Product Safety 99038 - Brake Booster to Pedal Asm. Attachment Nuts May Be Loose

DCS406 issued on August 31, 1999 released this campaign but instructed dealers to hold campaign claims until claim information was finalized and published. With receipt of this bulletin, dealers may begin submitting claims as indicated in the claims section of this bulletin.

The Highway 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 remedies, 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 divisional letter that is being sent to customers, the customers are being instructed to contact the appropriate 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.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999 Buick Park Avenue, Oldsmobile Aurora and 2000 Buick LeSabre model vehicles. Some of these vehicles exhibit a condition in which the brake booster to pedal assembly attachment nuts may be loose. If these nuts are loose, the driver may not be able to use the full travel of the brake pedal, the brakes may not release, and exhaust gases could enter the passenger compartment. The driver may notice that the pedal is low or that the pedal assembly is loose. If the nuts come off, braking may be lost. If loss of braking were to occur while the vehicle was in motion, a vehicle crash could result without prior warning.

To prevent the possibility of this condition occurring, dealers are to replace any missing brake booster to brake pedal assembly nuts and tighten all four (4) nuts to the specified torque.

Involved are certain 1999 Buick Park Avenue, Oldsmobile Aurora, and 2000 Buick LeSabre model vehicles built within the following VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer 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.

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order.

Important: It is estimated that very few, if any, involved vehicles will require nut replacement. Please order parts accordingly.

Customers will be notified of this campaign on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly).

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

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

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

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 correction has been made before selling or releasing the vehicle.

1. Remove the left (driver's side) I/P sound insulator.
2. Reposition the intermediate steering shaft dust seal/boot in order to gain access to the upper intermediate shaft pinch bolt.
3. Rotate the intermediate steering shaft to a position where the upper pinch bolt is easiest to remove.

Notice: The steering column must be in the locked position prior to the intermediate shaft being disconnected. Failure to do so could result in the SIR coil assembly becoming un-centered, which may cause damage to the coil assembly.

4. Lock the steering wheel by turning the key to the OFF/LOCK position.
5. Remove the intermediate steering shaft upper pinch bolt and disconnect the intermediate shaft from the steering column.
6. Position the intermediate shaft to provide access to the lower left brake booster attachment.
7. Inspect and verify that all four (4) brake booster-to-pedal assembly nuts are present. If any are missing, replace the missing nuts with service nut, P/N 25664438.

Tighten
Tighten all four nuts to 30 N·m (22 lb ft).

8. Connect the intermediate steering shaft to the steering column. Hand-start the intermediate shaft upper pinch bolt.

Tighten
Tighten the intermediate shaft upper pinch bolt to 47 N·m (35 lb ft).

9. Reposition and secure the dust seal/boot.
10. Install the left I/P sound insulator.
11. Install the GM 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 campaign number and 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 by the customer for periodic servicing. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday-Friday, 8:00 am to 4:30 pm Eastern Standard Time). Ask for Item Number S-1015 when ordering.

Apply the "Campaign Identification Label" only on a clean, dry surface.

Submit a Product Campaign Claim with the information indicated below. Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission.

Dear <Division(s)> Customer:

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

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999 Buick Park Avenue, Oldsmobile Aurora and 2000 Buick LeSabre model vehicles. Some of these vehicles exhibit a condition in which the brake booster to pedal assembly attachment nuts may be loose. If these nuts are loose, the driver may not be able to use the full travel of the brake pedal, the brakes may not release, and exhaust gases could enter the passenger compartment. The driver may notice that the pedal is low or that the pedal assembly is loose. If the nuts come off, braking may be lost. If loss of braking were to occur while the vehicle was in motion, a vehicle crash could result without prior warning.

To prevent the possibility of this condition occurring, dealers are to replace any missing brake booster to pedal assembly nuts and tighten all four (4) nuts to the specified torque.

The length of time required to perform this inspection and service correction is approximately 25 minutes. Additional time may be required to schedule and process your vehicle. If you dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed.

Please contact your <<Division>>dealer as soon as possible to arrange a service date. Parts are available and instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle.

Your <<Division>> dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed below:

If, after contacting the appropriate customer assistance center, 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 SW, Washington, DC 20590 or call 1-800-424-9393 (Washington, DC residents use 202-366-0123).

The enclosed 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 no longer own this vehicle, please let us know by completing the postage paid reply card and returning it to us.

Your dealer will provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation.

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.

<Division(s)>

General Motors Corporation

Enclosure