2004 CHEVROLET KODIAK Recalls, Complaints & Safety

STEERING

ON CERTAIN MEDIUM DUTY TRUCKS EQUIPPED WITH ZF MODEL 8018 STEERING GEARS, THE STEERING GEAR MAY HAVE BEEN PRODUCED INCORRECTLY. A STEERING GEAR WITH THIS CONDITION MAY PRODUCE THE FEELING OF HITTING A CURB AND A CRACKING OR PINGING SOUND WHEN THE STEERING WHEEL IS TURNED.

Remedy: DEALERS WILL INSPECT FOR CERTAIN DATE CODES AND VERIFY THE MILEAGE ON STEERING GEARS AND REPLACE GEARS AS NECESSARY. THE RECALL BEGAN ON OCTOBER 25, 2007. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438; GMC AT 1-866-996-9463; OR ISUZU AT 1-800-255-6727.

990 vehicles affected

SERVICE BRAKES, HYDRAULIC:FLUID

CERTAIN 2003-2005 MODEL YEAR 4500/5500 SERIES CHEVROLET KODIAK, SCHOOL BUS CHASSIS, AND GMC TOPKICK VEHICLES; AND 2003-2004 MODEL YEAR GMC SCHOOL BUS CHASSIS VEHICLES EQUIPPED WITH AN 8.1L ENGINE AND HYDROMAX BRAKE SYSTEM. THE POWER STEERING HOSE MAY COME INTO CONTACT WITH A PORTION OF THE INTERMEDIATE STEERING SHAFT. A HOLE COULD BE WORN IN THE HOSE AND A LOSS OF HYDRAULIC FLUID WOULD OCCUR.

Remedy: GM WILL NOTIFY ITS CUSTOMERS AND DEALERS WILL REROUTE THE POWER STEERING HOSE. IF THE STEEL BRAIDING OF THE HOSE IS EXPOSED, DEALERS ARE TO REPLACE THE HOSE FREE OF CHARGE. THE RECALL BEGAN ON JULY 12, 2005. OWNERS MAY CONTACT CHEVROLET AT 800-630-2438 OR GMC AT 866-996-9463.

6,698 vehicles affected

SERVICE BRAKES, HYDRAULIC

CERTAIN TRUCKS, SPORT UTILITY VEHICLES, AND VANS EQUIPPED WITH BOSCH HYDRO-BOOST BRAKE ASSEMBLIES, THE HYDRAULIC BRAKE BOOSTER PRESSURE ACCUMULATOR MAY CRACK AND SEPARATE FROM THE HYDRO-BOOST ASSEMBLY DURING NORMAL OPERATING CONDITIONS.

Remedy: DEALERS WILL TEST THE HYDRO-BOOST ASSEMBLY FOR FUNCTIONAL OPERATION OF THE TWO-FUNCTION VALVE. IF THE HYDRO-BOOST ASSEMBLY FAILS THE TEST, DEALERS WILL REPLACE THE ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON MARCH 23, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, GMC TRUCKS AT 1-866-996-9463 AND HUMMER AT 1-800-732-5493.

77,411 vehicles affected

STRUCTURE:BODY:TAILGATE:HINGE AND ATTACHMENTS

ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES, THE GALVANIZED STEEL TAILGATE SUPPORT CABLES THAT RETAIN THE TAILGATE IN THE FULL OPEN (HORIZONTAL) POSITION MAY CORRODE, WEAKEN, AND EVENTUALLY FRACTURE. IF BOTH CABLES FRACTURED, THE TAILGATE WOULD SUDDENLY DROP AND STRIKE THE TOP SURFACE OF THE REAR BUMPER.

Remedy: DEALERS WILL REPLACE THE CABLES. INTERIM OWNER NOTIFICATION BEGAN ON APRIL 7, 20004. THE RECALL BEGAN ON SEPTEMBER 24, 2004, WHEN REPLACEMENT PARTS WERE AVAILABLE, AND WILL CONTINUE THROUGH OCTOBER 29, 2004. OWNERS SHOULD CONTACT CADILLAC AT 1-866-982-2339, CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463, OR VISIT WWW.MYGMLINK.COM, AND ENTER YOUR VEHICLE IDENTIFICATION NUMBER.

3,662,211 vehicles affected

SERVICE BRAKES, HYDRAULIC:PEDALS AND LINKAGES

ON CERTAIN TRUCKS, THE SWITCH RETAINER HOLDING THE BRAKE BOOSTER PUSH ROD AND THE BRAKE PEDAL TOGETHER COULD BE MISSING.

