CHEVROLET ASTRO 2003: SUSPENSION:FRONT:CONTROL ARM:LOWER BALL JOINT

NHTSA Campaign ID Number: 03V328000

Production Dates: 2002-03-01 - 2003-06-30

Manufacturers Involved: General Motors, LLC

Manufacturer Campaign Number: 03044

Component: SUSPENSION:FRONT:CONTROL ARM:LOWER BALL JOINT

Potential Number Of Units Affected: 41477

Report Initiator: MFR MFR Report

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 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.

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.

GM RECALL NO. 03044.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT '1-888-327-4236'.