TSB - CMVSS Noncompliance - Brake Hydro-Boost Relief Valve Seal Fracture #04004A

Klaus · #1 07-26-2004, 10:36 PM

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<TD align=middle width="50%">Document ID# 1528250
2003 HUMMER
H2</TD>
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<H1>F/CMVSS Noncompliance - Brake Hydro-Boost Relief Valve Seal Fracture #04004A
- (06/18/2004)</H1></TABLE>04004A - Brake Hydro-Boost Relief Valve Seal Fracture

2003-2004 Cadillac Escalade, Escalade EXT, Escalade ESV</P>

2003-2004 Chevrolet Silverado, Avalanche, Suburban, Express</P>

2004 Chevrolet Tahoe</P>

2003-2004 GMC Sierra, Yukon, Yukon XL, Savana</P>

2003-2004 HUMMER H2</P>

THIS BULLETIN CANCELS AND REPLACES BULLETIN 04004, ISSUED JUNE 2004. THE
INSPECTION PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO INCLUDE ADDITIONAL
STAMPED NUMBERS ON THE HYDRAULIC BRAKE BOOSTER. ALL COPIES OF BULLETIN 04004
SHOULD BE DESTROYED.</P><A name=ss1-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss1-1528250">
<H5>Condition</A></H5>

General Motors has decided that certain 2003 and 2004 model year Cadillac
Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche,
Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; HUMMER H2; and
2004 model year Chevrolet Tahoe vehicles fail to conform to either
Federal/Canada Motor Vehicle Safety Standard 105, "Hydraulic and Electric Brake
System", or Standard 135, "Light Vehicle Brake Systems". These vehicles may have
a relief valve bore within the brake hydro-boost module that is not to
specification. An out-of-specification bore could result in fracture of the
relief valve o-ring seal within the module. If this happens, during brake
applications the driver may be able to hear an engine compartment noise similar
to the sound that occurs when the steering wheel is turned to a full stop
position. The driver could also experience a slight increase in steering efforts
while braking and parking. Under certain driving conditions, a fractured seal
may require a slight increase in the applied brake pedal effort to achieve the
same vehicle deceleration rate as prior to the seal fracture. If this were to
occur, it could result in a vehicle crash without prior warning.</P><A
name=ss2-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss2-1528250">
<H5>Correction</A></H5>

Dealers are to inspect the hydro-boost module and replace the relief valve,
if necessary.</P><A name=ss3-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss3-1528250">
<H5>Vehicles Involved</A></H5>

Involved are certain 2003 and 2004 model year Cadillac Escalade, Escalade EXT
and Escalade ESV; Chevrolet Silverado, Avalanche, Suburban, and Express; GMC
Sierra, Yukon, Yukon XL, and Savana; HUMMER H2 and 2004 model year Chevrolet
Tahoe vehicles built within these VIN breakpoints:</P>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Year</P></TH>
<TH vAlign=bottom align=middle>

Division</P></TH>
<TH vAlign=bottom align=middle>

Model</P></TH>
<TH vAlign=bottom align=middle>

From</P></TH>
<TH vAlign=bottom align=middle>

Through</P></TH></TR>
<TR>
<TD vAlign=center align=middle>

2003 </P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade</P></TD>
<TD vAlign=center align=middle>

3R302814 </P></TD>
<TD vAlign=center align=middle>

3R320163</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004 </P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade </P></TD>
<TD vAlign=center align=middle>

4R100129 </P></TD>
<TD vAlign=center align=middle>

4R104745</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade ESV</P></TD>
<TD vAlign=center align=middle>

3G299104</P></TD>
<TD vAlign=center align=middle>

3G324791</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

Cadillac </P></TD>
<TD vAlign=center align=middle>

Escalade ESV</P></TD>
<TD vAlign=center align=middle>

4G100051</P></TD>
<TD vAlign=center align=middle>

4G100053</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade EXT</P></TD>
<TD vAlign=center align=middle>

3G300225</P></TD>
<TD vAlign=center align=middle>

3G324703</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade EXT</P></TD>
<TD vAlign=center align=middle>

4G100044</P></TD>
<TD vAlign=center align=middle>

4G100048</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

Avalanche</P></TD>
<TD vAlign=center align=middle>

3G301959</P></TD>
<TD vAlign=center align=middle>

3G324088</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

Avalanche</P></TD>
<TD vAlign=center align=middle>

4G100025</P></TD>
<TD vAlign=center align=middle>

4G100065</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

Express</P></TD>
<TD vAlign=center align=middle>

31216183</P></TD>
<TD vAlign=center align=middle>

31238955</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

Express</P></TD>
<TD vAlign=center align=middle>

41100063</P></TD>
<TD vAlign=center align=middle>

41103650</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=4>

2003</P></TD>
<TD vAlign=center align=middle rowSpan=4>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=4>

Silverado</P></TD>
<TD vAlign=center align=middle>

3E346100</P></TD>
<TD vAlign=center align=middle>

3E376199</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3F192149</P></TD>
<TD vAlign=center align=middle>

3F259060</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3M110513</P></TD>
<TD vAlign=center align=middle>

3M112077</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3Z338002</P></TD>
<TD vAlign=center align=middle>

3Z361763</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=4>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=4>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=4>

Silverado</P></TD>
<TD vAlign=center align=middle>

4E100021</P></TD>
<TD vAlign=center align=middle>

4E100126</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4F100026</P></TD>
<TD vAlign=center align=middle>

4F100566</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4M100006</P></TD>
<TD vAlign=center align=middle>

4M100017</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4Z100115</P></TD>
<TD vAlign=center align=middle>

4Z101176</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=2>

2003</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Suburban</P></TD>
<TD vAlign=center align=middle>

3G285873</P></TD>
<TD vAlign=center align=middle>

3G324561</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3R302840</P></TD>
<TD vAlign=center align=middle>

3R319989</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Suburban</P></TD>
<TD vAlign=center align=middle>

4G100033</P></TD>
<TD vAlign=center align=middle>

4G100074</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4J100031</P></TD>
<TD vAlign=center align=middle>

4J100106</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4R100153</P></TD>
<TD vAlign=center align=middle>

4R104727</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=2>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Tahoe</P></TD>
<TD vAlign=center align=middle>

4J100021</P></TD>
<TD vAlign=center align=middle>

4J100103</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4R100130</P></TD>
<TD vAlign=center align=middle>

4R104749</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

GMC </P></TD>
<TD vAlign=center align=middle>

Savana</P></TD>
<TD vAlign=center align=middle>

31217178</P></TD>
<TD vAlign=center align=middle>

31905189</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

GMC</P></TD>
<TD vAlign=center align=middle>

Savana</P></TD>
<TD vAlign=center align=middle>

41100065</P></TD>
<TD vAlign=center align=middle>

41103637</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2003</P></TD>
<TD vAlign=center align=middle rowSpan=3>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Sierra</P></TD>
<TD vAlign=center align=middle>

3E346103</P></TD>
<TD vAlign=center align=middle>

3E376203</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3F232315</P></TD>
<TD vAlign=center align=middle>

3F259040</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3Z338024</P></TD>
<TD vAlign=center align=middle>

3Z359268</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=3>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Sierra</P></TD>
<TD vAlign=center align=middle>

4E100026</P></TD>
<TD vAlign=center align=middle>

4E100127</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4F100025</P></TD>
<TD vAlign=center align=middle>

4F100561</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4Z100032</P></TD>
<TD vAlign=center align=middle>

4Z101101</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

GMC</P></TD>
<TD vAlign=center align=middle>

Yukon</P></TD>
<TD vAlign=center align=middle>

3J308169</P></TD>
<TD vAlign=center align=middle>

3J335135</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=2>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=2>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Yukon</P></TD>
<TD vAlign=center align=middle>

4J100061</P></TD>
<TD vAlign=center align=middle>

4J100105</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4R100128</P></TD>
<TD vAlign=center align=middle>

4R104746</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2003</P></TD>
<TD vAlign=center align=middle rowSpan=3>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Yukon XL</P></TD>
<TD vAlign=center align=middle>

3G290353</P></TD>
<TD vAlign=center align=middle>

3G324315</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3J309243</P></TD>
<TD vAlign=center align=middle>

3J335111</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3R302820</P></TD>
<TD vAlign=center align=middle>

3R319538</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=3>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Yukon XL</P></TD>
<TD vAlign=center align=middle>

4G100026</P></TD>
<TD vAlign=center align=middle>

4G100070</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4J100065</P></TD>
<TD vAlign=center align=middle>

4J100104</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4R100133</P></TD>
<TD vAlign=center align=middle>

4R104750</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

HUMMER</P></TD>
<TD vAlign=center align=middle>

H2</P></TD>
<TD vAlign=center align=middle>

3H135425</P></TD>
<TD vAlign=center align=middle>

3H146453</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

HUMMER</P></TD>
<TD vAlign=center align=middle>

H2</P></TD>
<TD vAlign=center align=middle>

4H100001</P></TD>
<TD vAlign=center align=middle>

4H100034</P></TD></TR></TBODY></TABLE>

<FONT color=brown>
<H4>Important</H4>

Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle
Inquiry System) before beginning recall repairs. [Not all vehicles within the
above breakpoints may be involved.]</P></FONT>

</P>For US

For dealers with involved vehicles, a Campaign Initiation Detail Report
containing the complete Vehicle Identification Number, customer name and address
data has been prepared and will be loaded to the GM DealerWorld, Recall
Information website. The customer name and address data furnished will enable
dealers to follow up with customers involved in this program.</P>For Canada
& IPC

Computer listings containing the complete Vehicle Identification Number,
customer name and address data of involved vehicles have been prepared, and are
being furnished to involved dealers. The customer name and address data will
enable dealers to follow up with customers involved in this recall. Any dealer
not receiving a computer listing with the recall bulletin has no involved
vehicles currently assigned.</P>

These dealer listings may contain customer names and addresses obtained from
Motor Vehicle Registration Records. The use of such motor vehicle registration
data for any other purpose is a violation of law in several
states/provinces/countries. Accordingly, you are urged to limit the use of this
listing to the follow-up necessary to complete this recall.</P><A
name=ss4-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss4-1528250">
<H5>Parts Information</A></H5>

Parts required to complete this recall are to be obtained from General Motors
Service Parts Operations (GMSPO). Please refer to your "involved vehicles
listing" before ordering parts. Normal orders should be placed on a DRO = Daily
Replenishment Order. In an emergency situation, parts should be ordered on a CSO
= Customer Special Order.</P>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Part Number</P></TH>
<TH vAlign=bottom align=middle>

Description</P></TH>
<TH vAlign=bottom align=middle>

Qty/ Vehicle</P></TH></TR>
<TR>
<TD vAlign=center align=middle>

10398682</P></TD>
<TD vAlign=center align=middle>

Valve Kit, P/B Boos Cont</P></TD>
<TD vAlign=center align=middle>

1 (if req'd)</P></TD></TR></TBODY></TABLE>

<FONT color=brown>
<H4>Important</H4>

It is estimated that only 20% of involved vehicles will require Valve Kit
Repair. Please order parts accordingly. </P></FONT>

</P><A name=ss5-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss5-1528250">
<H5>Service Procedure</A></H5>

The following procedure provides instructions for inspecting, and if
necessary, replacing the hydraulic brake booster relief valve.</P>

<LI type=1>Open the hood.
[img]Brake Hydro-Boost Relief Valve Seal Fracture_files/TifToGif[/img]
<A
href="http://127.0.0.1:9001/servlets/RetrieveTif?pic=1478889">
[img]Brake Hydro-Boost Relief Valve Seal Fracture_files/tif.gif[/img]</A>

<FONT color=brown>
<H4>Important</H4>

You may notice that there is a blue epoxy-type material in the center of
the relief valve described in the next step. This material will be found in
both the original and replacement relief valves.</P></FONT>

