On certain vehicles, the rear engine cradle bolts may pull through due to corrosion of the retainers. If this should occur, the cradle would no longer be supported at these mounting locations and the steering shaft may separate from the steering gear. This could result in loss of steering control.
Certain vehicles may have been built with a steering gear pinion shaft that was improperly heat treated and could fracture in service. This could result in loss of vehicle control and a crash without prior warning.
Safety Risk
No risk description available.
Remedy
Manual steering gear will be replaced on affected vehicles.
NOTE: VEHICLES FOR OFF ROAD USE ONLY. ONE OF THE TWO PINCH CLAMPS SECURING THE HANDLEBAR TO THE FRONT FORK ASSEMBLY UTILIZES A BOLT WHICH IS TOO SHORT. THIS CAN RESULT IN FRACTURE OF THE CLAMP AND ALLOW THE HANDLEBAR TO ROTATE AROUND ITS MOUNTING AXIS. THIS COULD CAUSE LOSS OF STEERING CONTROL AND A POSSIBLE CRASH.
Safety Risk
No risk description available.
Remedy
PINCH CLAMP BOLTS WILL BE REPLACED WITH LONGER BOLTS. PINCH CLAMPS WILL BE REPLACED IF REQUIRED.
On certain vehicles, the extra keys operator's key ring may become temporarily lodged in the airbag screw access holes on the steering wheel back cover, hampering steering wheel return. In some cases, the force used to return the wheel may also cause the vehicle ignition to be turned off.
Safety Risk
No risk description available.
Remedy
Plugs will be installed in the steering wheel back cover airbag screw access holes to prevent the potential for any key interference.
THE STEERING SHAFT UNIVERSAL JOINT UPPER LOCKING BOLT MAY NOT HAVE BEEN SUFFICIENTLY TORQUED. AN UNDER TORQUED LOCKING BOLT COULD EVENTUALLY LOOSEN AND RENDER THE STEERING SYSTEM INOPERATIVE.
Safety Risk
No risk description available.
Remedy
THE STEERING SHAFT UNIVERSAL JOINT UPPER LOCKING BOLT WILL BE REPLACED AND PROPERLY TORQUED.
HANDLEBAR MOVEMENT DUE TO SOFT HANDLEBAR STAY CUSHION RUBBERS CAN LEAD TO CRACKS DEVELOPING AT THE CENTRE HOLE LOCATION OF THE HANDLEBAR BETWEEN THE HANDLEBAR MOUNTING STAYS. A CRACKED HANDLEBAR COULD RESULT IN LOSS OF STEERING CONTROL.
Safety Risk
No risk description available.
Remedy
HANDLEBAR STAY CUSHION RUBBERS WILL BE REPLACED ON AFFECTED VEHICLES.
VEHICLES MAY HAVE BEEN BUILT WITH LOOSE OR MISSING INTERMEDIATE STEERING SHAFT FASTENERS. IF THE FASTENERS ARE MISSING, THE INTERMEDIATE STEERING SHAFT CAN SEPARATE RESULTING IN A TOTAL LOSS OF STEERING CONTROL AND A POSSIBLE CRASH WITHOUT PRIOR WARNING.
Safety Risk
No risk description available.
Remedy
DEALERS WILL PROPERLY TORQUE OR INSTALL, IF NECESSARY, THE STEERING SHAFT PINCH BOLT.
THE PLASTIC RETAINING PINS IN THE COLLAPSIBLE STEERING COLUMN SHAFT WERE SHEARED PRIOR TO INSTALLATION OF THE COLUMN INTO THE VEHICLE. THIS COULD CAUSE THE UPPER STEERING COLUMN SHAFT TO SEPARATE FROM THE LOWER COLUMN SHAFT, WHICH COULD RESULT IN A LOSS OF STEERING CONTROL.
Safety Risk
No risk description available.
Remedy
A RESTRAINING SLEEVE WILL BE ADDED TO THE INTERMEDIATE SHAFT TO LIMIT THE AMOUNT OF STEERING COLUMN SHAFT MOVEMENT.
THE LOWER STEERING SHAFT ON THESE VEHICLES MAY SEPARATE DUE TO A MISLOCATED WELD. IF THIS WERE TO OCCUR WHILE THE VEHICLE WAS IN MOTION, A LOSS OF STEERING CONTROL COULD RESULT AND A VEHICLE CRASH COULD OCCUR WITHOUT PRIOR WARNING.
Safety Risk
No risk description available.
Remedy
DEALERS WILL INSPECT VEHICLES AND REPLACE STEERING SHAFT ASREQUIRED.
NOTE: MOTOCROSS OFF-ROAD COMPETITION VEHICLES.
THE LOWER HANDLEBAR HOLDERS MAY CRACK, RELEASING THE CLAMPING FORCE ON THE HANDLEBAR AND ALLOWING THE HANDLEBAR TO ROTATE IN THE CLAMPS. THIS COULD RESULT IN LOSS OF VEHICLE CONTROL.
Safety Risk
No risk description available.
Remedy
LOWER HANDLEBAR HOLDERS WILL BE REPLACED ON AFFECTED VEHICLES.
ON VEHICLES WITH MANUAL TRANSMISSION, THE ROLL PINS SECURING THE IGNITION LOCK CYLINDER IN THE STEERING COLUMN HOUSING MAY NOT REMAIN IN PLACE. THIS COULD CAUSE THE IGNITION LOCK CYLINDER TO DISENGAGE FROM THE STEERING COLUMN HOUSING WHICH COULD RESULT IN STEERING COLUMN LOCK-UP AND LOSS OF STEERING CONTROL.
