2004 Corvette Recalls, Technical Service Bulletins, & Maintenance Schedule

Recall 04V060000

• Make: Chevrolet
• Model: Corvette
• Model Year: 2004
• Manufacturer: General Motors Corp.
• Mfr’s Report Date: Feb 06, 2004
• Nhtsa Campaign Id Number: 04V060000
• Nhtsa Action Number: EA02031
• Component: Steering: Column Locking: Anti-Theft Device
• Potential Number Of Units Affected: 126624

Summary

On Certain Passenger Vehicles Equipped With Electronic Column Lock Systems (Ecl), When The Ignition Switch Is Turned To “lock,” The Ecl System Prevents Turning Of The Steering System. When The Vehicle Is Started, The Ecl Unlocks The Steering System. The Vehicle Is Designed So That If The Column Fails To Unlock When The Vehicle Is Started And The Customer Tries To Drive, The Fuel Supply Will Be Shut Off So That The Vehicle Cannot Move When The Vehicle Cannot Be Steered. If Voltage At The Powertrain Control Module Is Low Or Interrupted, However, The Fuel Shut Off May Not Occur And The Vehicle Can Be Accelerated While The Steering System Is Locked. Also When The Control System Shows That The Ecl Is Unlocked And The Vehicle Is Being Driven, The Lock Pin Location Can Vary. Depending On The Location Of The Lock Plate Relative To The Switch Transition Point, There Could Then Be Contact Between The Lock Plate And Pin Causing The Steering To Lock While Driving .

Consequence

If This Occurs, A Crash Could Occur Without Warning.

Remedy

On Vehicles Equipped With An Automatic Transmission, The Dealer Will Disable The Steering Column Lock By Removing The Column Lock Plate. When The Ignition Key Is Removed, The Transmission Shifter Will Lock But The Steering Column Will Not Lock. On Vehicles Equipped With A Manual Transmission, The Dealer Will Reprogram The Powertrain Control Module, Perform A Dimensional Check Of The Column Lock And, If Necessary, Replace The Lock Plate. The Steering Column On These Vehicles Will Continue To Lock When The Key Is Removed. Owner Notification To Owners Of 1997 Vehicles Equipped With Automatic Transmissions Began On April 26, 2004. Owners Of 1998 Through 2004 Vehicles (Except 1997-1998 Manual Transmission Vehicles) Will Be Notified Beginning On August 2, 2004. The Remaining Owners (1997-1998 Manual Transmission Vehicles) Will Be Notified Later In 2004, When Parts Are Available. Owners Should Contact Chevrolet At 1-800-630-2438.

Notes

GMRecall No. 04006. 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 04v273000

• Make: Chevrolet
• Model: Corvette
• Model Year: 2004
• Manufacturer: General Motors Corp.
• Mfr’s Report Date: Jun 03, 2004
• Nhtsa Campaign Id Number: 04v273000
• Nhtsa Action Number: N/A
• Component: Steering:linkages
• Potential Number Of Units Affected: 41928

Summary

On Certain Passenger Vehicles Involved In This Campaign, The Lower Control Arm Ball Stud Nut/washer Assemblies With Washers Were Made Of The Wrong Material. The Washers May Fracture And Become Loose Or Fall Away From The Vehicle, Reducing Clamp Load. Separation Of The Control Arm Ball Stud And Steering Knuckle, Due To Disengagement Of The Tapered Attachment And Retaining Nut, Is Possible.

Consequence

If The Control Arm Separates From The Knuckle, The Affected Corner Of The Vehicle Will Drop And The Control Arm Would Be Forced Downward, Contacting The Wheel. The Affected Wheel Could Tilt Outward And Create A Dragging Action That Would Tend To Slow The Vehicle And Create A Tendency For The Vehicle To Turn In The Direction Of The Affected Wheel. In Extreme Situations, The Affected Wheel Assembly Could Separate From The Vehicle. Separation Of The Wheel Assembly Would Also Sever That Wheel;s Hydraulic Brake Hose And Result In Diminished Braking Performance Of The Vehicle, Which Could Result In A Crash.