Remedy: DEALERS WILL INSPECT AND INSTALL A NEW RETAINER IF MISSING. OWNER NOTIFICATION BEGAN MARCH 5, 2004. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT GMCICT AT 1-800-862-4389.

2,037 vehicles affected

DT*: THE CONTACT STATED THERE WERE NUMEROUS PROBLEMS WITH THE VEHICLE. AT 20,000 MILES, THE LEFT WHEEL BEARING BACKED OUT AND AT 87,000 MILES, THE DRAG LINK FAILED. WHILE DRIVING 80 MPH, THE VEHICLE SUDDENLY DOWN SHIFTED TO 20 MPH WITH NO EFFORT FROM THE CONTACT. WHILE STARTING THE VEHICLE, THE RPM WILL NOT GO BEYOND 2000. THE VEHICLE HAS BEEN TAKEN TO THE DEALER ON NUMEROUS OCCASIONS AND THEY CAN NOT DETERMINE THE PROBLEM. THIS OCCURRED REGARDLESS OF THE TRAFFIC CONDITIONS, SPEED OR TERRAIN.*AK

BRAKE WARNING LIGHT FOR SERVICE BRAKES CAME ON. SOFT BRAKE PEDAL. FURTHER INVESTIGATION REVEALED LOSS OF BRAKE FLUID AND BRAKE FLUID SPRAYED ALL OVER LEFT FRONT WHEEL, CHASSIS, AND FRAME. OUTSIDE BRAKE LINE FROM THE BRAKE PRESSURE MODULATOR HAD A HOLE LEAKING BRAKE FLUID. CAUSE OF WORN BRAKE LINE WAS FROM THE POWER STEERING HOSE COMING FROM THE HYDRAULIC PUMP TO THE INLET SIDE OF THE STEERING GEAR BOX. THE POWER STEERING HOSE WAS RUBBING AGAINST THE BRAKE LINE. POWER STEERING HOSE WAS REPLACED AND BRAKE LINE REPAIRED. DEFECTIVE BRAKE LINE IS AVAILABLE FOR INSPECTION. *JB

DT*: THE CONTACT STATED THE FRONT END OF THE VEHICLE SHOOK AT ANY SPEED. THIS CAUSED ABNORMAL WEAR TO THE FRONT TIRES, THE TIRES MUST BE REPLACED EVERY 10,000 MILES. THE DEALERSHIP WAS UNABLE TO DETERMINE A PROBLEM WITH THE VEHICLE, BUT DETERMINED THE TIRES ARE NOT RATED TO CARRY THE LOAD OF THE VEHICLE.

DT: THE CONTACT EXPERIENCE A PROBLEM WITH THE DIESEL ENGINE DYING WHILE THE VEHICLE WAS DRIVE. THE VEHICLE DID NOT STALL, BUT SIMPLY DIED AT ONCE WITHOUT WARNING. THE CHECK ENGINE LIGHT ILLUMINATED AS A WARNING, AND THE ENGINE SHUT OFF . THE VEHICLE WAS USED AS A HAULER THAT PULLED A TRAILER DELIVERING BOATS. WHEN THE ENGINE DIED THERE WAS A LOSS OF POWER, RESULTING IN A LOSS OF POWER STEERING AND THE BRAKES. THE ONLY WAY TO STOP THE VEHICLE WAS BY USING THE IN CAB CONTROLLER TO ACTIVATE THE ELECTRIC BRAKES ON THE TRAILER WHICH ULTIMATELY SLOWED AND STOPPED THE VEHICLE. THE VEHICLE HAS BEEN TO 18 DEALERSHIPS ACROSS THE COUNTRY IN AN ATTEMPT TO REPAIR THIS PROBLEM. THE DEALERS WERE CAUSE OF THE UNABLE TO DETERMINE THE PROBLEM. THE VEHICLE DID NOT PRODUCE ANY TYPE OF DIAGNOSTIC CODE. THEREFORE, NO REPAIRS OR CORRECTIONS WERE MADE. THE LATEST INCIDENT RESULTED IN A JACKKNIFE CRASH ON THE HIGHWAY. THERE WAS AN INJURY, AND A POLICE REPORT WAS TAKEN. THE VEHICLE WAS NOT BEING DRIVEN DUE TO THE RISK OF THIS PROBLEM OCCURRING AGAIN. *AK

Crash 1 injured

CONSUMER IS UNABLE TO KEEP VEHICLE STRAYED OUT OF THE LANE. FRONT END HAD BEEN DONE EIGHT TIMES. THE REAR AXLE WAS MOUNTED WRONGLY ON THE VEHICLE. *AK