CAMPAIGN: TRANSAXLE SHIFT IND. DISPLAY MAY NOT BE VISIBLE DUE

Subject: PRODUCT NON-COMPLIANCE CAMPAIGN 95-C-64 TRANSAXLE SHIFT INDICATOR DISPLAY MAY NOT BE VISIBLE DUE TO INSTRUMENT CLUSTER TRIM PLATE SAG

MODELS: Affected:1995 PONTIAC SUNFIRE WITH AUTOMATIC TRANSAXLE

TO: ALL PONTIAC DEALERS

The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign 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 (60) 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 to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the lefter that is being sent to customers, the customers are being instructed to contact the Pontiac Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.

DEFECT INVOLVED

General Motors has determined that certain 1995 Pontiac Sunfire model vehicles may not conform to Federal Motor Vehicle Safety Standard (FMVSS) 101, "Control Location, Identification, and Illumination". The instrument panel cluster trim plate/bezel on some of these vehicles may sag and cover the light emitting diode (LED) portion (lighted pointer above PRNDL) of the transaxle shift indicator display. If this occurs, the driver of the vehicle may not be able to determine, with certainty, the actual position of the transaxle gear selector. This could result in a driver inadvertently leaving the transaxle of a parked or idling vehicle in DRIVE, REVERSE, or NEUTRAL rather than PARK, or selecting an incorrect transaxle shift position while driving the vehicle. If either of these situations should occur, a vehicle crash could occur, and vehicle occupants and/or pedestrians could be injured.

DEFECT INVOLVED (Continued)

To prevent this condition from occurring, dealers are to install a new instrument panel cluster trim plate/bezel assembly which is not subject to this condition.

VEHICLES INVOLVED

Involved are certain 1995 Pontiac Sunfire model vehicles built within the following VIN ranges. Up To/And Year Plant Beginning Including ---- ----- --------- --------- 1995 Lordstown S7500075 S7532183

1995 Lansing SB200001 SB200203

Complete vehicle identification number computer listings will be furnished to all involved dealers with the campaign bulletin. These listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

PARTS INFORMATION

NOTICE: A pre-shipment of part numbers 22653357 and 22653358, will be sent to involved dealers the week of February 1, 1996. Pre-shipment will equal parts for 50% of the number of vehicles to be repaired. Pre- shipment parts will be charged to the dealers' open parts account.

Additional parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2). All Goodwrench Parts System Test Dealers should order on a "V.I.P." order.

Part Quantity/ Description Number Vehicle ----------- ------ ---------

Plate/Bezel, Trim-I/P Cluster - Graphite 22653357 1 Plate/Bezel, Trim-I/P Cluster - Neutral 22653358 1

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Pontiac Division (see copy of owner letter included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected per the service procedure of this campaign bulletin BEFORE owners take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing are to be contacted by the dealer, and arrangements made to make the required inspection according to the instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owners letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the owner may not as yet have received the notification lefter.

This bulletin is notice to you that the new motor vehicles included in this campaign may not comply with the standard identified. Under Section 108 of the National Traffic and Motor Vehicle Safety Act, 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 campaign correction, your dealership may be subject to a civil penalty up to $1,000 for each such sale.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign inspection has been made before selling or releasing the vehicle.

SERVICE PROCEDURE

1. Disable Supplemental Inflatable Restraint (S.I.R.) system per instructions on page 8C2-5 of the service manual.

2. Remove defroster grille from center of instrument pad (I/P) by carefully prying with a non-marring tool. See figure 1.

3. Remove valence panel from front of I/P by carefully disengaging two pins from grommets (one at each end) and six clips. See figure 2.

IMPORTANT: DO NOT SCRATCH TOPPER PAD WITH VALENCE CLIPS WHEN REMOVING THE VALENCE.

4. Remove LH and RH end caps - 1 Phillips head screw each end cap. See figure 3.

5. Open glove box door to gain access to glove box trim plate screws and accessory trim plate screws.

6. Remove glove box trim plate - three Phillips head screws. See figure 2.

7. Remove two screws (7mm hex-head) from accessory/radio trim plate. Carefully remove trim plate by rotating and pulling out. See figure 4.