Remedy

Dealers Will Inspect The Ball Stud Joints And Measure The Torque Of The Nut For All Front Lower Control Arms In All Models Affected As Well As The Rear Lower Control Arms On The Xlr And Corvette. If The Torque Is Not At Specification, The Dealers Will Replace The Ball Stud, The Knuckle, And The Nut. If The Torque Is At Specification, The Dealers Will Replace The Nut/washer Assembly Only. The Recall Will Begin On August 25, 2004. Owners Should Contact Cadillac At 1-866-982-2339 Or Chevrolet At 1-800-630-2438.

Notes

GM Recall No. 04043. 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 09e012000

• Make: Chevrolet
• Model: Corvette
• Model Year: 2004
• Manufacturer: Sabersport
• Mfr’s Report Date: Mar 28, 2009
• Nhtsa Campaign Id Number: 09e012000
• Nhtsa Action Number: N/a
• Component: Exterior Lighting
• Potential Number Of Units Affected: 16270

Summary

Sabersport Is Recalling 16,270 Combination Corner And Bumper Lamp Assemblies Of Various Part Numbers Sold For Use As Aftermarket Equipment For Various Passenger Vehicles. These Headlamps Fail To Conform To The Requirements Of Federal Motor Vehicle Safety Standard No. 108, “Lamps, Reflective Devices, And Associated Equipment.” These Lamps Do Not Contain The Required Amber Side Reflectors.

Consequence

Decreased Lighting Visibility May Result In A Vehicle Crash.

Remedy

Sabersport Will Notify Owners And Offer A Full Refund For The Noncompliant Combination Lamps. The Safety Recall Began On May 11, 2009. Owners May Contact Sabersport At 1-909-598-7589.

Notes

This Recall Only Pertains To Aftermarket Replacement Equipment And Has No Relation To Any Original Equipment Installed On Vehicles Produced By The Vehicle Manufacturer. In Order To Determine If Your Aftermarket Lamp Assembly Is Affected By This Noncompliance, Please Review The List Of Model Numbers Provided To Us By Sabersport. The List Can Be Found Under “Document Search” Located At The Bottom Of Your Screen. Owners May Also 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 09e025000

• Make: Chevrolet
• Model: Corvette
• Model Year: 2004
• Manufacturer: Dope, Inc.
• Mfr’s Report Date: Apr 05, 2009
• Nhtsa Campaign Id Number: 09e025000
• Nhtsa Action Number: N/a
• Component: Exterior Lighting:headlights
• Potential Number Of Units Affected: 42540

Summary

Dope, Inc. Is Recalling 42,540 Combination Corner And Bumper Lamp Assemblies Of Various Part Numbers Sold For Use As Aftermarket Equipment For Various Passenger Vehicles. These Headlamps Fail To Conform To The Requirements Of Federal Motor Vehicle Safety Standard No. 108, “Lamps, Reflective Devices, And Associated Equipment.” These Lamps Do Not Contain The Required Amber Side Reflectors.

Consequence

Decreased Lighting Visibility May Result In A Vehicle Crash.

Remedy

Dope, Inc. Will Notify Owners And Offer A Full Refund For The Noncompliant Combination Lamps. The Safety Recall Began On July 28, 2009. Owners May Contact Dope, Inc. At 1-626-272-1798.

Notes

This Recall Only Pertains To Aftermarket Replacement Equipment And Has No Relation To Any Original Equipment Installed On Vehicles Produced By The Vehicle Manufacturer. In Order To Determine If Your Aftermarket Lamp Assembly Is Affected By This Noncompliance, Please Review The List Of Model Numbers Provided To Us By Dope, Inc. The List Can Be Found Under “Document Search” Located At The Bottom Of Your Screen. Owners May Also 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.

