAUSE A NO-START CONDITION AND POSSIBLY AN ENGINE COMPARTMENT FIRE.

DEALERS WILL UPDATE THE POWERTRAIN CONTROL MODULE PROGRAMMING. UNTIL THE CAMPAIGN REPAIR IS MADE, THE VEHICLE HOOD SHOULD BE SHUT WHENEVER STARTING THE VEHICLE TO REDUCE THE CHANCE OF PERSONAL INJURY.

THE DRIVER MAY NOT NOTICE THE WARNING LIGHT AND EXITS THE VEHICLE. THE VEHICLE COULD ROLL AWAY INCREASING THE RISK OF A VEHICLE ACCIDENT.

DEALERS WILL REPLACE THE PARKING BRAKE SOLENOID VALVE WITH ONE HAVING A 12 VOLT COIL AND THE ORIGINAL VALVE SPRING.

THIS CONDITION WILL ALLOW THE STEERING WHEEL TO SEPARATE FROM THE STEERING COLUMN INCREASING THE RISK OF A VEHICLE ACCIDENT.

DEALERS WILL INSPECT THE STEERING WHEEL FOR THE SUSPECT STEERING WHEEL LOT DATE CODE AND REPLACE ANY FOUND TO HAVE THIS SUSPECT DATE.

THIS CONDITION COULD RESULT IN SUDDEN LOSS OF VEHICLE CONTROL INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.

DEALERS WILL REPLACE THE FOUR REAR AXLE U-BOLTS ON THE AFFECTED VEHICLES.

VEHICLE USAGE COULD CAUSE THE NUTS TO LOOSEN AND EVENTUALLY FALL OFF THE U-BOLT. THIS COULD RESULT IN SUDDEN LOSS OF VEHICLE CONTROL INCREASING THE POTENTIAL FOR A VEHICLE CRASH.

DEALERS WILL CHECK THE U-BOLT NUT TORQUE AND RE-TORQUE ANY LOOSE U-BOLTS TO SPECIFICATION.

THIS CONDITION CAN CAUSE THE BRAKE LINE TO WEAR THROUGH, RESULTING IN LOSS OF BRAKE FLUID AND EVENTUAL LOSS OF ONE-HALF OF THE VEHICLE'S BRAKE SYSTEM, INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.

DEALERS WILL INSPECT THE VEHICLE FOR PROPER BRAKE LINE CLEARANCE AND REPOSITION THOSE BRAKE LINES FOUND TO HAVE LESS THAN MINIMAL CLEARANCE. ADDITIONALLY, THOSE BRAKE LINES FOUND TO HAVE AN INDENTATION CAUSED BY THE CONTACT WILL BE REPLACED AND PROPERLY ROUTED.

CONSEQUENCE OF NON-COMPLIANCE: THE ENGINE SPEED MAY NOT RETURN TO IDLE INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.

DEALERS WILL INSPECT FOR ADEQUATE THROTTLE CABLE TO DASH MAT CLEARANCE, AND IF THERE IS INSUFFICIENT CLEARANCE, CUT OUT A PORTION OF THE DASH MAT TO PROVIDE PROPER CLEARANCE.

CONSEQUENCE OF NON-COMPLIANCE: IF AN INCORRECT PART IS USED, THE BELT MAY NOT LATCH PROPERLY, INCREASING THE RISK OF INJURY TO THE OCCUPANT SHOULD A VEHICLE CRASH OCCUR.

DEALERS WILL INSPECT ALL FRONT AND REAR SAFETY BELT LATCH ENDS AND SAFETY BELT BUCKLES FOR CORRECT PARTS AND REPLACE ANY INCORRECT PARTS.

THESE TRANSMISSIONS COULD SEIZE AND LOCK THE REAR DRIVE WHEELS WHILE THE TRUCK IS BEING DRIVEN CAUSING A LOSS OF VEHICLE CONTROL INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.

DEALERS WILL INSPECT THE TRANSMISSION MAIN SHAFT OUTPUT TORQUE USING A SPECIAL TOOL. IF THE OUTPUT TORQUE DOES NOT MEET SPECIFICATIONS, THE TRANSMISSION WILL BE REPLACED.

IN A CRASH, THERE IS A POSSIBILITY OF A PARTIAL SEPARATION OF THE ROOF PANEL FLANGE SIDES, EXPOSING AN OCCUPANT TO AN INCREASED RISK OF INJURY.

DEALERS WILL REINFORCE THE ROOF FLANGE WITH STRUCTURAL FASTENERS.

