CAMPAIGN: STEERING GEAR ATTACHING BOSS MAY BREAK

Model and Year: 1985 CHEVROLET LIGHT DUTY ASTRO VAN MODEL TRUCKS EQUIPPED WITH RPO N40 (POWER STEERING)

TO: ALL CHEVROLET DEALERS

THIS BULLETIN IS BEING REISSUED TO SUPERSEDE PRODUCT CAMPAIGN BULLETIN 85C21 DATED APRIL, 1986. UPON RECEIPT OF THE REISSUED BULLETIN 85C21(a), DESTROY 85C21.

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 adequately repair within 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 appointments with owners and to repair their vehicles as soon as possible. As you will see in reading the attached copy of the letter which is being sent to owners, the owner is being instructed to contact the nearest Chevrolet Zone Office if the dealer does not remedy the condition within five days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed how to contact the National Highway Traffic Safety Administration.

DEFECT INVOLVED

General Motors has determined that a defect which relates to Motor Vehicle Safety exists in some 1985 Chevrolet Light Duty Astro Van Model trucks equipped with power steering. In some instances a part of the steering gear housing which attaches to the frame may break. If this condition occurs there will be some warning. The steering wheel will no longer be centered and the driver will have to turn the wheel noticeably more to the left than to the right when going around the same degree of turn.

Continued operation of the vehicle in this condition may cause the remain- ing attachments holding the steering gear to the frame to fracture result- ing in loss of vehicle control which could result in a vehicle crash. To prevent the possibility of this condition occurring on the vehicles in- volved one of two courses of action must be taken:

1. If the attaching boss has been broken or cracked, the steering gear must be replaced.

2. If the steering gear is not broken or cracked a brace must be installed which will provide additional support between the gears and the left hand frame rail.

VEHICLES INVOLVED

Involved are certain 1985 Chevrolet Light Duty Astro Van Model trucks equipped with RPO N40 (Power Steering) built within the following break- points:

PLANT FROM THROUGH ----- ---- ------- Baltimore FBI00038 FBI22613

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Iden- tification Number, owner name and address data, and are furnished to the 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 regis- tration 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 was not shipped any involved vehicles.

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of Owner Letter included with this bulletin).

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. Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.

PARTS INFORMATION

Parts are to be obtained from the Ceneral Motors Warehousing & Distribution Division (GMWDD). To ensure that these parts will be obtained as soon as possible, they should be ordered from GMWDD on a C.I.O. order with no special instruction code, but order on an advise code (2).

If necessary to replace gear - no power steering gear brace kit is required.

Part Quantity Number Description Per Vehicle ------ ----------- ----------- 26000502 Steering Gear (1) As Required

If power steering gear is not cracked/broken, install brace kit:

15555223 Brace Kit (1) As Required

Each kit contains the following parts:

15555226 Stud 2 15555225 Brace 1 2436163 Washer-3/8" 6 9422297 Nut-3/8" 2 9425082 Bolt, Hex-1/2-13Xl-l/4" 1 2436165 Washer-1/2" 2 9422301 Nut-1/2" 1 15555224 Instruction Sheet 1

SERVICE PROCEDURE

NOTICE: TORQUE VALUES MUST BE USED AS SPECIFIED DURING REASSEMBLY TO ASSURE PROPER RETENTION OF THESE PARTS.

1. Disconnect negative battery cable.

2. Raise and support vehicle on a hoist.

3. Remove lower mounting ear bolt which attaches the steering gear to the frame rail, Figure 1.

4. Thoroughly clean the lower mounting ear of all road dirt and under-coating material using a non petroleum base cleaner such as Brake Kleener. Carefully inspect to see if the gear is broken/cracked. Figure 1 View A.

5. If the mounting ear is broken/cracked replace with new gear, Part Number 26000502. Refer to the 1985 Astro Van Shop Manual ST-372-85 3B7-4 for removal and installation instructions. Install campaign completion label.

IF THE MOUNTING EAR IS NOT BROKEN PROCEED TO THE FOLLOWING STEPS:

6. Reinstall the steering gear to frame attaching bolt. Torque to 82 N-M (60 Ft-Lbs). Insure the remaining two gear to frame rail bolts are torqued to 82 N-M (60 Ft-Lbs).