2004 Corvette Service Bulletins

Service Bulletins 3850

• Make: Chevrolet
• Model: Corvette
• Model Year: 2004
• Manufacturer: General Motors Corp.
• Service Bulletin Number: 3850
• Nhtsa Item Number: 10019189
• Component: Structure:body

Summary

Water Leak In The Rear Compartment Area. *tt

Service Bulletins 3785

• Make: Chevrolet
• Model: Corvette
• Year: 2004
• Manufacturer: General Motors Corp.
• Service Bulletin Number: 3785
• Nhtsa Item Number: 10018625
• Component: Exterior Lighting:fog Lights

Summary

Fog Lamps Inoperative. *tt

Service Bulletins 3132

• Make: Chevrolet
• Model: Corvette
• Year: 2004
• Manufacturer: General Motors Corp.
• Service Bulletin Number: 3132
• Nhtsa Item Number: 10010628
• Component: Suspension:rear:shock Absorber

Summary

Lower Rear Shock Attaching Bolt May Break After Torqued. *tt

Service Bulletins 3359

• Make: Chevrolet
• Model: Corvette
• Year: 2004
• Manufacturer: General Motors Corp.
• Service Bulletin Number: 3359
• Nhtsa Item Number: 10013549
• Component: Suspension:rear

Summary

Lower Rear Shock Attaching Bolt May Break After Torqued. *tt

Service Bulletins 3060

• Make: Chevrolet
• Model: Corvette
• Year: 2004
• Manufacturer: General Motors Corp.
• Service Bulletin Number: 3060
• Nhtsa Item Number: 10009370
• Component: Power Train:automatic Transmission

Summary

The Engine Does Not Stall When Performing A P1870 Diagnostic Test With The Tech 2 Scan Tool Or When Commanding The Torque Converter Clutch Enable Solenoid On Applications That Do Not Have The P1870 Diagnostic Test Listed. 4l60e Or 4l65e Transmissions. *tt

2004 Corvette Maintenance Schedule

Engine Oil Scheduled Maintenance

Change engine oil and filter as indicated by the GM Oil Life System (or every 12 months, whichever occurs first). Reset the system. The system will show you when to change the oil – usually between 3,000 miles (5,000 km) and 10,000 miles (16,000 km) since your last oil change. Under severe conditions, the indicator may come on before 3,000 miles (5,000 km). Never drive your vehicle more than 10,000 miles (16,000 km) or 12 months without an oil and filter change. Use engine oil meeting the GM Standard GM4718M.

The GM Oil Life System won’t detect dust in the oil. So if you drive in a dusty area, be sure to change your oil and filter every 3,000 miles (5,000 km) or sooner if the CHANGE OIL SOON message appears. Remember to reset the Oil Life Monitor when the oil and filter have been changed. See “GM Oil Life System” (at the bottom of this page) for more information on resetting the system.

Scheduled Maintenance

Every 15,000 Miles (25,000 Kilometers)

Inspect air cleaner filter if you are driving in dusty conditions. Replace filter if necessary.

Every 30,000 Miles (50,000 Kilometers)

Replace Air Cleaner Filter

Every 45,000 Miles (75,000 Kilometers)

Inspect air cleaner filter if you are driving in dusty conditions. Replace filter if necessary.

Every 50,000 Miles (83,000 Kilometers)

Change automatic transmission fluid and filter if the vehicle is mainly driven under one or more of these conditions:

• In heavy city traffic where the outside temperature regularly reaches 90F (32C) or higher.
• In hilly or mountainous terrain.
• Uses such as high performance operation.

If you do not use your vehicle under any of these conditions, change the fluid and filter at 100,000 miles (166 000 km). Manual transmission fluid doesn’t require change.

Every 60,000 Miles (100,000 Kilometers)

Replace air cleaner filter and inspect engine accessory drive belt.

Every 75,000 Miles (125,000 Kilometers)

Inspect air cleaner filter if you are driving in dusty conditions. Replace filter if necessary.

Every 90,000 Miles (150,000 Kilometers)

Replace Air Cleaner Filter

Every 100,000 Miles (166,000 Kilometers)

Replace spark plugs and inspect spark plug wires.