</P>
<LI type=1>Locate the relieve valve (2) on the hydraulic brake booster. The
valve located in the front of the brake booster directly behind the master
cylinder reservoir (1).
<UL type=BULLET>
<LI>If the color of the relief valve is metallic yellow or has a brass
appearance, then no further action is required.
<LI>If the color of the relief valve is silver or aluminum, continue to the
next step. </LI>

<FONT color=brown>
<H4>Important</H4>

If present, the stamped number being described in the next step would be on
the mounting surface for the master cylinder on the hydraulic brake booster.
The number may be difficult to see if there is any corrosion on the unpainted
surface. As a result, it may be necessary to clean the surface with a piece of
emery or sandpaper.</P></FONT>

</P>
<LI type=1>Inspect the hydraulic brake booster at the location shown (4) for a
stamped number. The location (4) is the same surface that the master cylinder
mounts on, just above the outboard bolt and nut (5). Also inspect for a paint
mark (3) near the master cylinder outboard mounting bolt (5).
<UL type=BULLET>
<LI>If a yellow, pink, or white paint mark IS visible, no further inspection
or repairs are required. Disregard any stamped number found when a yellow,
pink, or white paint mark is visible.
<LI>If there are NO paint marks and there IS a stamped number 1 visible,
then proceed to the next step.
<LI>If there are NO paint marks and there IS a stamped number OTHER THAN "1"
(i.e. 0, 2, 3, 4, 5, etc.) visible, no further inspection or repairs are
required.
<LI>If there are NO paint marks and there are NO stamped numbers visible,
then proceed to the next step. </LI>[/list]

<FONT color=red>
<H4>Caution</H4>

Care should be taken when working around the accumulator since it contains
high-pressure compressed gas and hydraulic fluid.</P></FONT>

</P>
<LI type=1>With the ignition in the OFF position, pump the brake pedal a
minimum of ten times.
<LI type=1>On van models, remove the two bolts that attach the diagonal brace
between the left front fender and radiator support. Remove the brace and the
water deflector that is attached to it.
<LI type=1>On all models, remove the two nuts that attach the master cylinder
to the hydraulic brake booster. A 13mm wrench installed on the bolt head
may be required to prevent the bolt from spinning.

<FONT color=blue>
<H4>Notice</H4>

When repositioning the master cylinder in the next step, use care not to
pinch, kink or damage the brake hoses or pipes.</P></FONT>

</P>

<FONT color=brown>
<H4>Important</H4>

On fullsize pickups and utilities, the bracket that attaches the brake
combination valve will need to be removed from the mounting bolts at the same
time that the master cylinder is removed and repositioned in the next
step.</P></FONT>

</P>
<LI type=1>Remove and reposition the master cylinder away from the hydraulic
brake booster so that the machined surface on the front of the booster where
the master cylinder was mounted is visible.
[img]C:\TSB\Brake Hydro-Boost Relief Valve Seal Fracture_files\TifToGif[1).3][/img]
<A
href="http://127.0.0.1:9001/servlets/RetrieveTif?pic=1478924">
[img]Brake Hydro-Boost Relief Valve Seal Fracture_files/tif.gif[/img]</A>

<LI type=1>Inspect the machined surface that was covered by the master
cylinder on the front of the hydraulic brake booster at the location (1) shown
for a stamped number.
<UL type=BULLET>
<LI>If a stamped number 1 is visible, then the relief valve must be
replaced. Proceed to the next step.
<LI>If a stamped number OTHER THAN "1" (i.e. 0, 2, 3, 4, 5, etc.) is
visible, then no further action is required. Proceed to Step 14 and
reinstall the master cylinder.
<LI>If no stamped number is visible, then no further action is required.
Proceed to Step 14 and reinstall the master cylinder. </LI>[/list] <LI type=1>Cover the master cylinder with a clean shop towel in order to
protect it from fluids or cleaners. Also, place a shop towel under the
hydraulic brake booster to absorb any fluid that may leak out of the unit when
the relief valve is removed in the next step.
[img]C:\TSB\Brake Hydro-Boost Relief Valve Seal Fracture_files\TifToGif[1).2][/img]
<A
href="http://127.0.0.1:9001/servlets/RetrieveTif?pic=1478923">
[img]Brake Hydro-Boost Relief Valve Seal Fracture_files/tif.gif[/img]</A>

<LI type=1>Using the tool (2) included with the new relief valve, unscrew the
original relief valve (1) from the hydraulic brake booster.

<FONT color=blue>
<H4>Notice</H4>

DO NOT blow compressed air into the bore or use any commercially available
cleaners to flush the valve bore in the next step. This could damage the
booster or master cylinder.</P></FONT>

</P>
<LI type=1>Inspect the two O-rings on the original valve for signs of damage.
If an O-ring is missing, broken or damaged, inspect the bore in the hydraulic
brake booster for any pieces or debris using a non-metallic type tool or a
clean "lint-free" towel.

<FONT color=brown>
<H4>Important</H4>

A torque wrench must be used when tightening the valve in the next step. In
addition, a 3/8 inch drive to 1/4 inch drive adapter will be needed if your
torque wrench is a 3/8 inch drive.</P></FONT>

</P>

<FONT color=brown>
<H4>Important</H4>

After tightening the NEW relief valve in the next step, a small gap may
exist between the head on the valve and the hydraulic brake booster. This
condition is normal.</P></FONT>

</P>
<LI type=1>Insert the NEW relief valve into the bore. Tighten

Tighten to 17N·m (13lbft).</P>
<LI type=1>Using a clean shop towel, clean up any fluid that may have leaked
out of they hydraulic brake booster when removing the original valve.
<LI type=1>Position the master cylinder (and brake combination valve mounting
bracket on full size pickups and utilities) on the mounting bolts on the
hydraulic brake booster.
<LI type=1>With the master cylinder mounted flush to the booster, install the
nuts. Tighten

Tighten the nuts to 33N·m (24lbft).</P>
<LI type=1>On van models, install the diagonal brace with the water deflector
attached to it between the left fender and the radiator. Install the two
bolts. Tighten

Tighten the bolts to 25N·m (18lbft).</P>
<LI type=1>Start the engine and verify the hydraulic brake booster operation.
<LI type=1>Turn the engine OFF and check the power steering fluid reservoir.
Add fluid if necessary.
<LI type=1>Close the hood. </LI>[/list]<A name=ss6-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss6-1528250">
<H5>Courtesy Transportation</A></H5>

The General Motors Courtesy Transportation program is intended to minimize
customer inconvenience when a vehicle requires a repair that is covered by the
New Vehicle Limited Warranty. The availability of courtesy transportation to
customers whose vehicles are within the warranty coverage period and involved in
a product recall is very important in maintaining customer satisfaction. Dealers
are to ensure that these customers understand that shuttle service or some other
form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures
Manual for Courtesy Transportation guidelines.</P><A name=ss7-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss7-1528250">
<H5>Claim Information</A></H5>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Repair Performed</P></TH>
<TH vAlign=bottom align=middle>

Part Count</P></TH>
<TH vAlign=bottom align=middle>

Part No.</P></TH>
<TH vAlign=bottom align=middle>

Parts Allow</P></TH>
<TH vAlign=bottom align=middle>

CC-FC</P></TH>
<TH vAlign=bottom align=middle>

Labor Op</P></TH>
<TH vAlign=bottom align=middle>

Labor Hours*</P></TH>
<TH vAlign=bottom align=middle>

Net Item</P></TH></TR>
<TR>
<TD vAlign=center align=left>

Inspection Only - No Further Action Required</P>

Inspection #1: Inspect for Color & Stamped Number</P></TD>
<TD vAlign=center align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

MA-96</P></TD>
<TD vAlign=center align=middle>

V1109</P></TD>
<TD vAlign=center align=middle>

0.2</P></TD>
<TD vAlign=center align=middle>

N/A</P></TD></TR>
<TR>
<TD vAlign=center align=left>

Add: Inspection #2 - Hyd. Brake Booster</P></TD>
<TD>

</P></TD>
<TD>

</P></TD>
<TD>

</P></TD>
<TD vAlign=center align=middle>

</P></TD>
<TD vAlign=center align=middle>

</P></TD>
<TD vAlign=center align=middle>

0.1</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR>
<TR>
<TD vAlign=center>

Inspect & Replace Hydro-Boost Relief Valve (inc. all
inspections)</P></TD>
<TD align=middle>

1</P></TD>
<TD align=middle>

--</P></TD>
<TD align=middle>

**</P></TD>
<TD vAlign=center align=middle>

MA-96</P></TD>
<TD vAlign=center align=middle>

V1110</P></TD>
<TD align=middle>

0.4</P></TD>
<TD vAlign=center align=middle>

***</P></TD></TR>
<TR>
<TD vAlign=center>

Courtesy Transportation</P></TD>
<TD align=middle>

N/A</P></TD>
<TD align=middle>

N/A</P></TD>
<TD align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

MA-96</P></TD>
<TD vAlign=center align=middle>

****</P></TD>
<TD align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

*****</P></TD></TR>
<TR>
<TD vAlign=center align=left colSpan=8>

* -- For Program Administrative Allowance, add 0.1 hours to the "Labor
Hours".</P>

** -- The "Parts Allowance" should be the sum total of the current
GMSPO Dealer Net price plus applicable Mark-Up or Landed Cost Mark-Up (for
IPC) for the power brake booster assembly needed to complete the
repair.</P>

*** -- The amount identified in the "Net Item" column should represent
the sum total of the Current GMSPO Net Price plus applicable Mark-Up or
Landed Cost Mark-Up (for IPC) for the actual amount of power steering
fluid, if needed, to perform the required repairs.</P>

**** -- Submit courtesy transportation using normal labor operations
for courtesy transportation as indicated in the GM Service Policies and
Procedures Manual.</P>

***** -- The amount identified in the "Net Item" column should
represent the actual dollar amount for courtesy
transportation.</P></TD></TR></TBODY></TABLE>

Refer to the General Motors WINS Claim Processing Manual for details on
Product Recall Claim Submission.</P><A name=ss8-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss8-1528250">
<H5>Customer Notification - For US and Canada</A></H5>

General Motors will notify customers of this recall on their vehicle (see
copy of customer letter included with this bulletin).</P><A name=ss9-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss9-1528250">
<H5>Customer Notification - For IPC</A></H5>

Letters will be sent to known owners of record located within areas covered
by the US National Traffic and Motor Vehicle Safety Act. For owners outside
these areas, dealers should notify customers using the attached suggested dealer
letter.</P><A name=ss10-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss10-1528250">
<H5>Dealer Recall Responsibility - FOR US AND IPC (US States, Territories, and
Possessions)</A></H5>

The US National Traffic and Motor Vehicle Safety Act provides that each
vehicle that is subject to a recall of this type must be adequately repaired
within a reasonable time after the customer has tendered it for repair. A
failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not
adequately repaired within a reasonable time, the customer may be entitled to an
identical or reasonably equivalent vehicle at no charge or to a refund of the
purchase price less a reasonable allowance for depreciation. To avoid having
these burdensome remedies, every effort must be made to promptly schedule an
appointment with each customer and to repair their vehicle as soon as possible.
In the recall notification letters, customers are told how to contact the US
National Highway Traffic Safety Administration if the recall is not completed
within a reasonable time.</P>

This bulletin is notice to you that the new motor vehicles included in
this recall may not comply with the standard identified above. Under Title 49,
Section 30112 of the United States Code, it is illegal for a dealer to sell a
new motor vehicle which the dealer knows does not comply with an applicable
Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of
these motor vehicles without first performing the recall correction, your
dealership may be subject to a civil penalty for each such sale. </P><A
name=ss11-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss11-1528250">
<H5>Dealer Recall Responsibility - ALL</A></H5>

