CAMPAIGN: PARK BRAKE LEVER ASSEMBLY (REPLACE LEVER ASSY.)
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 OWNER 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 OWNER 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 OWNER AND TO REPAIR THEIR VEHICLE AS SOON AS POSSIBLE. AS YOU WILL SEE IN READING THE ATTACHED COPY OF THE LETTER WHICH IS BEING SENT TO OWNERS, THE OWNERS ARE BEING INSTRUCTED TO CONTACT THE BUICK 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 REASONABABLE TIME, THEY ARE INSTRUCTED ON HOW TO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION.
CONDITION
GENERAL MOTORS HAS DETERMINED THAT CERTAIN 1991 PARK AVENUE/ULTRA AND 1992 LESABRE MODEL VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFTEY STANDARD 105, "HYDRAULIC BRAKE SYSTEMS" WHICH, IN PART, COVERS PARKING BRAKE PERFORMANCE.
SOME OF THESE VEHICLES HAVE PARKING BRAKE LEVER ASSEMBLIES WHICH WHEN APPLIED CAN RELEASE ONE OR MORE TEETH. IF RELEASE OCCURS, THE CABLE LOAD APPLYING THE REAR BRAKES WILL BE REDUCED, AND DEPENDING UPON THE EXTENT OF LEVER RELEASE, THE PARKING BRAKE MAY NOT HOLD THE VEHICLE AS REQUIRED.
DEALER ACTION
TO PREVENT THIS CONDITION FROM OCCURRING, DEALERS ARE TO INSPECT AND, IF REQUIRED, REPLACE THE PARKING BRAKE LEVER ASSEMBLY.
VEHICLES INVOLVED
INVOLVED ARE CERTAIN 1991 PARK AVENUE/ULTRA AND 1992 LESABRE MODEL VEHICLES BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS:
PLANT YEAR MODEL PLANT CODE FROM THROUGH
1991 PARK AVENUE/ WENTZVILLE 1 M1682941 M1696285 ULTRA
1992 LESABRE BUICK CITY H NH400026 NH401426
NOTE: THERE ARE AN ESTIMATED 13,592 VEHICLES INVOLVED WITHIN THEESE VIN RANGES.
DEALER CAMPAIGN RESPONSIBILITY
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.
WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN IS TAKEN INTO YOUR NEW OR USED VEHICLE INVENTORY, OR IT IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, YOU SHOULD TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE RESELLING OR RELEASING THE VEHICLE.
THIS BULLETIN IS NOTICE TO YOU THAT THE NEW MOTOR VEHICLES INCLUDED IN THIS CAMPAIGN MAY NOT COMPLY WITH FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 105. UNDER NATIONAL TRAFFIC AND MOTOR VEHICLE SAFETY ACT, SECTION 108, 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 REGULATION. 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 OF EACH SUCH SALE.
OWNERS OF VEHICLES RECENTLY SOLD, FROM YOUR NEW VEHICLE INVENTORY ARE CONTACTED BY THE DEALER, AND ARRANGEMENTS MADE TO MAKE THE MODIFICATION ACCORDING TO INSTRUCTIONS CONTAINED IN THIS BULLETIN.
DEALER MATERIAL
IF YOUR DEALERSHIP HAS VEHICLES INVOLVED IN THIS CAMPAIGN, YOU WILL REIVE THE FOLLOWING ITEMS:
- LIST OF ALL VEHICLES INVOLVED IN THIS CAMPAIGN SHIPPED TO YOUR DEALERSHIP.
- ONE (1) CAMPAIGN IDENTIFICATION LABEL FOR EACH VEHICLE.
INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER COMPUTER LISTINGS. COMPUTER 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.
OWNER NOTIFICATION
OWNERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY BUICK MOTOR DIVISION (SEE COPY OF OWNER LETTER INCLUDED WITH THIS BULLETIN).
CHANGE OF OWNER INFORMATION
DEALERS ARE TO USE THE DEALER COMMUNICATION SYSTEM (D.C.S.) TO PROVIDE BUICK MOTOR DIVISION WITH SUBSEQUENT BUICK OWNER INFORMATION. BY REPORTING A CHANGE OF OWNER NAME OR ADDRESS OF A VEHICLE IN CAMPAIGN STATUS OVER THE D.C.S., THE NEED TO SEND IN A CVAR FORM FOR THAT VEHICLE IS ELIMINATED TERMINAL INPUT INSTRUCTIONS ARE COVERED IN THE D.C.S. MANUAL UNDER SECTION 9, PAGES 9-JO1A AND B.