Safety Risk
No risk description available.
Remedy
VEHICLES WILL BE INSPECTED AND IF ROLL PINS ARE PRESENT AND FULLY INSERTED, A PLASTIC SNAP-ON SLEEVE WILL BE INSTALLED TO PREVENT THE PINS FROM COMING OUT. IF ONE OR BOTH OR THE ROLL PINS ARE MISSING OR NOT FULLY INSERTED, THE IGNITION LOCK HOUSING ASSEMBLY WILL BE REPLACED (ALONG WITH THE DOOR LOCKS AND THE LIFTGATE/DECK-LID LOCKS SO THAT KEY COMPATIBILITY IS MAINTAINED).
THE UPPER STEERING COLUMN LOCKNUT WAS MANUFACTURED WITH A LOWER CLASS OF MATERIAL WHICH COULD RESULT IN A LOSS OF TIGHTENING TORQUE ON THE UPPER STEERING COLUMN FASTENER. LOOSENING OF THE FASTENER COULD RESULT IN PLAY IN THE STEERING SYSTEM AND CONSEQUENTIAL IMPAIRMENT OF HANDLING.
Safety Risk
No risk description available.
Remedy
LOCKNUT WILL BE REPLACED WITH ONE HAVING IMPROVED SELF-LOCKING PROPERTIES.
THE STEERING WHEEL CENTRE HUB MAY FRACTURE DURING CERTAIN TYPES OF FRONTAL AND NEAR FRONTAL VEHICLE CRASHES. THIS WOULD REDUCE THE DRIVER'S ABILITY TO CONTROL THE VEHICLE TO POSSIBLY AVOID ANY SECOND COLLISION AND COULD REDUCE THE CRASH PROTECTION OF THE STEERING SYSTEM AND DRIVER-SIDE AIR BAG.
Safety Risk
No risk description available.
Remedy
DEALERS WILL INSTALL A REINFORCEMENT PLATE TO THE STEERING WHEEL HUB.
THE TIE ROD ATTACHING BOLTS ON THESE VEHICLES MAY FAIL DUE TO UNDER TORQUING CAUSING SEPARATION OF THE TIE ROD ARM FROM THE STEER AXLE SPINDLE. THIS COULD RESULT IN LOSS OF STEERING CONTROL AND A CRASH WITHOUT PRIOR WARNING.
Safety Risk
No risk description available.
Remedy
VEHICLES WILL BE INSPECTED AND ATTACHING BOLTS REPLACED. TIE ROD ARMS AND SPINDLES WILL BE REPLACED AS APPROPRIATE.
On certain C3500HD vehicles, the tie rod may fracture through the damper stud mounting hole. Under moderate to heavy braking or significant power steering pump inputs, the wheel can pull out and slide resulting in a pulling to the left. This could result in a vehicle crash without prior warning.
Safety Risk
No risk description available.
Remedy
Tie rod assembly, damper and damper bracket will be replaced with newly designed parts.
A steering column coupling bolt may fracture due to hydrogen embrittlement, causing loss of clamping load on the steering column shaft coupling with resultant loss of steering control.
Safety Risk
No risk description available.
Remedy
Zinc plated steering column coupling bolts will be replaced with a phosphate coated bolt.
STEERING BOX RETAINING SCREWS MAY SLACKEN DUE TO ASSEMBLY LUBRICANTS IN THE MOUNTING HOLES. THIS COULD RESULT IN STEERING RESPONSE NOT BEING AS IMMEDIATE AS USUAL AND COULD CAUSE DIMINISHED DRIVER CONTROL.
Safety Risk
No risk description available.
Remedy
STEERING BOX RETAINING SCREWS WILL BE REPLACED ON AFFECTED VEHICLES.
On certain C3500, G3 and P30 vehicles, the left hand lower control arm can crack starting at the rear flange and progress to the ball joint mounting hole and eventually cause the lower ball joint to separate from the control arm. This could result in loss of vehicle control and a crash without prior warning.
Safety Risk
No risk description available.
Remedy
Dealers will install a reinforcement brace to the left-hand lower control arm.
THE ELECTRONICALLY CONTROLLED MOTOR PUMP POWER STEERING SYSTEM MAY MALFUNCTION, RESULTING IN INTERMITTENT LOSS OF POWER ASSIST. WHEN POWER ASSIST FAILS, THE VEHICLE MAY BE MANUALLY STEERED, HOWEVER, SINCE POWER STEERING ASSIST MAY COME BACK SUDDENLY AFTER THE LOSS OF POWER ASSIST HAS OCCURRED, IT CAN CONCEIVABLY LEAD TO LOSS OF VEHICLE CONTROL.
Safety Risk
No risk description available.
Remedy
DEALERS WILL INSTALL A NEW MODIFIED SIGNAL CONTROLLER AND POWER CONTROLLER ON AFFECTED VEHICLES.
ON VEHICLES WITH COLUMN SHIFT, IT MAY BE POSSIBLE FOR THE STEERING COLUMN TO LOCK WHILE THE VEHICLE IS IN MOTION AND IN GEAR AFTER TURNING THE IGNITION TO THE OFF POSITION. THIS WOULD AFFECT THE DRIVER'S ABILITY TO CONTROL THE VEHICLE RESULTING IN A POSSIBLE CRASH WITHOUT PRIOR WARNING.
Safety Risk
No risk description available.
Remedy
DEALERS WILL ADJUST THE PARK LOCK CABLE AND RE-ROUTE AND RESTRAIN THE BRAKE TRANSMISSION SHIFT INTERLOCK HARNESS AND CONNECTOR.