All unsold new vehicles in dealers' possession and subject to this recall
MUST be held and inspected/repaired per the service procedure of this recall
bulletin BEFORE customers take possession of these vehicles.</P>

Dealers are to service all vehicles subject to this recall at no charge to
customers, regardless of mileage, age of vehicle, or ownership, from this time
forward.</P>

Customers who have recently purchased vehicles sold from your vehicle
inventory, and for which there is no customer information indicated on the
dealer listing, are to be contacted by the dealer. Arrangements are to be made
to make the required correction according to the instructions contained in this
bulletin. This could be done by mailing to such customers a copy of the customer
letter accompanying this bulletin. Recall follow-up cards should not be used for
this purpose, since the customer may not as yet have received the notification
letter.</P>

In summary, whenever a vehicle subject to this recall enters your vehicle
inventory, or is in your dealership for service in the future, please take the
steps necessary to be sure the recall correction has been made before selling or
releasing the vehicle.</P>June 2004

Dear General Motors Customer:</P>

This notice is sent to you in accordance with the requirements of the
National Traffic and Motor Vehicle Safety Act. Federal regulation requires that
any vehicle lessor receiving this recall notice must forward a copy of this
notice to the lessee within ten days.</P><A name=ss12-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss12-1528250">
<H5>Reason For This Recall</A></H5>

General Motors has decided that certain 2003 and 2004 model year Cadillac
Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche,
Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; HUMMER H2; and
2004 model year Chevrolet Tahoe vehicles fail to conform to either
Federal/Canada Motor Vehicle Safety Standard 105, "Hydraulic and Electric Brake
System", or Standard 135, "Light Vehicle Brake Systems". These vehicles may have
a relief valve bore within the brake hydro-boost module that is not to
specification. An out-of-specification bore could result in fracture of the
relief valve o-ring seal within the module. If this happens, during brake
applications the driver may be able to hear an engine compartment noise similar
to the sound that occurs when the steering wheel is turned to a full stop
position. The driver could also experience a slight increase in steering efforts
while braking and parking. Under certain driving conditions, a fractured seal
may require a slight increase in the applied brake pedal effort to achieve the
same vehicle deceleration rate as prior to the seal fracture. If this were to
occur, it could result in a vehicle crash without prior warning.</P><A
name=ss13-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss13-1528250">
<H5>What Will Be Done</A></H5>

Your GM dealer will inspect the hydro-boost module, and replace the relief
valve if necessary. This service will be performed for you at no charge
.</P><A name=ss14-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss14-1528250">
<H5>How Long Will The Repair Take?</A></H5>

This inspection and correction, if necessary, will take approximately 20 to
25 minutes. However, due to scheduling requirements, your dealer may need your
vehicle for a longer period of time.</P><A name=ss15-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss15-1528250">
<H5>Contacting Your Dealer</A></H5>

To limit any possible inconvenience, we recommend that you contact your GM
dealer as soon as possible to schedule an appointment for this repair. By
scheduling an appointment, your dealer can ensure that the necessary parts will
be available on your scheduled appointment date. Should your dealer be unable to
schedule a service date within a reasonable time, you should contact the
appropriate Customer Assistance Center at the number listed below. The Customer
Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern
standard time Monday through Friday</P>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Division</P></TH>
<TH vAlign=bottom align=middle>

Number</P></TH>
<TH vAlign=bottom align=middle>

Text Telephones (TTY)</P></TH></TR>
<TR>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

1-866-982-2339</P></TD>
<TD vAlign=center align=middle>

1-800-833-2622</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

1-800-630-2438</P></TD>
<TD vAlign=center align=middle>

1-800-833-2438</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

GMC</P></TD>
<TD vAlign=center align=middle>

1-866-996-9463</P></TD>
<TD vAlign=center align=middle>

1-800-462-8583</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

HUMMER</P></TD>
<TD vAlign=center align=middle>

1-866-964-8663</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Puerto Rico - English</P></TD>
<TD vAlign=center align=middle>

1-800-496-9992</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Puerto Rico - Español</P></TD>
<TD vAlign=center align=middle>

1-800-496-9993</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Virgin Islands</P></TD>
<TD vAlign=center align=middle>

1-800-496-9994</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR></TBODY></TABLE>

If, after contacting the appropriate customer assistance center, you are
still not satisfied that we have done our best to remedy this condition without
charge and within a reasonable time, you may wish to write the Administrator,
National Highway Traffic Safety Administration, 400 Seventh Street SW,
Washington, DC 20590 or call 1-888-327-4236.</P><A name=ss16-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss16-1528250">
<H5>Customer Reply Form</A></H5>

The enclosed customer reply form identifies your vehicles. Presentation of
this form to your dealer will assist in making the necessary correction in the
shortest possible time. If you no longer own this vehicle, please let us know by
completing the form and mailing it back to us.</P><A name=ss17-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss17-1528250">
<H5>Courtesy Transportation</A></H5>

If your vehicle is within the New Vehicle Limited Warranty your dealer will
provide you with shuttle service or some other form of courtesy transportation
while your vehicle is at the dealership for this repair. Please refer to your
Owner's Manual and your dealer for details on Courtesy Transportation.</P><A
name=ss18-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss18-1528250">
<H5>Recall Information Online</A></H5>

More information about this recall (including answers to frequently asked
questions) is available online at the Owner Center at My GMLink. This free
online service offers vehicle and ownership related information and tools
tailored to your specific vehicle. To join, visit www.mygmlink.com ,
and enter your vehicle's 17-character vehicle identification number (VIN) shown
on the enclosed form to get the most personalized information for your
vehicle.</P>

We are sorry to cause you this inconvenience; however, we have taken this
action in the interest of your safety and continued satisfaction with our
products.</P>

General Motors Corporation</P>

Enclosure</P>

04004</P>

</P>
<TABLE width="100%">
<TBODY>
<TR>
<TD align=left width=778><FONT size=1>GM bulletins are intended for use by
professional technicians, NOT a "do-it-yourselfer". They are written
to inform these technicians of conditions that may occur on some vehicles,
or to provide information that could assist in the proper service of a
vehicle. Properly trained technicians have the equipment, tools,
safety instructions, and know-how to do a job properly and safely.
If a condition is described, DO NOT assume that the bulletin applies to
your vehicle, or that your vehicle will have that condition. See
your GM dealer for information on whether your vehicle may benefit from
the information.
</FONT></TD>
<TD align=middle width=42></TD>
<TD align=middle width=167><FONT size=2>WE SUPPORT VOLUNTARY TECHNICIAN
CERTIFICATION
</FONT></TD></TR></TBODY></TABLE>
<P align=center>© Copyright General Motors Corporation. All Rights
Reserved. </P>
<FORM name=bottomNavForm>
<HR>

<TABLE width="100%" align=center>
<TBODY>
<TR>
<TD width="25%" slign="LEFT"></TD>
<TD align=middle width="50%">Document ID# 1528250
2003 HUMMER
H2</TD>
<TD align=right width="25%"></TD></TR></TBODY></TABLE></FORM></BODY></HTML>

Klaus · #2 07-26-2004, 10:36 PM

<!DOCTYPE HTML PUBLIC "-//W3C//DTD HTML 4.0 Transitional//EN">

<HTML><HEAD><TITLE>Service Information</TITLE>
<META http-equiv=Content-Type content="text/html; charset=iso-8859-1">
<META content="Microsoft FrontPage 5.0" name=GENERATOR></HEAD>
<BODY bgColor=#ffffff>
<FORM name=topNavForm action=/servlets/CellHandler>
<TABLE width="100%" align=center>
<TBODY>
<TR>
<TD width="25%" slign="LEFT"></TD>
<TD align=middle width="50%">Document ID# 1528250
2003 HUMMER
H2</TD>
<TD align=right width="25%"></TD></TR></TBODY></TABLE>
<HR>
</FORM>
<H1>F/CMVSS Noncompliance - Brake Hydro-Boost Relief Valve Seal Fracture #04004A
- (06/18/2004)</H1></TABLE>04004A - Brake Hydro-Boost Relief Valve Seal Fracture

2003-2004 Cadillac Escalade, Escalade EXT, Escalade ESV</P>

2003-2004 Chevrolet Silverado, Avalanche, Suburban, Express</P>

2004 Chevrolet Tahoe</P>

2003-2004 GMC Sierra, Yukon, Yukon XL, Savana</P>

2003-2004 HUMMER H2</P>

THIS BULLETIN CANCELS AND REPLACES BULLETIN 04004, ISSUED JUNE 2004. THE
INSPECTION PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO INCLUDE ADDITIONAL
STAMPED NUMBERS ON THE HYDRAULIC BRAKE BOOSTER. ALL COPIES OF BULLETIN 04004
SHOULD BE DESTROYED.</P><A name=ss1-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss1-1528250">
<H5>Condition</A></H5>

General Motors has decided that certain 2003 and 2004 model year Cadillac
Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche,
Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; HUMMER H2; and
2004 model year Chevrolet Tahoe vehicles fail to conform to either
Federal/Canada Motor Vehicle Safety Standard 105, "Hydraulic and Electric Brake
System", or Standard 135, "Light Vehicle Brake Systems". These vehicles may have
a relief valve bore within the brake hydro-boost module that is not to
specification. An out-of-specification bore could result in fracture of the
relief valve o-ring seal within the module. If this happens, during brake
applications the driver may be able to hear an engine compartment noise similar
to the sound that occurs when the steering wheel is turned to a full stop
position. The driver could also experience a slight increase in steering efforts
while braking and parking. Under certain driving conditions, a fractured seal
may require a slight increase in the applied brake pedal effort to achieve the
same vehicle deceleration rate as prior to the seal fracture. If this were to
occur, it could result in a vehicle crash without prior warning.</P><A
name=ss2-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss2-1528250">
<H5>Correction</A></H5>

Dealers are to inspect the hydro-boost module and replace the relief valve,
if necessary.</P><A name=ss3-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss3-1528250">
<H5>Vehicles Involved</A></H5>

Involved are certain 2003 and 2004 model year Cadillac Escalade, Escalade EXT
and Escalade ESV; Chevrolet Silverado, Avalanche, Suburban, and Express; GMC
Sierra, Yukon, Yukon XL, and Savana; HUMMER H2 and 2004 model year Chevrolet
Tahoe vehicles built within these VIN breakpoints:</P>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Year</P></TH>
<TH vAlign=bottom align=middle>

Division</P></TH>
<TH vAlign=bottom align=middle>

Model</P></TH>
<TH vAlign=bottom align=middle>

From</P></TH>
<TH vAlign=bottom align=middle>

Through</P></TH></TR>
<TR>
<TD vAlign=center align=middle>

2003 </P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade</P></TD>
<TD vAlign=center align=middle>

3R302814 </P></TD>
<TD vAlign=center align=middle>

3R320163</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004 </P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade </P></TD>
<TD vAlign=center align=middle>

4R100129 </P></TD>
<TD vAlign=center align=middle>

4R104745</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade ESV</P></TD>
<TD vAlign=center align=middle>

3G299104</P></TD>
<TD vAlign=center align=middle>

3G324791</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

Cadillac </P></TD>
<TD vAlign=center align=middle>

Escalade ESV</P></TD>
<TD vAlign=center align=middle>

4G100051</P></TD>
<TD vAlign=center align=middle>

4G100053</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade EXT</P></TD>
<TD vAlign=center align=middle>

3G300225</P></TD>
<TD vAlign=center align=middle>

3G324703</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade EXT</P></TD>
<TD vAlign=center align=middle>