7. Torque the left and right hand idler arm to frame rail bolts, two each side, to 55 N-M (40 Ft-Lbs).

8. Remove the top two steering gear side cover bolts. Reference Figure #2.

9. Run a 3/8"-16 bottoming tap into the two holes until tap bottoms in hole. One to two additional threads will be cut. Use compressed air to clean holes. Threads must be free of oil, dirt or metal chips.

10. Install studs, adhesive coated end inserted into the gear. Torque to 65 N-M (50 Ft-Lbs). Figure 2.

11. Install the new brace on the steering gear side cover studs and locate the hole to be drilled in the frame rail, Figure 2. Thoroughly clean the frame at this location of all road dirt, undercoating and wax. Insure the inside of the frame rail is clean.

* In some isolated cases the steering gear to frame rail brace, P/N15555225, will not easily fit onto the steering gear side cover studs. In those instances it will be necessary to loosen the steering gear to frame attaching bolts, 3 total, enough that the gear can be moved away from the frame rail. Install brace on studs and retorque gear to frame attaching bolts to 82 N-M (60 Ft.lbs.).

12. Torque nuts on studs 40 N-M (30 Ft-Lbs). Torque remaining two side cover bolts to 75 N-M (55 Ft-Lbs).

13. Lower vehicle.

* Denotes Change

14. Drill a 1/2" diameter hole in the frame rail using the brace as a template. Remove all drill shavings.

Depending on the vehicle RPO content the brake master cylinder, emissions canister and a power steering return line may have to be moved to accommodate a drill motor.

15. Install brace attaching bolt in drilled hole, nut up, and torque nut to 88 N-M (65 Ft-Lbs). Use the hand access hole in the frame rail.

16. Spray undercoating material to all areas previously cleaned as required to prevent corrosion.

17. Reconnect negative battery cable.

18. Install Campaign completion label.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified 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 digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or ballpoint 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.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

** * *** Failed Parts Labor Labor Other Net Repair Performed PC Part NO. Allow FC OP Hrs Hrs Amount ---------------- -- -------- ----- -- -- --- --- ------

*Inspect & replace steering gear vehicles without KC4-Engine oil cooler or Z82 - H.D. Trailer Pkg. 1 26000502 00 V3070 1.0 .1 2.38

*Inspect & replace steering gear vehicles withKC4-Engine oil cooler or Z82 - H.D. Trailer Pkg. 1 26000502 00 V3072 1.2 .1 2.38

*Inspect Steering Gear & Install Brace Kit Vehilces without KC4- Engine Oil Cooler or Z82- H.D. Trailer Pkg. 1 15555223 00 V3071 1.4 .1

*Inspect Steering Gear & Install Brace Kit Vehicles with KC4- Engine Oil Cooler or Z82- H.D. Trailer Pkg 1 15555223 00 V3073 1.6 .1

* Campaign Administrative Allowance.

**The Parts Allowance should be the sum total of the current GMWDD Dealer Net price plus 30% of all parts required for the repair.

*** The Net Amount credit will automatically be given for Labor Operations V3070 and V3072 to cover the cost of power steering fluid.

Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim submission.

Dear Chevrolet Owner:

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

General Motors has deterained that a defect which relates to motor Vehicle Safety exists in some 1985 Chevrolet Astro Light Duty Van Model trucks equipped with power steering. In some instances a part of the steering gear housing which attaches to the frame may break. If the condition occurs there will be some warning. The steering wheel will no longer be centered and the driver will have to turn the wheel noticeably more to the left than to the right when going around the same degree of turn. Continued operation of the vehicle in this condition may cause the remaining attachments holding the steering gear to the frame to fracture resulting in loss of vehicle control which could result in a vehicle crash. To prevent this from occurring on your vehicle, please contact your Chevrolet dealer to arrange a service date.

Instructions for making this correction have been sent to your Chevrolet dealer. It is estimated that parts will be available to your dealer on April 25, 1986. The labor time necessary to perform this correction is approximately 60 to 90 minutes. Please allow additional time if necessary, for the dealer to process your vehicle.

Your Chevrolet Dealer is best equipped to obtain parts and provide service to ensure your vehicle is corrected as promptly as possible. However, if 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 days, we recommend you contact the nearest Chevrolet Zone Office, either in person or by telephone. The Zone Office will assist you and the dealer in getting your vehicle corrected. The locations and telephone numbers of the Zone offices are listed in your Owner's Manual.

After contacting your dealer and the Zone Office, if you are atill 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 St., S.W., Washington. D.C. 20590 or call 800-424-9393 (Washington, D.C. residents use 426-0123).

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 owner 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.

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.