PARTS INFORMATION
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).
QUANTITY/ PART NUMBER DESCRIPTION VEHICLE
25601809 PARKING BRAKE 1 AS REQUIRED LEVER ASSEMBLY
NOTE: IT IS ANTICIPATED THAT 52% OF THE VEHICLES WILL REQUIRE REPLACEMENT OF THE PARKING BRAKE LEVER ASSEMBLY.
SERVICE PROCEDURE
INSPECTION:
1. USING A FLASHLIGHT, INSPECT PARKING BRAKE LEVER ASSEMBLY FOR SUSPECT DATE CODES A1091, A1121, A1221,, A1231, A1261, A1271, A1281, A1291 OR A1301. THESE DATE CODES ARE STAMPED INTO THE INBOARD SIDE OF THE PARKING BRAKE PEDAL ASSEMBLY APPROXIMATELY THREE (3) INCHES ABOVE THE PEDAL PAD (SEE FIGURE 1).
- IF ONE OF THE SUSPECT DATE CODES LISTED ABOVE IS FOUND, PROCEED TO REPLACEMENT. IF THE DATE CODE CANNOT BE EASILY IDENTIFIED, ALSO PROCEED TO REPLACEMENT.
- IF THE DATE CODE IS NOT ONE OF THOSE LISTED ABOVE, PROCEED TO STEP 22 UNDER PARKING BRAKE CABLE ADJUSTMENT.
REPLACEMENT:
1. LOOSEN PARKING BRAKE CABLE UNDER CAR.
2. WITH THE IGNITION IN THE "OFF" POSITION, DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY. A MEMORY RETENTION DEVICE, SUCH AS KENT MOORE TOOL, KS 295A, MAY BE USED TO RETAIN MEMORY FUNCTIONS.
3. REMOVE LEFT LOWER IP SOUND INSULATION.
4. DISABLE THE SIR SYSTEM (REFER TO APPROPRIATE ELECTRICAL SYSTEMS MANUAL).
5. REMOVE FUSE BLOCK COVER, SET ASIDE FUSE BLOCK AND LIGHT CONTROL MODULE (IF EQUIPPED).
6. DISCONNECT RELEASE HANDLE CABLE (8) FROM LEVER ASSEMBLY (1) (SEE FIGURE 2, VIEW A).
7. DISCONNECT PARKING BRAKE CABLE (5) FROM LEVER ASSEMBLY (SEE FIGURE 2, VIEW D) AFTER REMOVING RETAINING CLIP (6) (IF SO EQUIPPED).
8. DISCONNECT ELECTRICAL CONNECTOR (9) FROM PARKING BRAKE SWITCH (10) (SEE FIGURE 2, VIEW C).
9. REMOVE LEVER ASSEMBLY ATTACHING NUTS (2 & 4) (SEE FIGURE 2).
10. REMOVE PARKING BRAKE LEVER ASSEMBLY.
11. TRANSFER SWITCH (10) AND PLASTIC SHIELD (IF SO EQUIPPED) TO NEW PARKING BRAKE LEVER ASSEMBLY.
12. REVERSE STEPS 5 THROUGH 10 TO INSTALL NEW LEVER ASSEMBLY.
CAUTION:
PARKING BRAKE CABLE AND LEVER ASSEMBLY ARE TO BE ROUTED LEFT OF TRANSMISSION SHIFT CABLE. DO NOT PLACE BRAKE CABLE OR LEVER ASSEMBLY OVER SHIFT CABLE. TORQUE TWO NUTS AT UPPER REAR LOCATIONS (2) AND NUT AT LOWER FRONT LOCATION (4) TO 18 N.M (13 LB.FT.).
