The defect
CERTAIN MINIVANS HAVE AN INTERFERENCE CONDITION BETWEEN THE LOWER BALL JOINT RUBBER BOOT AND THE STEERING KNUCKLE (BOTH LEFT/RIGHT SIDES), WHICH COULD RESULT IN CUTTING OF THE BOOT THAT IS INTENDED TO SEAL THE BALL JOINT. IF THE LOWER BALL JOINT BOOT WERE CUT, CONTAMINATION FROM THE ROAD (SALT, DIRT, WATER, ETC.) COULD ENTER THE BALL SOCKET AREA OF THE BALL JOINT CAUSING THE JOINT TO WEAR OUT TOO QUICKLY.
The risk
THE STEERING KNUCKLE COULD SEPARATE FROM THE LOWER CONTROL ARM, DROPPING DOWN THE AFFECTED CORNER OF THE VEHICLE. THE COIL SPRING WOULD PUSH THE CONTROL ARM DOWN INTO CONTACT WITH THE GROUND, CREATING A DRAG THAT WOULD SLOW THE VEHICLE. THE DRIVER COULD HAVE DIFFICULTY IN MAINTAINING THE DIRECTIONAL CONTROL OF THE VEHICLE. IN ADDITION, THE AFFECTED WHEEL ASSEMBLY COULD SEPARATE FROM THE VEHICLE IF FORCES RESULTING FROM THE WHEEL'S DRAGGING ACTION WERE SUFFICIENT TO FRACTURE THE TIE ROD END AND UPPER BALL JOINT CONNECTIONS. SEPARATION OF THE WHEEL ASSEMBLY WOULD ALSO SEVER THAT WHEEL'S HYDRAULIC BRAKE HOSE, RESULTING IN LOST BRAKING PERFORMANCE FROM THE FRONT BRAKE SYSTEM. VEHICLE STOPPING DISTANCE WOULD INCREASE, WHICH COULD RESULT IN A CRASH.
The remedy
DEALERS WILL REPLACE THE STEERING KNUCKLES. OWNER NOTIFICATION IS EXPECTED TO BEGIN ON APRIL 8, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.
NHTSA's own wording · initiated by MFR
Vehicles covered
| Model | Model years |
|---|---|
| Chevrolet Astro | 2003 |
| GMC Safari | 2003 |
Components: SUSPENSION:FRONT:CONTROL ARM:LOWER BALL JOINT
Model years in this recall
NHTSA complaints and the number of recall campaigns for each model year this recall covers.
| Model | Year | Complaints | Recalls |
|---|---|---|---|
| Chevrolet Astro | 2003 | 62 | 1 |
| GMC Safari | 2003 | 18 | 1 |
Other suspension recalls in 2003
25 of the 527 recall campaigns reported to NHTSA in 2003 concerned the suspension; GENERAL MOTORS CORP. filed 1,195 campaigns in all.
| 03V460000 10 Nov 2003 | DAIMLERCHRYSLER CORPORATION |
| 03V436000 4 Nov 2003 | RHODES TRAILERS |
| 03V411000 22 Oct 2003 | MOTOR COACH INDUSTRIES, INC |
| 03V371000 6 Oct 2003 | FINN CORPORATION |
| 03V369000 3 Oct 2003 | NEWMAR CORPORATION |
| 03V341000 15 Sept 2003 | TRAVEL SUPREME, INC. |
| 03V342000 12 Sept 2003 | COACHMEN RV COMPANY, LLC |
| 03V278000 1 Aug 2003 | MITSUBISHI FUSO TRK, AMER |
NHTSA recalls (public domain) · all recalls of 2003