4G100044</P></TD>
<TD vAlign=center align=middle>

4G100048</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

Avalanche</P></TD>
<TD vAlign=center align=middle>

3G301959</P></TD>
<TD vAlign=center align=middle>

3G324088</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

Avalanche</P></TD>
<TD vAlign=center align=middle>

4G100025</P></TD>
<TD vAlign=center align=middle>

4G100065</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

Express</P></TD>
<TD vAlign=center align=middle>

31216183</P></TD>
<TD vAlign=center align=middle>

31238955</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

Express</P></TD>
<TD vAlign=center align=middle>

41100063</P></TD>
<TD vAlign=center align=middle>

41103650</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=4>

2003</P></TD>
<TD vAlign=center align=middle rowSpan=4>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=4>

Silverado</P></TD>
<TD vAlign=center align=middle>

3E346100</P></TD>
<TD vAlign=center align=middle>

3E376199</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3F192149</P></TD>
<TD vAlign=center align=middle>

3F259060</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3M110513</P></TD>
<TD vAlign=center align=middle>

3M112077</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3Z338002</P></TD>
<TD vAlign=center align=middle>

3Z361763</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=4>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=4>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=4>

Silverado</P></TD>
<TD vAlign=center align=middle>

4E100021</P></TD>
<TD vAlign=center align=middle>

4E100126</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4F100026</P></TD>
<TD vAlign=center align=middle>

4F100566</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4M100006</P></TD>
<TD vAlign=center align=middle>

4M100017</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4Z100115</P></TD>
<TD vAlign=center align=middle>

4Z101176</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=2>

2003</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Suburban</P></TD>
<TD vAlign=center align=middle>

3G285873</P></TD>
<TD vAlign=center align=middle>

3G324561</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3R302840</P></TD>
<TD vAlign=center align=middle>

3R319989</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Suburban</P></TD>
<TD vAlign=center align=middle>

4G100033</P></TD>
<TD vAlign=center align=middle>

4G100074</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4J100031</P></TD>
<TD vAlign=center align=middle>

4J100106</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4R100153</P></TD>
<TD vAlign=center align=middle>

4R104727</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=2>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Tahoe</P></TD>
<TD vAlign=center align=middle>

4J100021</P></TD>
<TD vAlign=center align=middle>

4J100103</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4R100130</P></TD>
<TD vAlign=center align=middle>

4R104749</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

GMC </P></TD>
<TD vAlign=center align=middle>

Savana</P></TD>
<TD vAlign=center align=middle>

31217178</P></TD>
<TD vAlign=center align=middle>

31905189</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

GMC</P></TD>
<TD vAlign=center align=middle>

Savana</P></TD>
<TD vAlign=center align=middle>

41100065</P></TD>
<TD vAlign=center align=middle>

41103637</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2003</P></TD>
<TD vAlign=center align=middle rowSpan=3>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Sierra</P></TD>
<TD vAlign=center align=middle>

3E346103</P></TD>
<TD vAlign=center align=middle>

3E376203</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3F232315</P></TD>
<TD vAlign=center align=middle>

3F259040</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3Z338024</P></TD>
<TD vAlign=center align=middle>

3Z359268</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=3>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Sierra</P></TD>
<TD vAlign=center align=middle>

4E100026</P></TD>
<TD vAlign=center align=middle>

4E100127</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4F100025</P></TD>
<TD vAlign=center align=middle>

4F100561</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4Z100032</P></TD>
<TD vAlign=center align=middle>

4Z101101</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

GMC</P></TD>
<TD vAlign=center align=middle>

Yukon</P></TD>
<TD vAlign=center align=middle>

3J308169</P></TD>
<TD vAlign=center align=middle>

3J335135</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=2>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=2>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Yukon</P></TD>
<TD vAlign=center align=middle>

4J100061</P></TD>
<TD vAlign=center align=middle>

4J100105</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4R100128</P></TD>
<TD vAlign=center align=middle>

4R104746</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2003</P></TD>
<TD vAlign=center align=middle rowSpan=3>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Yukon XL</P></TD>
<TD vAlign=center align=middle>

3G290353</P></TD>
<TD vAlign=center align=middle>

3G324315</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3J309243</P></TD>
<TD vAlign=center align=middle>

3J335111</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3R302820</P></TD>
<TD vAlign=center align=middle>

3R319538</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=3>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Yukon XL</P></TD>
<TD vAlign=center align=middle>

4G100026</P></TD>
<TD vAlign=center align=middle>

4G100070</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4J100065</P></TD>
<TD vAlign=center align=middle>

4J100104</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4R100133</P></TD>
<TD vAlign=center align=middle>

4R104750</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

HUMMER</P></TD>
<TD vAlign=center align=middle>

H2</P></TD>
<TD vAlign=center align=middle>

3H135425</P></TD>
<TD vAlign=center align=middle>

3H146453</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

HUMMER</P></TD>
<TD vAlign=center align=middle>

H2</P></TD>
<TD vAlign=center align=middle>

4H100001</P></TD>
<TD vAlign=center align=middle>

4H100034</P></TD></TR></TBODY></TABLE>

<FONT color=brown>
<H4>Important</H4>

Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle
Inquiry System) before beginning recall repairs. [Not all vehicles within the
above breakpoints may be involved.]</P></FONT>

</P>For US

For dealers with involved vehicles, a Campaign Initiation Detail Report
containing the complete Vehicle Identification Number, customer name and address
data has been prepared and will be loaded to the GM DealerWorld, Recall
Information website. The customer name and address data furnished will enable
dealers to follow up with customers involved in this program.</P>For Canada
& IPC

Computer listings containing the complete Vehicle Identification Number,
customer name and address data of involved vehicles have been prepared, and are
being furnished to involved dealers. The customer name and address data will
enable dealers to follow up with customers involved in this recall. Any dealer
not receiving a computer listing with the recall bulletin has no involved
vehicles currently assigned.</P>

These dealer listings may contain customer names and addresses obtained from
Motor Vehicle Registration Records. The use of such motor vehicle registration
data for any other purpose is a violation of law in several
states/provinces/countries. Accordingly, you are urged to limit the use of this
listing to the follow-up necessary to complete this recall.</P><A
name=ss4-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss4-1528250">
<H5>Parts Information</A></H5>

Parts required to complete this recall are to be obtained from General Motors
Service Parts Operations (GMSPO). Please refer to your "involved vehicles
listing" before ordering parts. Normal orders should be placed on a DRO = Daily
Replenishment Order. In an emergency situation, parts should be ordered on a CSO
= Customer Special Order.</P>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Part Number</P></TH>
<TH vAlign=bottom align=middle>

Description</P></TH>
<TH vAlign=bottom align=middle>

Qty/ Vehicle</P></TH></TR>
<TR>
<TD vAlign=center align=middle>

10398682</P></TD>
<TD vAlign=center align=middle>

Valve Kit, P/B Boos Cont</P></TD>
<TD vAlign=center align=middle>

1 (if req'd)</P></TD></TR></TBODY></TABLE>

<FONT color=brown>
<H4>Important</H4>

It is estimated that only 20% of involved vehicles will require Valve Kit
Repair. Please order parts accordingly. </P></FONT>

</P><A name=ss5-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss5-1528250">
<H5>Service Procedure</A></H5>

The following procedure provides instructions for inspecting, and if
necessary, replacing the hydraulic brake booster relief valve.</P>

<LI type=1>Open the hood.
[img]Brake Hydro-Boost Relief Valve Seal Fracture_files/TifToGif[/img]
<A
href="http://127.0.0.1:9001/servlets/RetrieveTif?pic=1478889">
[img]Brake Hydro-Boost Relief Valve Seal Fracture_files/tif.gif[/img]</A>

<FONT color=brown>
<H4>Important</H4>

You may notice that there is a blue epoxy-type material in the center of
the relief valve described in the next step. This material will be found in
both the original and replacement relief valves.</P></FONT>

</P>
<LI type=1>Locate the relieve valve (2) on the hydraulic brake booster. The
valve located in the front of the brake booster directly behind the master
cylinder reservoir (1).
<UL type=BULLET>
<LI>If the color of the relief valve is metallic yellow or has a brass
appearance, then no further action is required.
<LI>If the color of the relief valve is silver or aluminum, continue to the
next step. </LI>

<FONT color=brown>
<H4>Important</H4>

If present, the stamped number being described in the next step would be on
the mounting surface for the master cylinder on the hydraulic brake booster.
The number may be difficult to see if there is any corrosion on the unpainted
surface. As a result, it may be necessary to clean the surface with a piece of
emery or sandpaper.</P></FONT>

</P>
<LI type=1>Inspect the hydraulic brake booster at the location shown (4) for a
stamped number. The location (4) is the same surface that the master cylinder
mounts on, just above the outboard bolt and nut (5). Also inspect for a paint
mark (3) near the master cylinder outboard mounting bolt (5).
<UL type=BULLET>
<LI>If a yellow, pink, or white paint mark IS visible, no further inspection
or repairs are required. Disregard any stamped number found when a yellow,
pink, or white paint mark is visible.
<LI>If there are NO paint marks and there IS a stamped number 1 visible,
then proceed to the next step.
<LI>If there are NO paint marks and there IS a stamped number OTHER THAN "1"
(i.e. 0, 2, 3, 4, 5, etc.) visible, no further inspection or repairs are
required.
<LI>If there are NO paint marks and there are NO stamped numbers visible,
then proceed to the next step. </LI>[/list]

<FONT color=red>
<H4>Caution</H4>

Care should be taken when working around the accumulator since it contains
high-pressure compressed gas and hydraulic fluid.</P></FONT>

</P>
<LI type=1>With the ignition in the OFF position, pump the brake pedal a
minimum of ten times.
<LI type=1>On van models, remove the two bolts that attach the diagonal brace
between the left front fender and radiator support. Remove the brace and the
water deflector that is attached to it.
<LI type=1>On all models, remove the two nuts that attach the master cylinder
to the hydraulic brake booster. A 13mm wrench installed on the bolt head
may be required to prevent the bolt from spinning.

<FONT color=blue>
<H4>Notice</H4>

When repositioning the master cylinder in the next step, use care not to
pinch, kink or damage the brake hoses or pipes.</P></FONT>

</P>

<FONT color=brown>
<H4>Important</H4>

On fullsize pickups and utilities, the bracket that attaches the brake
combination valve will need to be removed from the mounting bolts at the same
time that the master cylinder is removed and repositioned in the next
step.</P></FONT>

</P>
<LI type=1>Remove and reposition the master cylinder away from the hydraulic
brake booster so that the machined surface on the front of the booster where
the master cylinder was mounted is visible.
[img]C:\TSB\Brake Hydro-Boost Relief Valve Seal Fracture_files\TifToGif[1).3][/img]
<A
href="http://127.0.0.1:9001/servlets/RetrieveTif?pic=1478924">
[img]Brake Hydro-Boost Relief Valve Seal Fracture_files/tif.gif[/img]</A>

<LI type=1>Inspect the machined surface that was covered by the master
cylinder on the front of the hydraulic brake booster at the location (1) shown
for a stamped number.
<UL type=BULLET>
<LI>If a stamped number 1 is visible, then the relief valve must be
replaced. Proceed to the next step.
<LI>If a stamped number OTHER THAN "1" (i.e. 0, 2, 3, 4, 5, etc.) is
visible, then no further action is required. Proceed to Step 14 and
reinstall the master cylinder.
<LI>If no stamped number is visible, then no further action is required.
Proceed to Step 14 and reinstall the master cylinder. </LI>[/list] <LI type=1>Cover the master cylinder with a clean shop towel in order to
protect it from fluids or cleaners. Also, place a shop towel under the
hydraulic brake booster to absorb any fluid that may leak out of the unit when
the relief valve is removed in the next step.
[img]C:\TSB\Brake Hydro-Boost Relief Valve Seal Fracture_files\TifToGif[1).2][/img]
<A
href="http://127.0.0.1:9001/servlets/RetrieveTif?pic=1478923">
[img]Brake Hydro-Boost Relief Valve Seal Fracture_files/tif.gif[/img]</A>

<LI type=1>Using the tool (2) included with the new relief valve, unscrew the
original relief valve (1) from the hydraulic brake booster.