13. ENABLE THE SIR SYSTEM (REFER TO APPROPRIATE ELECTRICAL SYSTEMS MANUAL).
14. REINSTALL LEFT LOWER IP SOUND INSULATOR.
15. WITH THE IGNITION IN THE OFF POSITION, RECONNECT THE NEGATIVE BATTERY CABLE AND REMOVE MEMORY RETENTION DEVICE IF USED. IN THE INTEREST OF CUSTOMER SATISFACTION, PLEASE ADVISE CUSTOMER THAT THE BATTERY WAS DISCONNECTED (NOT REQUIRED IF A MEMORY RETENTION TOOL WAS USED) AND MEMORY IN THE RADIO, CLOCK, OR OTHER MEMORY OPTIONS MAY NEED RESETTING.
PARKING BRAKE CABLE ADJUSTMENT:
1. RAISE VEHICLE AND SUITABLY SUPPORT (REFER TO SERVICE MANUAL SECTION OA).
2. MARK RELATIONSHIP OF REAR WHEEL TO WHEEL STUDS IN BEARING FLANGE.
3. REMOVE REAR WHEEL AND TIRE ASSEMBLIES.
4. MARK RELATIONSHIP OF REAR DRUM TO WHEEL STUDS IN BEARING FLANGE.
5. REMOVE BRAKE DRUMS.
6. MAKE SURE LEVER STOPS (16) (REFER TO FIGURE 3) ON BOTH PARK BRAKE LEVERS (12) ARE AGAINST EDGES OF SHOE WEBS ON PARK BRAKE SHOES (11) IF PARK BRAKE CABLE IS HOLDING STOPS OFF EDGE OF SHOE WEB, LOOSEN PARK BRAKE CABLE ADJUSTMENT.
7. MEASURE THE INSIDE DIAMETER (ID) OF THE DRUM USING J21177-A OR J22364-01.
8. TURNING STAR WHEEL ON ADJUSTING SCREW ASSEMBLY (15), ADJUST SHOE AND LINING DIAMETER TO BE 1.27 MM (0.050 IN.) LESS THAN INSIDE DRUM DIAMETER FOR EACH REAR WHEEL.
9. INSTALL DRUMS AND WHEEL AND TIRE ASSEMBLIES, ALIGNING MARKS MADE AT REMOVAL.
10. LOWER VEHICLE.
11. TORQUE WHEEL NUTS TO 140 N.M (100 LB. FT.).
12. APPLY AND RELEASE SERVICE BRAKE PEDAL 30 TO 35 TIMES WITH NORMAL PEDAL FORCE. PAUSE ABOUT ONE (1) SECOND BETWEEN PEDAL APPLIES.
13. APPLY AND RELEASE PARKING BRAKE FIVE (5) TIMES TO 10 CLICKS. RELEASE PARK BRAKE PEDAL.
14. CHECK PARK BRAKE PEDAL FOR FULL RELEASE BY TURNING IGNITION TO "ON" AND CHECKING THE "BRAKE"INDICATOR LIGHT. THE LIGHT SHOULD BE OFF. IF THE LIGHT IS ON AND THE BRAKE APPEARS TO BE RELEASED, OPERATE PEDAL RELEASE LEVER AND PULL DOWNWARD ON THE FRONT PARKING BRAKE CABLE TO REMOVE SLACK.
15. RAISE VEHICLE AND SUITABLY SUPPORT.
16. REMOVE ACCESS HOLE PLUG IN REAR BRAKE BACKING PLATES.
17. ADJUST PARKING BRAKE CABLE UNTIL A 1/8-INCH DRILL BIT CAN BE INSERTED THROUGH ACCESS HOLE IN SPACE BETWEEN SHOE WEB (11) AND PARK BRAKE LEVER (12). (REFER TO FIGURE 4). SATISFACTORY CABLE ADJUSTMENT IS ACHIEVED WHEN A 1/8-INCH BIT WILL FIT INTO THE SPACE, BUT A 1/4-INCH BIT WILL NOT.
18. APPLY PARK BRAKE TO FOUR CLICKS. THE WHEEL SHOULD NOT MOVE WHEN ONE ATTEMPTS TO ROTATE IT (BY HAND) IN A FORWARD DIRECTION. THE WHEEL SHOULD DRAG OR NOT MOVE WHEN ATTEMPTING TO ROTATE IN A REARWARD DIRECTION.