Change automatic transmission fluid and filter if the vehicle is mainly driven under one or more of these conditions:

• In heavy city traffic where the outside temperature regularly reaches 90F (32C) or higher.
• In hilly or mountainous terrain.
• Uses such as high performance operation.

Manual transmission fluid doesn’t require change.

NOTE: If you haven’t used your vehicle under severe conditions listed previously and, therefore, haven’t changed your automatic transmission fluid, change both the fluid and filter. Manual transmission fluid doesn’t require change.

Every 150,000 Miles (240,000 Kilometers)

Drain, flush and refill the cooling system (or every 60 months since last service, whichever occurs first). See “Engine Coolant” in the “1997 Corvette Fluids/Lubricants” chart (in the right margin of this page) for what to use.

Owner Inspection & Service Items

At Each Fuel Fill

NOTE: It is important for you or a service station attendant to perform these underhood checks at each fuel fill.

Engine Oil Level Check: Check the engine oil level and add the proper oil if necessary.

Engine Coolant Level Check: Check the engine coolant level and add DEX-COOL coolant mixture if necessary.

Windshield Washer Fluid Level Check: Check the windshield washer fluid level in the windshield washer tank and add the proper fluid if necessary.

At Least Once a Month

Tire Inflation Check: Make sure tires are inflated to the correct pressures.

Cassette Deck Service (if so equipped): Clean cassette deck. Cleaning should be done every 50 hours of tape play.

Power Antenna Service: Clean power antenna mast.

At Least Twice A Year

Restraint System Check: Make sure the safety belt reminder light and all your belts, buckles, latch plates, retractors and anchorages are working properly. Look for any other loose or damaged safety belt system parts. If you see anything that might keep a safety belt system from doing its job, have it repaired. Have any torn or frayed safety belts replaced. Also look for any opened or broken air bag coverings, and have them repaired or replaced. (The air bag system does not need regular maintenance.)

Wiper Blade Check: Inspect wiper blades for wear or cracking. Replace blade inserts that appear worn or damaged or that streak or miss areas of the windshield.

Weatherstrip Lubrication: Silicone grease on weatherstrips will make them last longer, seal better, and not stick or squeak. Apply silicone grease with a clean cloth. During very cold, damp weather more frequent application may be required. (See “Recommended Fluids and Lubricants” in the right margin of this page).

Manual Transmission Check (if so equipped):  Check the transmission fluid level; add if needed. (See “Manual Transmission Fluid” in the right margin of this page). Check for leaks. A fluid leak is the only reason for fluid loss. Have the system inspected and repaired if needed.

Automatic Transmission Visual Inspection: It is not necessary to check the transmission fluid level during a visual inspection of the actual transmission. A transmission fluid leak is the only reason for fluid loss. Check for leaks. If a leak occurs, take the vehicle to your Chevrolet dealership service department and have it repaired as soon as possible.

At Least Once A Year

Key Lock Cylinder Service: Lubricate the key lock cylinders.

Body Lubrication Service: Lubricate all body door hinges. Also lubricate all hinges and latches, including those for the hood, rear compartment, console door and any folding seat hardware. More frequent lubrication may be required when exposed to a corrosive environment.

Starter Switch Check:  CAUTION: When you are doing this check, the vehicle could move suddenly. If it does, you or others could be injured. Before you start, be sure you have enough room around the vehicle. Firmly apply the parking brake and the regular brake.

On automatic transmission vehicles, try to start the engine in each gear. The starter should work only in PARK (P) orNEUTRAL (N). If the starter works in any other position, your vehicle needs service.

On manual transmission vehicles, put the shift lever in NEUTRAL (N), push the clutch down halfway and try to start the engine. The starter should work only when the clutch is pushed down all the way to the floor. If the starter works when the clutch isn’t pushed all the way down, your vehicle needs service.

Automatic Transmission Shift Lock Control System Check: CAUTION: When you are doing this check, the vehicle could move suddenly. If it does, you or others could be injured. Before you start, be sure you have enough room around the vehicle. It should be parked on a level surface. Firmly apply the parking brake. (NOTE: Be prepared to apply the parking brake immediately if the vehicle begins to move.)