8. Remove topper pad as follows: rotating and pulling out. See figure 4.

0 Two 7mm hex screws (gold/brass colored) forward of supplemental inflatable restraint (SIR) panel.

IMPORTANT: THE GOLD/BRASS COLORED SCREWS MUST BE RE-INSTALLED INTO THE SAME FASTENER LOCATIONS AT THE FRONT OF THE SIR PANEL.

0 Four 7mm hex (or Tl5 torx) screws (black) from lower rear edge of pad.

0 Four 7mm hex (or Tl5 torx) screws (black) from upper forward edge of pad.

0 Carefully remove topper pad by pulling away from I/P.

IMPORTANT: HANDLE TOPPER PAD CAREFULLY TO AVOID DAMAGE.

See figure 5.

9. Remove thick gray foam padding (@ 1 " thick) from area between underside of topper pad and topside of I/P cluster trim plate/bezel.

10. Remove I/P cluster trim plate/bezel from rear of topper pad - five 7mm hex (or Tl5 torx) screws. See figure 6.

11. Install new I/P cluster trim plate/bezel to rear of topper pad with five 7mm hex (or Tl5 torx) screws, using the same fastener locations utilized on old trim plate/bezel.

[Do not attempt to install a screw in the center upper screw position.]

Tighten screws to 2.3 Nm (1.7 Lbs.Ft. or 20 Lbs.in.). OR Screws are to be fully driven, seated, but not stripped. See figure 6.

IMPORTANT: MAKE SURE THAT FOAM PADDING (GRAY -@ 1" THICK) HAS BEEN REMOVED FROM UNDERSIDE OF TOPPER PAD ABOVE I/P CLUSTER TRIM PLATE/BEZEL. FAILURE TO REMOVE THIS PADDING MAY RESULT IN REPEATED SAGGING OF THE CLUSTER TRIM PLATE/BEZEL.

12. Carefully position topper pad to I/P.

13. Install four 7mm hex (or Tl5 torx) screws (black) to upper forward edge of topper pad. Tighten screws to 2.3 Nm (1.7 Lbs.Ft. or 20 Lbs.In.). OR Screws are to be fully driven, seated, but not stripped. See figure 5.

SERVICE PROCEDURE (Continued)

14. Install four 7mm hex (or Tl5 torx) screws (black) to lower rear edge of topper pad. Tighten screws to 2.3 Nm (1.7 Lbs.Ft. or 20 Lbs.In.). OR Screws are to be fully driven, seated, but not stripped. See figure 5.

15. Install two 7mm hex screws (gold/brass colored) to topper pad at forward edge of SIR panel. Tighten screws to 2.3 Nm (1.7 Lbs.Ft. or 20 Lbs.In.). Or Screws are to be fully driven, seated, but not stripped. See figure 5.

IMPORTANT: THE GOLD/BRASS COLORED SCREWS MUST BE INSTALLED INTO THEIR ORIGINAL LOCATIONS AT THE FORWARD EDGE OF THE SIR PANEL.

SOME VEHICLES (A VERY SMALL NUMBER) MAY HAVE THREE FASTENER LOCATIONS AT THE FORWARD EDGE OF THE SIR PANEL. ON THESE VEHICLES, THE FASTENERS MUST BE INSTALLED IN THE TWO LOCATIONS CLOSEST TO THE LEFT (DRIVER'S) SIDE OF THE SIR PANEL.

16. Install glove box trim plate using three Phillips head screws. Tighten screws to 2.3 Nm (1.7 Lbs.Ft. or 20 Lbs. In.). OR Screws are to be fully driven, seated, but not stripped. See figure 5.

17. Position RH and LH end caps to lower I/P and loose assemble screw to each end cap. Adjust end caps upward and rearward to minimize gap to topper pad before tightening screws. Tighten screws to 2.3 Nm (1.7 Lbs.Ft. or 20 Lbs.In.). OR Screws are to be fully driven, seated, but not stripped. See figure 3.

