For 1990-2009 cars

# Upcoming Safety Recall Power Steering Gear Lower Pinion Bearing Separation

Subject: | Upcoming Safety Recall Power Steering Gear Lower Pinion Bearing Separation

Models: | 1996-1998 Chevrolet Cavalier

| 1996 Chevrolet Lumina APV

| 1997-1998 Chevrolet Venture

| 1996-1998 Pontiac Sunfire, Trans Sport

| 1997-1998 Pontiac Grand Prix

| 1996-1998 Oldsmobile Silhouette

Attention: | Dealer Operator, General Manager, Sales Manager, Service Manager and Parts Manager

Based on preliminary information from the NHTSA website, the media may report that a safety recall is to be announced involving 1996-98 Chevrolet Cavalier and Pontiac Sunfire cars, Chevrolet Lumina/Venture, Oldsmobile Silhouette, and Pontiac Trans Sport minivans and 1997-98 Pontiac Grand Prix cars.

These vehicles were built from January 1, 1996 through October 31, 1997 and may have a lower pinion bearing in the power steering gear that could separate. If this occurs, the driver may experience an intermittent loss of power steering assist when making left turns, usually at low speeds. Power assist is normal in right hand turns. When trying to turn left, some drivers could experience higher resistance or, in a few cases, unintended power assist to the right. If this happens while the vehicle is moving, a crash could result.

There are approximately 1.5 million vehicles involved. Due to parts availability and special tool requirements, the recall is not planned to be announced by General Motors until January 2003.

Listed below are some anticipated questions and answers to assist in responding to customer inquiries.

Q1: What is the condition that prompted a safety recall?

A1: In some 1996-98 Chevrolet Cavalier and Pontiac Sunfire cars, Chevrolet Lumina/Venture, Oldsmobile Silhouette, and Pontiac Trans Sport minivans, and 1997-98 Pontiac Grand Prix cars using certain power steering gear applications, the lower pinion bearing in the rack and pinion steering gear assembly may separate.

Q2: What might occur as a result of this condition?

A2: If the lower bearing separates and the pinion shaft moves, the driver may experience an intermittent increase in steering efforts when turning left. If the pinion shaft moves too far, the driver could experience a higher resistance and, in a few cases, unintended power assist to the right.

Q3: What is "unintended power assist to the right?"

A3: A condition in which the driver steers the vehicle to the left and the power steering assist turns the vehicle to the right. (This condition can only occur with the left turn steering inputs. This condition is rare - five reports consistent with this condition were found.)

Q4: How does "assist to the right" happen?

A4: As the driver steers the vehicle to the left, the pinion shaft moves and power steering fluid is misdirected, so the power assist is to the right instead of to the left.

Q5: How would a vehicle owner realize the condition exists?

A5: The first indication of a problem is an intermittent increase in steering efforts in left hand turns because of lack of power assist. (Power assist is normal in right hand turns.)

Q6: Have there been any reports from the field of crashes, injuries, or fatalities related to this condition?

A6: GM is aware of 15 crashes and three injuries that may be related to this condition, but there are no fatal injuries. The crashes were reported as steering issues and it is not confirmed whether the lower pinion was the root cause

Q7: Were the injuries serious?

A7: No. Bruises and cuts.

Q8: How was this condition discovered?

A8: Separation of bearings was first identified through examination of parts replaced under warranty. Since then, GM and its supplier have done extensive testing and analysis. In November, 2001, GM received notice that NHTSA has begun a preliminary analysis of steering complaints on the 1997 Grand Prix. GM cooperated with the investigation.

Q9: What was the cause of the condition?

A9: Some of the lower pinion bearings were not manufactured properly and can separate with vehicle usage over time. When the bearing separates, steering performance may change when the pinion shaft moves upward in the valve housing during some left turns.

Q10: Who is the supplier of the lower pinion bearings?

A10: GM does not name suppliers in recalls.

Q11: Where were these vehicles built?

A11: The vehicles involved in this recall were built at the GM assembly plants in Doraville, Georgia (Chevrolet Venture, Oldsmobile Silhouette, and Pontiac Trans Sport minivans); Tarrytown, New York (Chevrolet Lumina APV); Fairfax, Kansas (Pontiac Grand Prix); and Lordstown, Ohio, Lansing, Michigan, and Ramos Arizpe, Mexico (Chevrolet Cavalier and Pontiac Sunfire).

Q12: What will GM do to correct this condition on the subject vehicles?

A12: Chevrolet, Oldsmobile, and Pontiac dealers will inspect the steering gear lower pinion bearing. The dealers will replace the lower pinion bearing or, if necessary because of the condition of the old bearing, replace the rack and pinion steering gear assembly. These repairs will be performed at no cost to the customers.

Q13: Are parts at the dealers, and can owners bring in their vehicles for repair right away?

A13: No. Replacement bearings will not be available until January 2003.

Q14: Why can't GM begin repair sooner than January?

A14: Due to the large number of vehicles involved in this recall, it will take several months to build and ship enough parts and special tools to fix the condition.

Q15: What if the driver experiences lack of power assist in left turns before they get the recall notice?

A15: If drivers experience lack of power assist only in left turns, they should contact a dealer. Otherwise, they should continue to drive their vehicles unless, of course, there are other vehicle concerns that should be addressed outside of this recall.

Important: Until replacement bearings are available, dealers will have to replace the steering gear assembly to correct this condition. All such claims should be held until the "V" labor operation for this recall is released via the recall bulletin in January 2003. Steering gear assemblies that are replaced for reasons other than a customer complaint of "lack of power assist only when turning left" will not be covered by this recall.