With the engine off, turn the key to the ON position, but don’t start the engine. Without applying the regular brake, try to move the shift lever out of PARK (P) with normal effort. If the shift lever moves out of PARK (P), your vehicle needs service.

Ignition Automatic Transmission Lock Check: While parked, and with the parking brake set, try to turn the ignition key to OFF in each shift lever position. The key should turn to OFF only when the shift lever is in PARK (P).

On all vehicles, the key should come out only in OFF. Parking Brake and Automatic Transmission PARK (P) Mechanism Check: CAUTION: When you are doing this check, your vehicle could begin to move. You or others could be injured and property could be damaged. Make sure there is room in front of your vehicle in case it begins to roll. Be ready to apply the regular brake at once should the vehicle begin to move.

Park on a fairly steep hill, with the vehicle facing downhill. Keeping your foot on the regular brake, set the parking brake.

To check the parking brake’s holding ability: With the engine running and transmission in NEUTRAL (N), slowly remove foot pressure from the regular brake pedal. Do this until the vehicle is held by the parking brake only.

To check the PARK (P) mechanism’s holding ability: With the engine running, shift to PARK (P). Then release the parking brake followed by the regular brake

Underbody Flushing Service: At least every spring, use plain water to flush any corrosive materials from the underbody. Take care to clean thoroughly any areas where mud and other debris can collect.

Dealership Inspection & Service Items

At Least Twice A Year

Steering and Suspension Inspection: Inspect the front and rear suspension and steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect the power steering lines and hoses for proper hook-up, binding, leaks, cracks, chafing, etc.

Tire and Wheel Inspection: Inspect the tires for uneven wear or damage. If there is irregular or premature wear, check the wheel alignment. Inspect for damaged wheels.

Exhaust System Inspection: Inspect the complete exhaust system. Inspect the body near the exhaust system. Look for broken, damaged, missing or out-of-position parts as well as open seams, holes, loose connections or other conditions which could cause a heat build-up in the floor pan or could let exhaust fumes into the vehicle.

Engine Cooling System Inspection: Inspect the hoses and have them replaced if they are cracked, swollen or deteriorated. Inspect all pipes, fittings and clamps; replace as needed. Clean the outside of the radiator and air conditioning condenser. To help ensure proper operation, a pressure test of the cooling system and pressure cap is recommended at least once a year.

Rear Axle Service: Check the gear lubricant level in the rear axle and add if needed. A fluid loss may indicate a problem. Check the axle and repair it if needed.

Brake System Inspection: Inspect the complete system. Inspect brake lines and hoses for proper hook-up, binding, leaks, cracks, chafing, etc. Inspect disc brake pads for wear and rotors for surface condition. Inspect other brake parts, including calipers, parking brake, etc. You may need to have your brakes inspected more often if your driving habits or conditions result in frequent braking.

GM Oil Life System

Your vehicle has a computer that lets you know when to change your engine oil. This is not based on mileage, but on engine revolutions and engine operating temperature. When the computer has calculated that the oil needs changing, the GM Oil Life System will indicate that a change is necessary. The mileage between oil changes will vary depending on how you drive your vehicle — usually between 3,000 miles (5 000 km) and 10,000 miles (16 000 km) since your last oil and filter change. Under severe conditions, the system may come on before 3,000 miles (5 000 km). Never drive your vehicle more than 10,000 miles (16 000 km) or 12 months (whichever occurs first) without an oil change. Use engine oil meeting the GM Standard GM4718M.

The system won’t detect dust in the oil. So, if you drive in a dusty area, be sure to change your oil and filter every 3,000 miles (5 000 km) or sooner if the CHANGE OIL SOON message appears. Remember to reset the system whenever the oil is changed.

How to Reset the Change Oil Soon Message

To reset the CHANGE OIL SOON message after an oil change, do the following:
1. Turn the ignition to ON and with the engine off.
2. Press the TRIP button so the OIL LIFE percentage is displayed.
3. Press RESET and hold for two seconds. OIL LIFE REMAIN 100% will appear.