1997 Pontiac Sunfire Recalls

1. Recall Description

   CERTAIN PASSENGER VEHICLES AND MINI VANS HAVE LOWER PINION BEARINGS IN THE POWER RACK AND PINION ASSEMBLY IN WHICH THE RETAINER TABS WERE NOT CRIMPED PROPERLY. THESE AND SOME OTHER RETAINERS USED IN VEHICLES ASSEMBLED BETWEEN JANUARY 1, 1996 AND OCTOBER 31, 1997, COULD FAIL AND PERMIT THE BALL BEARINGS TO ESCAPE.

   Possible Effects

   IF THIS OCCURS, THE PINION SHAFT CAN BE FORCED UPWARD DURING LEFT TURNS AND BACK DOWN AS THE STEERING WHEEL IS MOVED BACK AND TO THE RIGHT. IF THE PINION SHAFT MOVES FURTHER, THE DRIVER WILL NEED TO EXERT MORE EFFORT TO TURN THE STEERING WHEEL, SIMILAR TO A VEHICLE WITHOUT POWER ASSISTED STEERING. IF THE PINION SHAFT MOVES EVEN FURTHER, THE DRIVER WILL REQUIRE MUCH HIGHER EFFORT TO TURN LEFT AND MAY NOT BE ABLE TO TURN THE WHEEL AS MUCH AS INTENDED. WITH THE MAXIMUM PINION SHAFT MOVEMENT, WHICH REQUIRES INTERNAL GEAR COMPONENT DAMAGE, THE DRIVER CAN ENCOUNTER HIGH RESISTANCE TO TURNING LEFT, FOLLOWED BY UNINTENDED POWER ASSIST TO THE RIGHT. IN ANY OF THESE CONDITIONS, A CRASH COULD OCCUR.

   Action

   DEALERS WILL INSTALL A NEW LOWER PINION BEARING UNLESS INSPECT OF THE EXISTING BEARING INDICATES THAT REPLACEMENT OF THE GEAR ASSEMBLY IS NECESSARY. OWNER NOTIFICATION BEGAN JANUARY 24, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1020, PONTIAC AT 1-800-762-2737, OR OLDSMOBILE AT 1-800-442-6537.

   Notes

   GM RECALL NO. 02049.ALSO, CUSTOMERS CAN CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION''S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

   Recall Manufacture Dates

   1996-07-01 - 1997-07-31

   Vehicles Affected

   1159156

2. Recall Description

   ON CERTAIN PASSENGER VEHICLES. IF THE ENGINE FAILS TO START AND THE DRIVER HOLDS THE KEY IN THE "START" POSITION FOR AN EXTENDED PERIOD, HIGH CURRENT FLOWS THROUGH THE IGNITION SWITCH, AND SOMETIMES PRODUCES ENOUGH HEAT TO MELT INTERNAL SWITCH PARTS.

   Possible Effects

   IF THE SWITCH IS DAMAGED, A FIRE COULD OCCUR IN THE STEERING COLUMN, EVEN WITH THE ENGINE OFF AND THE KEY REMOVED.

   Action

   DEALERS WILL INSTALL A RELAY KIT IN THESE VEHICLES TO PREVENT HIGH CURRENT FROM FLOWING THROUGH THE IGNITION SWITCH. OWNER NOTIFICATION BEGAN MARCH 27, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1020, PONTIAC AT 1-800-762-2737, BUICK AT 1-800-521-7300, OR OLDSMOBILE AT 1-800-442-6537.

   Notes

   CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION''S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

   Recall Manufacture Dates

   1996-07-01 - 1997-07-31

   Vehicles Affected

   1589948

3. Recall Description

   VEHICLE DESCRIPTION: PASSENGER VEHICLES. ONE OF THE REAR SUSPENSION TRAILING ARM BOLTS CAN FATIGUE AND BREAK.

   Possible Effects

   IF THIS WERE TO OCCUR WHILE THE VEHICLE WAS IN MOTION, A LOSS OF VEHICLE CONTROL CAN OCCUR, INCREASING THE RISK OF A CRASH.

   Action

   DEALERS WILL REPLACE THE REAR SUSPENSION TRAILING ARM FASTENERS.

   Notes

   OWNER NOTIFICATION BEGAN DECEMBER 28, 1998. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1020 OR PONTIAC AT 1-800-762-2737. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION''S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

   Recall Manufacture Dates

   1996-06-01 - 1997-03-31

   Vehicles Affected

   27083

4. Recall Description

   VEHICLE DESCRIPTION: PASSENGER VEHICLES. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG''S SENSING AND DIAGNOSTIC MODULE, AN INADVERTENT AIR BAG DEPLOYMENT COULD OCCUR IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN.

   Possible Effects

   AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED OCCUPANTS WHO ARE TOO CLOSE TO THEM.

   Action

   DEALERS WILL RECALIBRATE THE AIR BAG SENSING AND DIAGNOSTIC MODULE.

   Notes

   OWNER NOTIFICATION BEGAN DURING AUGUST 1998.OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1022 OR PONTIAC AT 1-800-762-2737.ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION''S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4326).

   Recall Manufacture Dates

   1996-07-01 - 1997-05-31

   Vehicles Affected

   675302

5. Recall Description

   VEHICLE DESCRIPTION: PASSENGER VEHICLES. THESE VEHICLES WERE BUILT WITH MIS-LOCATED WELDS AT THE JOINT BETWEEN THE LEFT ROCKER PANEL INNER REINFORCEMENT AND THE BODY SIDE RING. THIS DOES NOT MEET THE REQUIREMENTS OF FMVSS NO. 214, "SIDE DOOR STRENGTH."