<FONT color=blue>
<H4>Notice</H4>

DO NOT blow compressed air into the bore or use any commercially available
cleaners to flush the valve bore in the next step. This could damage the
booster or master cylinder.</P></FONT>

</P>
<LI type=1>Inspect the two O-rings on the original valve for signs of damage.
If an O-ring is missing, broken or damaged, inspect the bore in the hydraulic
brake booster for any pieces or debris using a non-metallic type tool or a
clean "lint-free" towel.

<FONT color=brown>
<H4>Important</H4>

A torque wrench must be used when tightening the valve in the next step. In
addition, a 3/8 inch drive to 1/4 inch drive adapter will be needed if your
torque wrench is a 3/8 inch drive.</P></FONT>

</P>

<FONT color=brown>
<H4>Important</H4>

After tightening the NEW relief valve in the next step, a small gap may
exist between the head on the valve and the hydraulic brake booster. This
condition is normal.</P></FONT>

</P>
<LI type=1>Insert the NEW relief valve into the bore. Tighten

Tighten to 17N·m (13lbft).</P>
<LI type=1>Using a clean shop towel, clean up any fluid that may have leaked
out of they hydraulic brake booster when removing the original valve.
<LI type=1>Position the master cylinder (and brake combination valve mounting
bracket on full size pickups and utilities) on the mounting bolts on the
hydraulic brake booster.
<LI type=1>With the master cylinder mounted flush to the booster, install the
nuts. Tighten

Tighten the nuts to 33N·m (24lbft).</P>
<LI type=1>On van models, install the diagonal brace with the water deflector
attached to it between the left fender and the radiator. Install the two
bolts. Tighten

Tighten the bolts to 25N·m (18lbft).</P>
<LI type=1>Start the engine and verify the hydraulic brake booster operation.
<LI type=1>Turn the engine OFF and check the power steering fluid reservoir.
Add fluid if necessary.
<LI type=1>Close the hood. </LI>[/list]<A name=ss6-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss6-1528250">
<H5>Courtesy Transportation</A></H5>

The General Motors Courtesy Transportation program is intended to minimize
customer inconvenience when a vehicle requires a repair that is covered by the
New Vehicle Limited Warranty. The availability of courtesy transportation to
customers whose vehicles are within the warranty coverage period and involved in
a product recall is very important in maintaining customer satisfaction. Dealers
are to ensure that these customers understand that shuttle service or some other
form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures
Manual for Courtesy Transportation guidelines.</P><A name=ss7-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss7-1528250">
<H5>Claim Information</A></H5>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Repair Performed</P></TH>
<TH vAlign=bottom align=middle>

Part Count</P></TH>
<TH vAlign=bottom align=middle>

Part No.</P></TH>
<TH vAlign=bottom align=middle>

Parts Allow</P></TH>
<TH vAlign=bottom align=middle>

CC-FC</P></TH>
<TH vAlign=bottom align=middle>

Labor Op</P></TH>
<TH vAlign=bottom align=middle>

Labor Hours*</P></TH>
<TH vAlign=bottom align=middle>

Net Item</P></TH></TR>
<TR>
<TD vAlign=center align=left>

Inspection Only - No Further Action Required</P>

Inspection #1: Inspect for Color & Stamped Number</P></TD>
<TD vAlign=center align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

MA-96</P></TD>
<TD vAlign=center align=middle>

V1109</P></TD>
<TD vAlign=center align=middle>

0.2</P></TD>
<TD vAlign=center align=middle>

N/A</P></TD></TR>
<TR>
<TD vAlign=center align=left>

Add: Inspection #2 - Hyd. Brake Booster</P></TD>
<TD>

</P></TD>
<TD>

</P></TD>
<TD>

</P></TD>
<TD vAlign=center align=middle>

</P></TD>
<TD vAlign=center align=middle>

</P></TD>
<TD vAlign=center align=middle>

0.1</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR>
<TR>
<TD vAlign=center>

Inspect & Replace Hydro-Boost Relief Valve (inc. all
inspections)</P></TD>
<TD align=middle>

1</P></TD>
<TD align=middle>

--</P></TD>
<TD align=middle>

**</P></TD>
<TD vAlign=center align=middle>

MA-96</P></TD>
<TD vAlign=center align=middle>

V1110</P></TD>
<TD align=middle>

0.4</P></TD>
<TD vAlign=center align=middle>

***</P></TD></TR>
<TR>
<TD vAlign=center>

Courtesy Transportation</P></TD>
<TD align=middle>

N/A</P></TD>
<TD align=middle>

N/A</P></TD>
<TD align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

MA-96</P></TD>
<TD vAlign=center align=middle>

****</P></TD>
<TD align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

*****</P></TD></TR>
<TR>
<TD vAlign=center align=left colSpan=8>

* -- For Program Administrative Allowance, add 0.1 hours to the "Labor
Hours".</P>

** -- The "Parts Allowance" should be the sum total of the current
GMSPO Dealer Net price plus applicable Mark-Up or Landed Cost Mark-Up (for
IPC) for the power brake booster assembly needed to complete the
repair.</P>

*** -- The amount identified in the "Net Item" column should represent
the sum total of the Current GMSPO Net Price plus applicable Mark-Up or
Landed Cost Mark-Up (for IPC) for the actual amount of power steering
fluid, if needed, to perform the required repairs.</P>

**** -- Submit courtesy transportation using normal labor operations
for courtesy transportation as indicated in the GM Service Policies and
Procedures Manual.</P>

***** -- The amount identified in the "Net Item" column should
represent the actual dollar amount for courtesy
transportation.</P></TD></TR></TBODY></TABLE>

Refer to the General Motors WINS Claim Processing Manual for details on
Product Recall Claim Submission.</P><A name=ss8-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss8-1528250">
<H5>Customer Notification - For US and Canada</A></H5>

General Motors will notify customers of this recall on their vehicle (see
copy of customer letter included with this bulletin).</P><A name=ss9-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss9-1528250">
<H5>Customer Notification - For IPC</A></H5>

Letters will be sent to known owners of record located within areas covered
by the US National Traffic and Motor Vehicle Safety Act. For owners outside
these areas, dealers should notify customers using the attached suggested dealer
letter.</P><A name=ss10-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss10-1528250">
<H5>Dealer Recall Responsibility - FOR US AND IPC (US States, Territories, and
Possessions)</A></H5>

The US National Traffic and Motor Vehicle Safety Act provides that each
vehicle that is subject to a recall of this type must be adequately repaired
within a reasonable time after the customer has tendered it for repair. A
failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not
adequately repaired within a reasonable time, the customer may be entitled to an
identical or reasonably equivalent vehicle at no charge or to a refund of the
purchase price less a reasonable allowance for depreciation. To avoid having
these burdensome remedies, every effort must be made to promptly schedule an
appointment with each customer and to repair their vehicle as soon as possible.
In the recall notification letters, customers are told how to contact the US
National Highway Traffic Safety Administration if the recall is not completed
within a reasonable time.</P>

This bulletin is notice to you that the new motor vehicles included in
this recall may not comply with the standard identified above. Under Title 49,
Section 30112 of the United States Code, it is illegal for a dealer to sell a
new motor vehicle which the dealer knows does not comply with an applicable
Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of
these motor vehicles without first performing the recall correction, your
dealership may be subject to a civil penalty for each such sale. </P><A
name=ss11-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss11-1528250">
<H5>Dealer Recall Responsibility - ALL</A></H5>

All unsold new vehicles in dealers' possession and subject to this recall
MUST be held and inspected/repaired per the service procedure of this recall
bulletin BEFORE customers take possession of these vehicles.</P>

Dealers are to service all vehicles subject to this recall at no charge to
customers, regardless of mileage, age of vehicle, or ownership, from this time
forward.</P>

Customers who have recently purchased vehicles sold from your vehicle
inventory, and for which there is no customer information indicated on the
dealer listing, are to be contacted by the dealer. Arrangements are to be made
to make the required correction according to the instructions contained in this
bulletin. This could be done by mailing to such customers a copy of the customer
letter accompanying this bulletin. Recall follow-up cards should not be used for
this purpose, since the customer may not as yet have received the notification
letter.</P>

In summary, whenever a vehicle subject to this recall enters your vehicle
inventory, or is in your dealership for service in the future, please take the
steps necessary to be sure the recall correction has been made before selling or
releasing the vehicle.</P>June 2004

Dear General Motors Customer:</P>

This notice is sent to you in accordance with the requirements of the
National Traffic and Motor Vehicle Safety Act. Federal regulation requires that
any vehicle lessor receiving this recall notice must forward a copy of this
notice to the lessee within ten days.</P><A name=ss12-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss12-1528250">
<H5>Reason For This Recall</A></H5>

General Motors has decided that certain 2003 and 2004 model year Cadillac
Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche,
Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; HUMMER H2; and
2004 model year Chevrolet Tahoe vehicles fail to conform to either
Federal/Canada Motor Vehicle Safety Standard 105, "Hydraulic and Electric Brake
System", or Standard 135, "Light Vehicle Brake Systems". These vehicles may have
a relief valve bore within the brake hydro-boost module that is not to
specification. An out-of-specification bore could result in fracture of the
relief valve o-ring seal within the module. If this happens, during brake
applications the driver may be able to hear an engine compartment noise similar
to the sound that occurs when the steering wheel is turned to a full stop
position. The driver could also experience a slight increase in steering efforts
while braking and parking. Under certain driving conditions, a fractured seal
may require a slight increase in the applied brake pedal effort to achieve the
same vehicle deceleration rate as prior to the seal fracture. If this were to
occur, it could result in a vehicle crash without prior warning.</P><A
name=ss13-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss13-1528250">
<H5>What Will Be Done</A></H5>

Your GM dealer will inspect the hydro-boost module, and replace the relief
valve if necessary. This service will be performed for you at no charge
.</P><A name=ss14-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss14-1528250">
<H5>How Long Will The Repair Take?</A></H5>

This inspection and correction, if necessary, will take approximately 20 to
25 minutes. However, due to scheduling requirements, your dealer may need your
vehicle for a longer period of time.</P><A name=ss15-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss15-1528250">
<H5>Contacting Your Dealer</A></H5>

To limit any possible inconvenience, we recommend that you contact your GM
dealer as soon as possible to schedule an appointment for this repair. By
scheduling an appointment, your dealer can ensure that the necessary parts will
be available on your scheduled appointment date. Should your dealer be unable to
schedule a service date within a reasonable time, you should contact the
appropriate Customer Assistance Center at the number listed below. The Customer
Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern
standard time Monday through Friday</P>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Division</P></TH>
<TH vAlign=bottom align=middle>

Number</P></TH>
<TH vAlign=bottom align=middle>

Text Telephones (TTY)</P></TH></TR>
<TR>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

1-866-982-2339</P></TD>
<TD vAlign=center align=middle>

1-800-833-2622</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

1-800-630-2438</P></TD>
<TD vAlign=center align=middle>

1-800-833-2438</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

GMC</P></TD>
<TD vAlign=center align=middle>

1-866-996-9463</P></TD>
<TD vAlign=center align=middle>

1-800-462-8583</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

HUMMER</P></TD>
<TD vAlign=center align=middle>

1-866-964-8663</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Puerto Rico - English</P></TD>
<TD vAlign=center align=middle>

1-800-496-9992</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Puerto Rico - Español</P></TD>
<TD vAlign=center align=middle>