19. RELEASE PARK BRAKE AND CHECK FOR FREE WHEEL ROTATION.
20. REINSTALL ACCESS HOLE PLUGS.
21. LOWER VEHICLE.
22. INSTALL CAMPAIGN IDENTIFICATION LABEL.
CAMPAIGN IDENTIFICATION LABEL
EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL" EACH LABEL PROVIDES A SPACE TO INCLUDE THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN.
EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN FOR PERIODIC SERVICING BY THE OWNER.
APPLY "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE.
DISPOSITION OF REPLACED PARTS
REPLACED PARTS MUST BE HELD FOR DISPOSITION BY BUICK ZONE/BRANCH CONTACT PERSONNEL. PARTS MUST HAVE A CLAIM TAG ATTACHED SHOWING THE REPAIR ORDER AND THE VIN OF THE VEHICLE FROM WHICH THEY WERE REMOVED.
WARRANTY INFORMATION
SUBLE PART FAILED PART FAILURE LABOR LABOR OTHER DLR. OPER. COUNT PART NO. ALLOW. CODE OP.NO. HOURS HOURS MTL.TWG.
O INSPECT PARKING BRAKE LEVER ASSEMBLY DATE CODE
-- -- -- 96 V6940 0.2 *0.1 --
O INSPECT AND REPLACE PARKING BRAKE LEVER ASSEMBLY
1 25601809 ** 96 V6941 1.6 *0.1
* CAMPAIGN ADMINISTRATIVE ALLOWANCE
** LIST CURRENT DEALER PRICE, PLUS 30% OF INSTALLED PART
COPYRIGHT 1991 GENERAL MOTORS CORPORATION ALL RIGHTS RESERVED
====================================================================== OWNER LETTER
OCTOBER, 1991
DEAR BUICK OWNER:
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 1991 PARK AVENUE/ULTRA AND 1992 LESABRE MODEL VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD 105, "HYDRAULIC BRAKE SYSTEMS", WHICH IN PART, COVERS PARKING BRAKE PERFORMANCE.
SOME OF THESE VEHICLES HAVE PARKING BRAKE LEVER ASSEMBLIES WHICH WHEN APPLIED CAN RELEASE ONE OR MORE TEETH. IF RELEASE OCCURS, THE CABLE LOAD APPLYING THE REAR BRAKES WILL BE REDUCED AND DEPENDING UPON THE EXTENT OF LEVER RELEASE, THE PARKING BRAKE MAY NOT HOLD THE VEHICLE AS REQUIRED.
WHAT WE WILL DO
TO PREVENT THIS CONDITION FROM OCCURRING, YOUR BUICK DEALER WILL INSPECT AND IF REQUIRED, REPLACE THE PARKING BRAKE LEVER ASSEMBLY. THIS SERVICE WILL BE PERFORMED FOR YOU AT NO CHARGE.
WHAT YOU SHOULD DO
PLEASE CONTACT YOUR BUICK DEALER AS SOON AS POSSIBLE TO ARRANGE A SERVICE DATE. INSTRUCTIONS FOR MAKING THIS CORRECTION HAVE BEEN SENT TO YOUR DEALER AND PARTS ARE CURRENTLY AVAILABLE. THE LABOR TIME NECESSARY TO PERFORM THE INSPECTION IS APPROXIMATELY 15 MINUTES, IF REPLACEMENT IS REQUIRED ALLOW (1) HOUR AND APPROXIMATELY (40) MINUTES. PLEASE ASK YOUR DEALER IF YOU WISH TO KNOW HOW MUCH ADDITIONAL TIME WILL BE NEEDED TO SCHEDULE AND PROCESS YOUR VEHICLE.
YOUR BUICK DEALER IS BEST EQUIPPED TO OBTAIN PARTS AND PROVIDE SERVICE TO INSURE 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 BUICK CUSTOMER ASSISTANCE CENTER BY CALLING 1-800-521-7300.
AFTER CONTACTING YOUR DEALER AND THE 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, D.C. 20590 OR CALL 1-800-424-9393 (WASHINGTON D. C. RESIDENTS USE 366-0123).
THE ENCLOSED OWNER 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 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.
BUICK MOTOR DIVISION GENERAL MOTORS CORPORATION
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.
