New front Diff.

[drmiles]

Document ID# 1516297
2004 Cadillac Escalade

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Snap/Popping Type Noise Coming From Front of Vehicle (Remove Front Crossmember and Slot Mounting Holes) #03-08-61-002B - (05/20/2004)
Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember and Slot Mounting Holes)
2003-2005 Cadillac Escalade

2003-2005 Chevrolet Avalanche, Suburban, Tahoe

2004-2005 Chevrolet Silverado with Recirculating Ball Type Steering

2003-2005 GMC Yukon, Yukon XL

2004-2005 GMC Sierra with Recirculating Ball Type Steering

All 1500 Series (½ Ton) with Two-Wheel Drive

This bulletin is being revised to add models and update the correction information. Please discard Corporate Bulletin Number 03-08-61-002A (Section 08 -- Body and Accessories).

Condition
Some customers may comment on a snap or popping-type noise coming from the front of the vehicle. This condition is most apparent during hard left or right turns at low speeds. Going over bumps while turning may also aid in producing this noise.

Correction
Slot the left side mounting holes on the front crossmember using the procedure listed below.

Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual.
Remove the mounting nuts, bolts and front crossmember from the vehicle.
Clean all the undercoating off the crossmember in the area of the left side mounting holes.

Notice
Use a die grinder or file to cut slots. DO NOT use a torch. Using a torch may compromise the structural integrity of the vehicle.


Enlarge the mounting holes on the left side of the crossmember into slots. Cut the slots to the inboard side (toward center of crossmember) of the holes, 2 mm (0.07874 in).
Reinstall the crossmember with the bolts and nuts. Tighten
Tighten the bolts to 120 N·m (89 lb ft).

Apply an even coat of Anti-Corrosion Coating, P/N 12346501, or equivalent to the crossmember where removed. Overlap the original coating in order to provide an effective corrosion protection.
Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

A9976*
Pop/Noise, Frame Rail - Repair
0.5 hr


*This is a unique labor operation number for use only with this bulletin. This number will not be published in the Labor Time Guide.



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.
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