1-800-496-9993</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Virgin Islands</P></TD>
<TD vAlign=center align=middle>

1-800-496-9994</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR></TBODY></TABLE>

If, after contacting the appropriate customer assistance center, you are
still not satisfied that we have done our best to remedy this condition without
charge and within a reasonable time, you may wish to write the Administrator,
National Highway Traffic Safety Administration, 400 Seventh Street SW,
Washington, DC 20590 or call 1-888-327-4236.</P><A name=ss16-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss16-1528250">
<H5>Customer Reply Form</A></H5>

The enclosed customer reply form identifies your vehicles. Presentation of
this form to your dealer will assist in making the necessary correction in the
shortest possible time. If you no longer own this vehicle, please let us know by
completing the form and mailing it back to us.</P><A name=ss17-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss17-1528250">
<H5>Courtesy Transportation</A></H5>

If your vehicle is within the New Vehicle Limited Warranty your dealer will
provide you with shuttle service or some other form of courtesy transportation
while your vehicle is at the dealership for this repair. Please refer to your
Owner's Manual and your dealer for details on Courtesy Transportation.</P><A
name=ss18-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc=sm#ss18-1528250">
<H5>Recall Information Online</A></H5>

More information about this recall (including answers to frequently asked
questions) is available online at the Owner Center at My GMLink. This free
online service offers vehicle and ownership related information and tools
tailored to your specific vehicle. To join, visit www.mygmlink.com ,
and enter your vehicle's 17-character vehicle identification number (VIN) shown
on the enclosed form to get the most personalized information for your
vehicle.</P>

We are sorry to cause you this inconvenience; however, we have taken this
action in the interest of your safety and continued satisfaction with our
products.</P>

General Motors Corporation</P>

Enclosure</P>

04004</P>

</P>
<TABLE width="100%">
<TBODY>
<TR>
<TD align=left width=778><FONT size=1>GM bulletins are intended for use by
professional technicians, NOT a "do-it-yourselfer". They are written
to inform these technicians of conditions that may occur on some vehicles,
or to provide information that could assist in the proper service of a
vehicle. Properly trained technicians have the equipment, tools,
safety instructions, and know-how to do a job properly and safely.
If a condition is described, DO NOT assume that the bulletin applies to
your vehicle, or that your vehicle will have that condition. See
your GM dealer for information on whether your vehicle may benefit from
the information.
</FONT></TD>
<TD align=middle width=42></TD>
<TD align=middle width=167><FONT size=2>WE SUPPORT VOLUNTARY TECHNICIAN
CERTIFICATION
</FONT></TD></TR></TBODY></TABLE>
<P align=center>© Copyright General Motors Corporation. All Rights
Reserved. </P>
<FORM name=bottomNavForm>
<HR>

<TABLE width="100%" align=center>
<TBODY>
<TR>
<TD width="25%" slign="LEFT"></TD>
<TD align=middle width="50%">Document ID# 1528250
2003 HUMMER
H2</TD>
<TD align=right width="25%"></TD></TR></TBODY></TABLE></FORM></BODY></HTML>

Klaus · #3 07-26-2004, 10:36 PM

<!DOCTYPE HTML PUBLIC "-//W3C//DTD HTML 4.0 Transitional//EN">

<HTML><HEAD><TITLE>Service Information</TITLE>
<META http-equiv=Content-Type content="text/html; charset=iso-8859-1">
<META content="Microsoft FrontPage 5.0" name=GENERATOR></HEAD>
<BODY bgColor=#ffffff>
<FORM name=topNavForm action=/servlets/CellHandler>
<TABLE width="100%" align=center>
<TBODY>
<TR>
<TD width="25%" slign="LEFT"></TD>
<TD align=middle width="50%">Document ID# 1528250
2003 HUMMER
H2</TD>
<TD align=right width="25%"></TD></TR></TBODY></TABLE>
<HR>
</FORM>
<H1>F/CMVSS Noncompliance - Brake Hydro-Boost Relief Valve Seal Fracture #04004A
- (06/18/2004)</H1></TABLE>04004A - Brake Hydro-Boost Relief Valve Seal Fracture

2003-2004 Cadillac Escalade, Escalade EXT, Escalade ESV</P>

2003-2004 Chevrolet Silverado, Avalanche, Suburban, Express</P>

2004 Chevrolet Tahoe</P>

2003-2004 GMC Sierra, Yukon, Yukon XL, Savana</P>

2003-2004 HUMMER H2</P>

THIS BULLETIN CANCELS AND REPLACES BULLETIN 04004, ISSUED JUNE 2004. THE
INSPECTION PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO INCLUDE ADDITIONAL
STAMPED NUMBERS ON THE HYDRAULIC BRAKE BOOSTER. ALL COPIES OF BULLETIN 04004
SHOULD BE DESTROYED.</P><A name=ss1-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss1-1528250">
<H5>Condition</A></H5>

General Motors has decided that certain 2003 and 2004 model year Cadillac
Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche,
Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; HUMMER H2; and
2004 model year Chevrolet Tahoe vehicles fail to conform to either
Federal/Canada Motor Vehicle Safety Standard 105, "Hydraulic and Electric Brake
System", or Standard 135, "Light Vehicle Brake Systems". These vehicles may have
a relief valve bore within the brake hydro-boost module that is not to
specification. An out-of-specification bore could result in fracture of the
relief valve o-ring seal within the module. If this happens, during brake
applications the driver may be able to hear an engine compartment noise similar
to the sound that occurs when the steering wheel is turned to a full stop
position. The driver could also experience a slight increase in steering efforts
while braking and parking. Under certain driving conditions, a fractured seal
may require a slight increase in the applied brake pedal effort to achieve the
same vehicle deceleration rate as prior to the seal fracture. If this were to
occur, it could result in a vehicle crash without prior warning.</P><A
name=ss2-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss2-1528250">
<H5>Correction</A></H5>

Dealers are to inspect the hydro-boost module and replace the relief valve,
if necessary.</P><A name=ss3-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss3-1528250">
<H5>Vehicles Involved</A></H5>

Involved are certain 2003 and 2004 model year Cadillac Escalade, Escalade EXT
and Escalade ESV; Chevrolet Silverado, Avalanche, Suburban, and Express; GMC
Sierra, Yukon, Yukon XL, and Savana; HUMMER H2 and 2004 model year Chevrolet
Tahoe vehicles built within these VIN breakpoints:</P>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Year</P></TH>
<TH vAlign=bottom align=middle>

Division</P></TH>
<TH vAlign=bottom align=middle>

Model</P></TH>
<TH vAlign=bottom align=middle>

From</P></TH>
<TH vAlign=bottom align=middle>

Through</P></TH></TR>
<TR>
<TD vAlign=center align=middle>

2003 </P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade</P></TD>
<TD vAlign=center align=middle>

3R302814 </P></TD>
<TD vAlign=center align=middle>

3R320163</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004 </P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade </P></TD>
<TD vAlign=center align=middle>

4R100129 </P></TD>
<TD vAlign=center align=middle>

4R104745</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade ESV</P></TD>
<TD vAlign=center align=middle>

3G299104</P></TD>
<TD vAlign=center align=middle>

3G324791</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

Cadillac </P></TD>
<TD vAlign=center align=middle>

Escalade ESV</P></TD>
<TD vAlign=center align=middle>

4G100051</P></TD>
<TD vAlign=center align=middle>

4G100053</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade EXT</P></TD>
<TD vAlign=center align=middle>

3G300225</P></TD>
<TD vAlign=center align=middle>

3G324703</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

Escalade EXT</P></TD>
<TD vAlign=center align=middle>

4G100044</P></TD>
<TD vAlign=center align=middle>

4G100048</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

Avalanche</P></TD>
<TD vAlign=center align=middle>

3G301959</P></TD>
<TD vAlign=center align=middle>

3G324088</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

Avalanche</P></TD>
<TD vAlign=center align=middle>

4G100025</P></TD>
<TD vAlign=center align=middle>

4G100065</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

Express</P></TD>
<TD vAlign=center align=middle>

31216183</P></TD>
<TD vAlign=center align=middle>

31238955</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

Express</P></TD>
<TD vAlign=center align=middle>

41100063</P></TD>
<TD vAlign=center align=middle>

41103650</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=4>

2003</P></TD>
<TD vAlign=center align=middle rowSpan=4>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=4>

Silverado</P></TD>
<TD vAlign=center align=middle>

3E346100</P></TD>
<TD vAlign=center align=middle>

3E376199</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3F192149</P></TD>
<TD vAlign=center align=middle>

3F259060</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3M110513</P></TD>
<TD vAlign=center align=middle>

3M112077</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3Z338002</P></TD>
<TD vAlign=center align=middle>

3Z361763</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=4>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=4>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=4>

Silverado</P></TD>
<TD vAlign=center align=middle>

4E100021</P></TD>
<TD vAlign=center align=middle>

4E100126</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4F100026</P></TD>
<TD vAlign=center align=middle>

4F100566</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4M100006</P></TD>
<TD vAlign=center align=middle>

4M100017</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4Z100115</P></TD>
<TD vAlign=center align=middle>

4Z101176</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=2>

2003</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Suburban</P></TD>
<TD vAlign=center align=middle>

3G285873</P></TD>
<TD vAlign=center align=middle>

3G324561</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3R302840</P></TD>
<TD vAlign=center align=middle>

3R319989</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Suburban</P></TD>
<TD vAlign=center align=middle>

4G100033</P></TD>
<TD vAlign=center align=middle>

4G100074</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4J100031</P></TD>
<TD vAlign=center align=middle>

4J100106</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4R100153</P></TD>
<TD vAlign=center align=middle>

4R104727</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=2>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Chevrolet</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Tahoe</P></TD>
<TD vAlign=center align=middle>

4J100021</P></TD>
<TD vAlign=center align=middle>

4J100103</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4R100130</P></TD>
<TD vAlign=center align=middle>

4R104749</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

GMC </P></TD>
<TD vAlign=center align=middle>

Savana</P></TD>
<TD vAlign=center align=middle>

31217178</P></TD>
<TD vAlign=center align=middle>

31905189</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

GMC</P></TD>
<TD vAlign=center align=middle>

Savana</P></TD>
<TD vAlign=center align=middle>

41100065</P></TD>
<TD vAlign=center align=middle>

41103637</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2003</P></TD>
<TD vAlign=center align=middle rowSpan=3>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Sierra</P></TD>
<TD vAlign=center align=middle>

3E346103</P></TD>
<TD vAlign=center align=middle>

3E376203</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3F232315</P></TD>
<TD vAlign=center align=middle>

3F259040</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3Z338024</P></TD>
<TD vAlign=center align=middle>

3Z359268</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=3>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Sierra</P></TD>
<TD vAlign=center align=middle>

4E100026</P></TD>
<TD vAlign=center align=middle>

4E100127</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4F100025</P></TD>
<TD vAlign=center align=middle>

4F100561</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4Z100032</P></TD>
<TD vAlign=center align=middle>

4Z101101</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

GMC</P></TD>
<TD vAlign=center align=middle>

Yukon</P></TD>
<TD vAlign=center align=middle>

3J308169</P></TD>
<TD vAlign=center align=middle>

3J335135</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=2>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=2>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=2>

Yukon</P></TD>
<TD vAlign=center align=middle>

4J100061</P></TD>
<TD vAlign=center align=middle>

4J100105</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4R100128</P></TD>
<TD vAlign=center align=middle>

4R104746</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2003</P></TD>
<TD vAlign=center align=middle rowSpan=3>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Yukon XL</P></TD>
<TD vAlign=center align=middle>

3G290353</P></TD>
<TD vAlign=center align=middle>

3G324315</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3J309243</P></TD>
<TD vAlign=center align=middle>

