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Tracker frame rust

Chevrolet has issued a bulletin that alerts owners of 1999-2004 model year Chevrolet Trackers of the possibility that some of  the front suspension crossmembers did not receive adequate corrosion protection. The result of this condition may be most noticeable on vehicles driven in areas where rust is most common, such as areas where salt is used to control snow and ice. The corrosion may advance and cause rust-through perforation of the crossmember in the area of the left and/or right front lower control arm attachment brackets. As the corrosion progresses, the crossmember will become thinner and the perforations will grow in size. If there are a substantial amount of large perforations, the left and/or right front lower control arm attachment brackets will become weakened and begin to flex. If this occurs, the customer may notice front tire wobble, steering looseness, vehicle pull to one side, front end noises (clunk, bang, rattle, etc) vehicle shaking, or steering wheel rotation when shifting from reverse to drive and drive to reverse.

Corrosion may progress over time until the front lower control arm bracket separates from the crossmember. Take your vehicle to your Chevrolet dealer if you believe that your vehicle may have the condition as described above. If this condition occurs on your 1999-2004 Chevrolet Tracker within 10 years of the date that the vehicle was originally placed in service, or 150,000 miles, whichever occurs first, the condition will be repaired for you at no charge.

The following photo's show the area of concern. These photo's are from a 2000 Tracker with 82,000 miles. It shows some surface rust but no signs of perforations. The first photo is showing the crossmember looking in from the left front wheel well. This photo shows the control arm brackets that are the concern.

The second photo is looking up at the left side of the crossmember from the bottom. Notice the drain hole that is located on the 'dipped' area of the crossmember. Keep this drain hole open.

This is the cross member viewed from the left front wheel well. This frame member has some surface rust but no advanced rust perforations. Notice the welded tabs that hold the front control arm bushing. This is the area that is of concern for possible failure.

This view is the bottom of the front crossmember. It is the left side and the aluminum casting is the steering assembly. The steering assembly is behind the cross member. Notice the drain holes on the crossmember, keep them open.