18. Position two pins on LH side of accessory trim plate into grommets in lower I/P and rotate trim plate into position. Install two Phillips head screws and tighten to 2.3 Nm (1.7 Lbs.Ft. or 20 Lbs.In.). OR Screws are to be fully driven, seated, but not stripped. See figure 4.

19. Close glove box door.

20. Carefully position valence to forward edge of topper pad.

IMPORTANT: USE CAUTION WHEN POSITIONING VALENCE TO TOPPER PAD TO AVOID DAMAGE TO TOPPER PAD.

21. Position pins at each end of valence to I/P grommets and push in to seat. See figure 2.

22. Secure valence to topper pad by seating six clips. Seat outboard clips first and seat remaining clips by working inward towards middle of panel.

23. Position defroster grille and push into topper pad until secure. See figure 1.

24. Enable S.I.R. system per instructions on page 8C2-6 of the service manual.

25. Install campaign identification label.

CAMPAIGN IDENTIFICATION LABEL

Each label provides space to print the campaign number and the five digit dealer code of the dealership performing the campaign. Insert this information with a typewriter or a ball point pen. When installing label, clean and dry the surface of the radiator support tie bar and apply the campaign label where it is readily visible when the hood is raised. Be sure to apply the clear protective plastic cover over the label.

Additional GM Campaign Identification Labels (Item Number S-1015) are available at no cost from Vispac, Inc., 35000 Industrial Road, Livonia, MI 48150, 1-800-269-5100 (Monday - Friday 8:00 AM to 4:30 PM Est.).

CLAIM INFORMATION

A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.

DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:

Failure Labor Labor Operation Code Operation Hours --------- ------- --------- -----

Replace I/P Plate/Bezel 96 V9830 0.6*

* ADD: For Campaign Administrative Allowance, add 0.1 hours to the "Labor Hours". This entry will not require authorization.

The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 40% dealer handling allowance.

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the labor operation as outlined.

RECORDING COMPLETION

Repairs submitted for vehicles not involved in the campaign will not be paid.

Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS." Customers are being asked to present the customer reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.

PONTIAC DIVISION General Motors Corporation One Pontiac Plaza Pontiac, Michigan 48340-2952 Non-Compliance Campaign 95-C-64

February, 1996

Dear Pontiac Sunfire Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

REASON FOR RECALL

General Motors has determined that certain 1995 Pontiac Sunfire model vehicles may not conform to Federal Motor Vehicle Safety Standard (FMVSS) 101, "Control Location, Identification, and Illumination". The instrument panel cluster trim plate/bezel on some of these vehicles may sag and cover the light emitting diode (LED) portion (lighted pointer above PRNDL) of the transaxle shift indicator display. If this occurs, the driver of the vehicle may not be able to determine, with certainty, the actual position of the transaxle gear selector. This could result in a driver inadvertently leaving the transaxle of a parked or idling vehicle in DRIVE, REVERSE, or NEUTRAL rather than PARK, or selecting an incorrect transaxle shift position while driving the vehicle. If either of these situations should occur, a vehicle crash could occur, and vehicle occupants and/or pedestrians could be injured.

WHAT WE WILL DO

To prevent this condition from occurring, dealers are to install a new instrument panel cluster trim plate/bezel assembly which is not subject to this condition.

This service will be performed for you at no charge.

WHAT YOU SHOULD DO

Please contact your Pontiac dealer as soon as possible to arrange an appointment and so the dealer may order the necessary parts for the repair.

Instructions for making this correction have been sent to your dealer. The labor time necessary to perform this correction is approximately 1 hour. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

Your Pontiac dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date, or within five (5) days, we recommend you contact the Pontiac Customer Assistance Center by calling:1-800-762-2737.

After contacting your dealer and the Pontiac Customer Assistance Center, if 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, S. W., Washington, DC 20590 or call 1-80O-424-9393 (Washington, DC residents use 366-0123).

The enclosed Campaign Customer Reply Card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage-paid Customer Reply Card and returning it to us.

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.

PONTIAC DIVISION General Motors Corporation

Enclosure

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those 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 a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.