3J335111</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

3R302820</P></TD>
<TD vAlign=center align=middle>

3R319538</P></TD></TR>
<TR>
<TD vAlign=center align=middle rowSpan=3>

2004</P></TD>
<TD vAlign=center align=middle rowSpan=3>

GMC</P></TD>
<TD vAlign=center align=middle rowSpan=3>

Yukon XL</P></TD>
<TD vAlign=center align=middle>

4G100026</P></TD>
<TD vAlign=center align=middle>

4G100070</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4J100065</P></TD>
<TD vAlign=center align=middle>

4J100104</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

4R100133</P></TD>
<TD vAlign=center align=middle>

4R104750</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2003</P></TD>
<TD vAlign=center align=middle>

HUMMER</P></TD>
<TD vAlign=center align=middle>

H2</P></TD>
<TD vAlign=center align=middle>

3H135425</P></TD>
<TD vAlign=center align=middle>

3H146453</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

2004</P></TD>
<TD vAlign=center align=middle>

HUMMER</P></TD>
<TD vAlign=center align=middle>

H2</P></TD>
<TD vAlign=center align=middle>

4H100001</P></TD>
<TD vAlign=center align=middle>

4H100034</P></TD></TR></TBODY></TABLE>

<FONT color=brown>
<H4>Important</H4>

Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle
Inquiry System) before beginning recall repairs. [Not all vehicles within the
above breakpoints may be involved.]</P></FONT>

</P>For US

For dealers with involved vehicles, a Campaign Initiation Detail Report
containing the complete Vehicle Identification Number, customer name and address
data has been prepared and will be loaded to the GM DealerWorld, Recall
Information website. The customer name and address data furnished will enable
dealers to follow up with customers involved in this program.</P>For Canada
& IPC

Computer listings containing the complete Vehicle Identification Number,
customer name and address data of involved vehicles have been prepared, and are
being furnished to involved dealers. The customer name and address data will
enable dealers to follow up with customers involved in this recall. Any dealer
not receiving a computer listing with the recall bulletin has no involved
vehicles currently assigned.</P>

These dealer listings may contain customer names and addresses obtained from
Motor Vehicle Registration Records. The use of such motor vehicle registration
data for any other purpose is a violation of law in several
states/provinces/countries. Accordingly, you are urged to limit the use of this
listing to the follow-up necessary to complete this recall.</P><A
name=ss4-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss4-1528250">
<H5>Parts Information</A></H5>

Parts required to complete this recall are to be obtained from General Motors
Service Parts Operations (GMSPO). Please refer to your "involved vehicles
listing" before ordering parts. Normal orders should be placed on a DRO = Daily
Replenishment Order. In an emergency situation, parts should be ordered on a CSO
= Customer Special Order.</P>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Part Number</P></TH>
<TH vAlign=bottom align=middle>

Description</P></TH>
<TH vAlign=bottom align=middle>

Qty/ Vehicle</P></TH></TR>
<TR>
<TD vAlign=center align=middle>

10398682</P></TD>
<TD vAlign=center align=middle>

Valve Kit, P/B Boos Cont</P></TD>
<TD vAlign=center align=middle>

1 (if req'd)</P></TD></TR></TBODY></TABLE>

<FONT color=brown>
<H4>Important</H4>

It is estimated that only 20% of involved vehicles will require Valve Kit
Repair. Please order parts accordingly. </P></FONT>

</P><A name=ss5-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss5-1528250">
<H5>Service Procedure</A></H5>

The following procedure provides instructions for inspecting, and if
necessary, replacing the hydraulic brake booster relief valve.</P>

<LI type=1>Open the hood.
[img]Brake Hydro-Boost Relief Valve Seal Fracture_files/TifToGif[/img]
<A
href="http://127.0.0.1:9001/servlets/RetrieveTif?pic=1478889">
[img]Brake Hydro-Boost Relief Valve Seal Fracture_files/tif.gif[/img]</A>

<FONT color=brown>
<H4>Important</H4>

You may notice that there is a blue epoxy-type material in the center of
the relief valve described in the next step. This material will be found in
both the original and replacement relief valves.</P></FONT>

</P>
<LI type=1>Locate the relieve valve (2) on the hydraulic brake booster. The
valve located in the front of the brake booster directly behind the master
cylinder reservoir (1).
<UL type=BULLET>
<LI>If the color of the relief valve is metallic yellow or has a brass
appearance, then no further action is required.
<LI>If the color of the relief valve is silver or aluminum, continue to the
next step. </LI>

<FONT color=brown>
<H4>Important</H4>

If present, the stamped number being described in the next step would be on
the mounting surface for the master cylinder on the hydraulic brake booster.
The number may be difficult to see if there is any corrosion on the unpainted
surface. As a result, it may be necessary to clean the surface with a piece of
emery or sandpaper.</P></FONT>

</P>
<LI type=1>Inspect the hydraulic brake booster at the location shown (4) for a
stamped number. The location (4) is the same surface that the master cylinder
mounts on, just above the outboard bolt and nut (5). Also inspect for a paint
mark (3) near the master cylinder outboard mounting bolt (5).
<UL type=BULLET>
<LI>If a yellow, pink, or white paint mark IS visible, no further inspection
or repairs are required. Disregard any stamped number found when a yellow,
pink, or white paint mark is visible.
<LI>If there are NO paint marks and there IS a stamped number 1 visible,
then proceed to the next step.
<LI>If there are NO paint marks and there IS a stamped number OTHER THAN "1"
(i.e. 0, 2, 3, 4, 5, etc.) visible, no further inspection or repairs are
required.
<LI>If there are NO paint marks and there are NO stamped numbers visible,
then proceed to the next step. </LI>[/list]

<FONT color=red>
<H4>Caution</H4>

Care should be taken when working around the accumulator since it contains
high-pressure compressed gas and hydraulic fluid.</P></FONT>

</P>
<LI type=1>With the ignition in the OFF position, pump the brake pedal a
minimum of ten times.
<LI type=1>On van models, remove the two bolts that attach the diagonal brace
between the left front fender and radiator support. Remove the brace and the
water deflector that is attached to it.
<LI type=1>On all models, remove the two nuts that attach the master cylinder
to the hydraulic brake booster. A 13mm wrench installed on the bolt head
may be required to prevent the bolt from spinning.

<FONT color=blue>
<H4>Notice</H4>

When repositioning the master cylinder in the next step, use care not to
pinch, kink or damage the brake hoses or pipes.</P></FONT>

</P>

<FONT color=brown>
<H4>Important</H4>

On fullsize pickups and utilities, the bracket that attaches the brake
combination valve will need to be removed from the mounting bolts at the same
time that the master cylinder is removed and repositioned in the next
step.</P></FONT>

</P>
<LI type=1>Remove and reposition the master cylinder away from the hydraulic
brake booster so that the machined surface on the front of the booster where
the master cylinder was mounted is visible.
[img]C:\TSB\Brake Hydro-Boost Relief Valve Seal Fracture_files\TifToGif[1).3][/img]
<A
href="http://127.0.0.1:9001/servlets/RetrieveTif?pic=1478924">
[img]Brake Hydro-Boost Relief Valve Seal Fracture_files/tif.gif[/img]</A>

<LI type=1>Inspect the machined surface that was covered by the master
cylinder on the front of the hydraulic brake booster at the location (1) shown
for a stamped number.
<UL type=BULLET>
<LI>If a stamped number 1 is visible, then the relief valve must be
replaced. Proceed to the next step.
<LI>If a stamped number OTHER THAN "1" (i.e. 0, 2, 3, 4, 5, etc.) is
visible, then no further action is required. Proceed to Step 14 and
reinstall the master cylinder.
<LI>If no stamped number is visible, then no further action is required.
Proceed to Step 14 and reinstall the master cylinder. </LI>[/list] <LI type=1>Cover the master cylinder with a clean shop towel in order to
protect it from fluids or cleaners. Also, place a shop towel under the
hydraulic brake booster to absorb any fluid that may leak out of the unit when
the relief valve is removed in the next step.
[img]C:\TSB\Brake Hydro-Boost Relief Valve Seal Fracture_files\TifToGif[1).2][/img]
<A
href="http://127.0.0.1:9001/servlets/RetrieveTif?pic=1478923">
[img]Brake Hydro-Boost Relief Valve Seal Fracture_files/tif.gif[/img]</A>

<LI type=1>Using the tool (2) included with the new relief valve, unscrew the
original relief valve (1) from the hydraulic brake booster.

<FONT color=blue>
<H4>Notice</H4>

DO NOT blow compressed air into the bore or use any commercially available
cleaners to flush the valve bore in the next step. This could damage the
booster or master cylinder.</P></FONT>

</P>
<LI type=1>Inspect the two O-rings on the original valve for signs of damage.
If an O-ring is missing, broken or damaged, inspect the bore in the hydraulic
brake booster for any pieces or debris using a non-metallic type tool or a
clean "lint-free" towel.

<FONT color=brown>
<H4>Important</H4>

A torque wrench must be used when tightening the valve in the next step. In
addition, a 3/8 inch drive to 1/4 inch drive adapter will be needed if your
torque wrench is a 3/8 inch drive.</P></FONT>

</P>

<FONT color=brown>
<H4>Important</H4>

After tightening the NEW relief valve in the next step, a small gap may
exist between the head on the valve and the hydraulic brake booster. This
condition is normal.</P></FONT>

</P>
<LI type=1>Insert the NEW relief valve into the bore. Tighten

Tighten to 17N·m (13lbft).</P>
<LI type=1>Using a clean shop towel, clean up any fluid that may have leaked
out of they hydraulic brake booster when removing the original valve.
<LI type=1>Position the master cylinder (and brake combination valve mounting
bracket on full size pickups and utilities) on the mounting bolts on the
hydraulic brake booster.
<LI type=1>With the master cylinder mounted flush to the booster, install the
nuts. Tighten

Tighten the nuts to 33N·m (24lbft).</P>
<LI type=1>On van models, install the diagonal brace with the water deflector
attached to it between the left fender and the radiator. Install the two
bolts. Tighten

Tighten the bolts to 25N·m (18lbft).</P>
<LI type=1>Start the engine and verify the hydraulic brake booster operation.
<LI type=1>Turn the engine OFF and check the power steering fluid reservoir.
Add fluid if necessary.
<LI type=1>Close the hood. </LI>[/list]<A name=ss6-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss6-1528250">
<H5>Courtesy Transportation</A></H5>

The General Motors Courtesy Transportation program is intended to minimize
customer inconvenience when a vehicle requires a repair that is covered by the
New Vehicle Limited Warranty. The availability of courtesy transportation to
customers whose vehicles are within the warranty coverage period and involved in
a product recall is very important in maintaining customer satisfaction. Dealers
are to ensure that these customers understand that shuttle service or some other
form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures
Manual for Courtesy Transportation guidelines.</P><A name=ss7-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss7-1528250">
<H5>Claim Information</A></H5>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Repair Performed</P></TH>
<TH vAlign=bottom align=middle>

Part Count</P></TH>
<TH vAlign=bottom align=middle>

Part No.</P></TH>
<TH vAlign=bottom align=middle>

Parts Allow</P></TH>
<TH vAlign=bottom align=middle>

CC-FC</P></TH>
<TH vAlign=bottom align=middle>

Labor Op</P></TH>
<TH vAlign=bottom align=middle>

Labor Hours*</P></TH>
<TH vAlign=bottom align=middle>

Net Item</P></TH></TR>
<TR>
<TD vAlign=center align=left>

Inspection Only - No Further Action Required</P>

Inspection #1: Inspect for Color & Stamped Number</P></TD>
<TD vAlign=center align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