THIS CONDITION CAN BE AGGRAVATED BY THE SEVERE DUTY CYCLE OF THESE VEHICLES AND EVENTUALLY CAUSE THE LOWER CONTROL ARM TO FRACTURE COMPLETELY CAUSING A LOSS OF VEHICLE CONTROL WITHOUT PRIOR WARNING.

DEALERS WILL REPLACE BOTH REAR LOWER CONTROL ARMS AND REAR STABILIZER BAR ATTACHMENTS.

IF THE LOWER CONTROL ARM BALL JOINT LOOSENS, FATIGUES AND SEPARATES FROM THE FRONT SUSPENSION KNUCKLE, IT COULD CAUSE LOSS OF VEHICLE CONTROL.

DEALERS WILL INSPECT BOTH FRONT LOWER CONTROL ARM BALL JOINT ATTACHMENT NUTS FOR PROPER TORQUE. IF THE BALL JOINT HAS LOOSENED FROM THE KNUCKLE, BOTH THE BALL JOINT AND THE KNUCKLE WILL BE REPLACED.

THE LOWER CONTROL ARM BALL JOINT CAN LOOSEN, FATIGUE, AND SEPARATE FROM THE FRONT SUSPENSION KNUCKLE RESULTING IN A LOSS OF VEHICLE CONTROL.

DEALERS WILL INSPECT BOTH FRONT LOWER CONTROL ARM BALL JOINT ATTACHMENT NUTS FOR PROPER TORQUE. IF THE BALL JOINT HAS LOOSENED, BOTH THE BALL JOINT AND THE KNUCKLE WILL BE REPLACED.

VEHICLE FIRES CAN OCCUR DUE TO THE SPILLAGE OF TRANSMISSION FLUID.

DEALERS WILL REPLACE THE TRANSMISSION OIL COOLER LINES.

THE HORN PAD CAN SEPARATE FROM THE STEERING WHEEL FALLING BETWEEN THE STEERING WHEEL SPOKES. THE HORN PAD COULD BECOME JAMMED BETWEEN THE STEERING WHEEL SPOKES AND THE TURN SIGNAL LEVER, RESULTING IN DAMAGE TO THE TURN SIGNAL LEVER, HORN PAD, AND HORN WIRING.

DEALERS WILL MODIFY THE HORN PAD RETENTION CLIPS, INSTALL HORN PAD RETENTION BRACKETS TO THE STEERING WHEEL, REINSTALL THE HORN PAD AND ASSURE THAT THE HORN PAD IS PROPERLY RETAINED.

IF THIS OCCURS WHILE THE HOOD OR ENGINE COMPARTMENT WAS OPEN, A PERSON IN THE VICINITY OF THE ENGINE COULD BE STRUCK BY A FAN SEGMENT AND INJURED.

DEALERS WILL REPLACE THE EXISTING ENGINE COOLING FAN WITH A NEWLY RELEASED FAN ASSEMBLY HAVING RIVETS WITH LARGER HEADS.

THIS LOOSE ENGAGEMENT CAN PROVIDE NOTICEABLE NOISE AND ABNORMAL STEERING FEELING TO THE DRIVER AND, IF LEFT UNATTENDED, THE STEERING SHAFTS CAN SEPARATE RESULTING IN A LOSS OF STEERING CONTROL.

DEALERS WILL TORQUE THE SUSPECT FASTENERS TO THE PROPER SPECIFICATIONS.

CONSEQUENCE OF NON-COMPLIANCE: THE DRIVER OF THE VEHICLE WOULD NOT BE ABLE TO SEE THE ACTUAL POSITION OF THE TRANSAXLE GEAR SELECTOR RESULTING IN A DRIVER EITHER INADVERTENTLY LEAVING A PARKED OR IDLING VEHICLE IN DRIVE, REVERSE, OR NEUTRAL RATHER THAN PARK, OR SELECTING AN INCORRECT TRANSAXLE SHIFT POSITION WHILE DRIVING THE VEHICLE.

DEALERS ARE TO INSTALL A NEW INSTRUMENT PANEL CLUSTER TRIM PLATE/BEZEL ASSEMBLY WHICH IS NOT SUBJECT TO THIS CONDITION.

THIS CAN RESULT IN LOSS OF SUFFICIENT TRANSMISSION FLUID TO CAUSE THE TRANSMISSION TO STOP TRANSMITTING POWER TO THE REAR WHEELS AND COULD ALSO CAUSE SEVERE TRANSMISSION DAMAGE.

DEALERS WILL REPLACE THE SUSPECT TRANSMISSION OIL COOLER HOSES WITH PARTS THAT MEET SPECIFICATIONS.