   Possible Effects

   IN THE EVENT OF A VEHICLE CRASH, THE SHEET METAL STRUCTURE WOULD NOT PERFORM AS DESIRED INCREASING THE RISK OF PERSONAL INJURY.

   Action

   DEALERS WILL INSPECT THE WELDS AND, IF NECESSARY, PLACE FIVE WELDS BETWEEN THE INVOLVED PANELS AND APPLY PRIMER AND TOPCOAT FINISH MATERIALS.

   Notes

   OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING MARCH 1998.OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1020 OR PONTIAC AT 1-800-762-2737.ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION''S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

   Recall Manufacture Dates

   1997-04-01 - 1997-04-30

   Vehicles Affected

   8

6. Recall Description

   VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE COMPACT SPARE TIRE ASSEMBLIES WERE ASSEMBLED WITH INCORRECT RIMS. IF THE SPARE TIRE IS UNDERINFLATED, THE BEAD CAN SEPARATE FROM THE RIM CAUSING A RAPID LOSS OF AIR. THIS DOES NOT COMPLY WITH THE REQUIREMENTS OF FMVSS NO. 110, "TIRE SELECTION AND RIMS."

   Possible Effects

   A RAPID LOSS OF AIR CAN INCREASE THE RISK OF A VEHICLE CRASH.

   Action

   DEALERS WILL REPLACE THE RIM ON THE COMPACT SPARE TIRE ASSEMBLY. OWNERS ARE REQUESTED NOT TO USE THE SPARE TIRE UNTIL THE RIM HAS BEEN REPLACED.

   Notes

   OWNER NOTIFICATION:OWNER NOTIFICATION WILL BEGIN DURING JULY 1997. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1020 OR PONTIAC AT 1-800-762-2737.ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION''S AUTO SAFETY HOTLINE AT 1-800-424-9393.

   Recall Manufacture Dates

   1997-04-01 - 1997-04-30

   Vehicles Affected

   652

7. Recall Description

   CERTAIN DELPHI AFTERMARKET FUEL PUMP MODULES / MODULE RESERVOIR ASSEMBLIES (MRA) THAT WERE SOLD FOR USE ON THE ABOVE LISTED VEHICLES. DURING PRODUCTION THE MRAS VENT AND FUEL RETURN TUBES WERE REVERSED. THIS CONDITION CAN RESULT IN THE VEHICLE NOT RUNNING CORRECTLY (IDLE ROUGH AND/OR STALL) DUE TO AN OVERLY RICH FUEL BLEND OR THE VEHICLE''S EVAPORATIVE EMISSION CARBON CANISTER MAY LEAK FUEL.

   Possible Effects

   A STALLED VEHICLE CAN INCREASE THE RISK OF A VEHICLE CRASH. A FUEL LEAK CAN RESULT IN A FIRE.

   Action

   DELPHI WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE MRAS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2007. OWNERS CAN CONTACT DELPHI AT 1-877-335-7443.

   Notes

   THIS RECALL ONLY PERTAINS TO AFTERMARKET DELPHI FUEL PUMP MODULES AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON VEHICLES MANUFACTURED BY GENERAL MOTORS CORPORATION.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION''S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

   Recall Manufacture Dates

   -

   Vehicles Affected

   3124

8. Recall Description

   CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

   Possible Effects

   WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

   Action

   PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.

   Notes

   THIS RECALL ONLY PERTAINS TO PRO-A MOTORS AFTERMARKET LAMPS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON THE LISTED PASSENGER VEHICLES.FOR MORE INFORMATION ON THE LAMP MODEL NUMBERS, CLICK ON DOCUMENT SEARCH AND VIEW DOCUMENT TITLED "LAMP MODEL NUMBERS."CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION''S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

   Recall Manufacture Dates

   -

   Vehicles Affected

   61944

9. Recall Description

   DORMAN PRODUCTS IS RECALLING 3,900 INTERMEDIATE STEERING SHAFTS DORMAN PART NOS. 425-151, 425-152, AND 425-153, (SOLD UNDER DORMAN''S "OE SOLUTIONS" BRAND NAME), BALKAMP #''S 7-3057, 7-3058, 7-3059 (SOLD UNDER THE "NAPA" BRAND NAME), AND PLATINUM PARTS #''S 2425151, 2425152, AND 2425153 MANUFACTURED DURING THE MONTH OF SEPTEMBER 2007. THESE REPLACEMENT STEERING SHAFTS CAN BE USED ON THE VEHICLES LISTED ABOVE. THE WELD CONNECTING THE INNER TUBE TO THE OUTER TUBE MAY BE DEFECTIVE.

   Possible Effects

   IF THE WELD FAILS, LOSS OF STEERING COULD RESULT, POSSIBLY RESULTING IN A VEHICLE CRASH.

   Action

   DORMAN WILL NOTIFY OWNERS AND REPLACE THE STEERING SHAFTS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 16, 2008. OWNERS MAY CONTACT DORMAN TOLL FREE AT 1-800-523-2492.

   Notes

   THIS RECALL ONLY PERTAINS TO DORMAN''S OE SOLUTIONS BRAND NAME, BALKAMP''S NAPA BRAND, AND THE PLATINUM BRAND STEERING SHAFTS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON VEHICLES MANUFACTURED BY GENERAL MOTORS CORPORATION.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION''S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

   Recall Manufacture Dates

   -

   Vehicles Affected

   3855