MA-96</P></TD>
<TD vAlign=center align=middle>

V1109</P></TD>
<TD vAlign=center align=middle>

0.2</P></TD>
<TD vAlign=center align=middle>

N/A</P></TD></TR>
<TR>
<TD vAlign=center align=left>

Add: Inspection #2 - Hyd. Brake Booster</P></TD>
<TD>

</P></TD>
<TD>

</P></TD>
<TD>

</P></TD>
<TD vAlign=center align=middle>

</P></TD>
<TD vAlign=center align=middle>

</P></TD>
<TD vAlign=center align=middle>

0.1</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR>
<TR>
<TD vAlign=center>

Inspect & Replace Hydro-Boost Relief Valve (inc. all
inspections)</P></TD>
<TD align=middle>

1</P></TD>
<TD align=middle>

--</P></TD>
<TD align=middle>

**</P></TD>
<TD vAlign=center align=middle>

MA-96</P></TD>
<TD vAlign=center align=middle>

V1110</P></TD>
<TD align=middle>

0.4</P></TD>
<TD vAlign=center align=middle>

***</P></TD></TR>
<TR>
<TD vAlign=center>

Courtesy Transportation</P></TD>
<TD align=middle>

N/A</P></TD>
<TD align=middle>

N/A</P></TD>
<TD align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

MA-96</P></TD>
<TD vAlign=center align=middle>

****</P></TD>
<TD align=middle>

N/A</P></TD>
<TD vAlign=center align=middle>

*****</P></TD></TR>
<TR>
<TD vAlign=center align=left colSpan=8>

* -- For Program Administrative Allowance, add 0.1 hours to the "Labor
Hours".</P>

** -- The "Parts Allowance" should be the sum total of the current
GMSPO Dealer Net price plus applicable Mark-Up or Landed Cost Mark-Up (for
IPC) for the power brake booster assembly needed to complete the
repair.</P>

*** -- The amount identified in the "Net Item" column should represent
the sum total of the Current GMSPO Net Price plus applicable Mark-Up or
Landed Cost Mark-Up (for IPC) for the actual amount of power steering
fluid, if needed, to perform the required repairs.</P>

**** -- Submit courtesy transportation using normal labor operations
for courtesy transportation as indicated in the GM Service Policies and
Procedures Manual.</P>

***** -- The amount identified in the "Net Item" column should
represent the actual dollar amount for courtesy
transportation.</P></TD></TR></TBODY></TABLE>

Refer to the General Motors WINS Claim Processing Manual for details on
Product Recall Claim Submission.</P><A name=ss8-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss8-1528250">
<H5>Customer Notification - For US and Canada</A></H5>

General Motors will notify customers of this recall on their vehicle (see
copy of customer letter included with this bulletin).</P><A name=ss9-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss9-1528250">
<H5>Customer Notification - For IPC</A></H5>

Letters will be sent to known owners of record located within areas covered
by the US National Traffic and Motor Vehicle Safety Act. For owners outside
these areas, dealers should notify customers using the attached suggested dealer
letter.</P><A name=ss10-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss10-1528250">
<H5>Dealer Recall Responsibility - FOR US AND IPC (US States, Territories, and
Possessions)</A></H5>

The US National Traffic and Motor Vehicle Safety Act provides that each
vehicle that is subject to a recall of this type must be adequately repaired
within a reasonable time after the customer has tendered it for repair. A
failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not
adequately repaired within a reasonable time, the customer may be entitled to an
identical or reasonably equivalent vehicle at no charge or to a refund of the
purchase price less a reasonable allowance for depreciation. To avoid having
these burdensome remedies, every effort must be made to promptly schedule an
appointment with each customer and to repair their vehicle as soon as possible.
In the recall notification letters, customers are told how to contact the US
National Highway Traffic Safety Administration if the recall is not completed
within a reasonable time.</P>

This bulletin is notice to you that the new motor vehicles included in
this recall may not comply with the standard identified above. Under Title 49,
Section 30112 of the United States Code, it is illegal for a dealer to sell a
new motor vehicle which the dealer knows does not comply with an applicable
Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of
these motor vehicles without first performing the recall correction, your
dealership may be subject to a civil penalty for each such sale. </P><A
name=ss11-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss11-1528250">
<H5>Dealer Recall Responsibility - ALL</A></H5>

All unsold new vehicles in dealers' possession and subject to this recall
MUST be held and inspected/repaired per the service procedure of this recall
bulletin BEFORE customers take possession of these vehicles.</P>

Dealers are to service all vehicles subject to this recall at no charge to
customers, regardless of mileage, age of vehicle, or ownership, from this time
forward.</P>

Customers who have recently purchased vehicles sold from your vehicle
inventory, and for which there is no customer information indicated on the
dealer listing, are to be contacted by the dealer. Arrangements are to be made
to make the required correction according to the instructions contained in this
bulletin. This could be done by mailing to such customers a copy of the customer
letter accompanying this bulletin. Recall follow-up cards should not be used for
this purpose, since the customer may not as yet have received the notification
letter.</P>

In summary, whenever a vehicle subject to this recall enters your vehicle
inventory, or is in your dealership for service in the future, please take the
steps necessary to be sure the recall correction has been made before selling or
releasing the vehicle.</P>June 2004

Dear General Motors Customer:</P>

This notice is sent to you in accordance with the requirements of the
National Traffic and Motor Vehicle Safety Act. Federal regulation requires that
any vehicle lessor receiving this recall notice must forward a copy of this
notice to the lessee within ten days.</P><A name=ss12-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss12-1528250">
<H5>Reason For This Recall</A></H5>

General Motors has decided that certain 2003 and 2004 model year Cadillac
Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche,
Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; HUMMER H2; and
2004 model year Chevrolet Tahoe vehicles fail to conform to either
Federal/Canada Motor Vehicle Safety Standard 105, "Hydraulic and Electric Brake
System", or Standard 135, "Light Vehicle Brake Systems". These vehicles may have
a relief valve bore within the brake hydro-boost module that is not to
specification. An out-of-specification bore could result in fracture of the
relief valve o-ring seal within the module. If this happens, during brake
applications the driver may be able to hear an engine compartment noise similar
to the sound that occurs when the steering wheel is turned to a full stop
position. The driver could also experience a slight increase in steering efforts
while braking and parking. Under certain driving conditions, a fractured seal
may require a slight increase in the applied brake pedal effort to achieve the
same vehicle deceleration rate as prior to the seal fracture. If this were to
occur, it could result in a vehicle crash without prior warning.</P><A
name=ss13-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss13-1528250">
<H5>What Will Be Done</A></H5>

Your GM dealer will inspect the hydro-boost module, and replace the relief
valve if necessary. This service will be performed for you at no charge
.</P><A name=ss14-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss14-1528250">
<H5>How Long Will The Repair Take?</A></H5>

This inspection and correction, if necessary, will take approximately 20 to
25 minutes. However, due to scheduling requirements, your dealer may need your
vehicle for a longer period of time.</P><A name=ss15-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss15-1528250">
<H5>Contacting Your Dealer</A></H5>

To limit any possible inconvenience, we recommend that you contact your GM
dealer as soon as possible to schedule an appointment for this repair. By
scheduling an appointment, your dealer can ensure that the necessary parts will
be available on your scheduled appointment date. Should your dealer be unable to
schedule a service date within a reasonable time, you should contact the
appropriate Customer Assistance Center at the number listed below. The Customer
Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern
standard time Monday through Friday</P>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Division</P></TH>
<TH vAlign=bottom align=middle>

Number</P></TH>
<TH vAlign=bottom align=middle>

Text Telephones (TTY)</P></TH></TR>
<TR>
<TD vAlign=center align=middle>

Cadillac</P></TD>
<TD vAlign=center align=middle>

1-866-982-2339</P></TD>
<TD vAlign=center align=middle>

1-800-833-2622</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Chevrolet</P></TD>
<TD vAlign=center align=middle>

1-800-630-2438</P></TD>
<TD vAlign=center align=middle>

1-800-833-2438</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

GMC</P></TD>
<TD vAlign=center align=middle>

1-866-996-9463</P></TD>
<TD vAlign=center align=middle>

1-800-462-8583</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

HUMMER</P></TD>
<TD vAlign=center align=middle>

1-866-964-8663</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Puerto Rico - English</P></TD>
<TD vAlign=center align=middle>

1-800-496-9992</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Puerto Rico - Español</P></TD>
<TD vAlign=center align=middle>

1-800-496-9993</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Virgin Islands</P></TD>
<TD vAlign=center align=middle>

1-800-496-9994</P></TD>
<TD vAlign=center align=middle>

</P></TD></TR></TBODY></TABLE>

If, after contacting the appropriate customer assistance center, you are
still not satisfied that we have done our best to remedy this condition without
charge and within a reasonable time, you may wish to write the Administrator,
National Highway Traffic Safety Administration, 400 Seventh Street SW,
Washington, DC 20590 or call 1-888-327-4236.</P><A name=ss16-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss16-1528250">
<H5>Customer Reply Form</A></H5>

The enclosed customer reply form identifies your vehicles. Presentation of
this form to your dealer will assist in making the necessary correction in the
shortest possible time. If you no longer own this vehicle, please let us know by
completing the form and mailing it back to us.</P><A name=ss17-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss17-1528250">
<H5>Courtesy Transportation</A></H5>

If your vehicle is within the New Vehicle Limited Warranty your dealer will
provide you with shuttle service or some other form of courtesy transportation
while your vehicle is at the dealership for this repair. Please refer to your
Owner's Manual and your dealer for details on Courtesy Transportation.</P><A
name=ss18-1528250><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1528250&pubid=293&evc= sm#ss18-1528250">
<H5>Recall Information Online</A></H5>

More information about this recall (including answers to frequently asked
questions) is available online at the Owner Center at My GMLink. This free
online service offers vehicle and ownership related information and tools
tailored to your specific vehicle. To join, visit www.mygmlink.com ,
and enter your vehicle's 17-character vehicle identification number (VIN) shown
on the enclosed form to get the most personalized information for your
vehicle.</P>

We are sorry to cause you this inconvenience; however, we have taken this
action in the interest of your safety and continued satisfaction with our
products.</P>

General Motors Corporation</P>

Enclosure</P>

04004</P>

</P>
<TABLE width="100%">
<TBODY>
<TR>
<TD align=left width=778><FONT size=1>GM bulletins are intended for use by
professional technicians, NOT a "do-it-yourselfer". They are written
to inform these technicians of conditions that may occur on some vehicles,
or to provide information that could assist in the proper service of a
vehicle. Properly trained technicians have the equipment, tools,
safety instructions, and know-how to do a job properly and safely.
If a condition is described, DO NOT assume that the bulletin applies to
your vehicle, or that your vehicle will have that condition. See
your GM dealer for information on whether your vehicle may benefit from
the information.
</FONT></TD>
<TD align=middle width=42></TD>
<TD align=middle width=167><FONT size=2>WE SUPPORT VOLUNTARY TECHNICIAN
CERTIFICATION
</FONT></TD></TR></TBODY></TABLE>
<P align=center>© Copyright General Motors Corporation. All Rights
Reserved. </P>
<FORM name=bottomNavForm>
<HR>

<TABLE width="100%" align=center>
<TBODY>
<TR>
<TD width="25%" slign="LEFT"></TD>
<TD align=middle width="50%">Document ID# 1528250
2003 HUMMER
H2</TD>
<TD align=right width="25%"></TD></TR></TBODY></TABLE></FORM></BODY></HTML>

HGW · #4 07-26-2004, 11:22 PM

Thanks Klaus:

I have been experiencing this problem and was looking to fix it. Never had my H2 to the dealer and never will. It is just a hassle for me.

I certainly did not by my H2 expecting GM to fix much, if anything.

TMKHUM · #5 08-02-2004, 10:44 PM

Klaus

Can you post the pics or email to me?

The pics are blank with an X...

tomklepcyk@earthlink.net

Thanks!

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