CAMPAIGN: BUCKET SEAT RECLINER BOLT BREAKAGE. Chevrolet Astro

SUBJECT: BUCKET SEAT RECLINER BOLT BREAKAGE

MODELS: 1985-91 M-Vans, 1990-91 L-Vans and 1989-90 R/V Suburbans

TO: ALL GENERAL MOTORS DEALERS

General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1985-91 2-Wheel Drive Safari/Astro Vans, 1990-91 All Wheel Drive Safari/Astro Vans, (with RPO A78) and 1989-90 R/V Suburbans (with RPO A95) equipped with bucket seats with knob type recliner mechanisms. A front seat recliner bolt may fatigue and break. If this occurred to the driver's seat, it could lead to a sudden loss of vehicle control and a vehicle crash without prior warning.

The bolt fatigue results from high load inputs from the seat occupant when the joint between the recliner mechanism and the seat frame is loose. The recliner mechanism and the seat frame may have foam, cloth or vinyl between them, creating a "soft" joint. This "soft" joint can result in lower than specified bolt torque and lead to joint looseness.

To prevent the possibility of this condition occurring, dealers are to remove the foam, cloth or vinyl from between the recliner mechanism and the seat frame "soft" joint and replace the recliner bolts.

VEHICLES INVOLVED

Involved are certain 1985-91 M-Vans, 1990-91 L-Vans and 1989-90 R/V Suburbans equipped with bucket seats with knob type recliner mechanisms (RPO A78 for M/L Vans; RPO A95 for R/V Suburbans) and built within the following VIN breakpoints:

Year Model Plant Plant Code From Through ---- ----- ----- ---------- ---- ------- 1985-89 GMC M-Van Baltimore 'B' SOP EOP 1990 GMC M/L Van Baltimore 'B' SOP EOP 1991 GMC M/L Van Baltimore 'B' SOP MB517751 1989-90 GMC R/V Suburban Flint 'F' SOP EOP 1985-89 Chev M-Van Baltimore 'B' SOP EOP 1990 Chev M/L Van Baltimore 'B' SOP EOP 1991 Chev M/L Van Baltimore 'B' SOP MB154710 89-90 Chev R/V Suburban Flint 'F' SOP EOP

NOTE: PLEASE CHECK DCS SCREEN 45 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

DEALER CAMPAIGN RESPONSIBILITY

All unsold new vehicles in dealer's possession and subject to this campaign must be held and inspected/repaired per the Service Procedure of this Campaign Bulletin before owners take possession of these vehicles.

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometers traveled, 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 correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner 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 letter

In summary, whenever a vehicle subject to this campaign is taken into your new or used 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.

CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors (see copy of owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.

PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 9440181 Bolt (R/V Suburban) 4

15990580 Bolt (M/L Van) 4

PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ----------- -------------- 2A Replace Bolts & cut back trim .8 (R/V Suburban)

3A Replace Bolts & cut back trim 1.1 (M Vans)

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 30% to cover parts handling.

SERVICE PROCEDURE - R/V SUBURBAN:

1. Disconnect the electrical connectors if vehicle is equipped with power seats.

2. Remove seat belt guide, if applicable.

3. Remove seat riser to floor retaining bolts (do not discard).

4. Remove seat. To provide support, lay seat on its side on a workbench or equivalent.

5. Remove seat back recliner retaining bolts (Figure 1, Item 2 - bolts will not be reused). Move seat back aside to gain access to the cloth/foam around the bolts.

6. Cut cloth/foam material away to allow the recliner mechanism to properly seat against the seat frame (Figure 1, Item 1).

7. Install new recliner bolts and torque to 20-35 N.m (14-26 lbs. ft.) (Figure 1, Item 2). New bolts are coated with a shiny finish to allow easy identification.

NOTICE: WHEN REINSTALLING BOLTS, ALL CLOTH AND FOAM MUST BE CLEAR OF BOLT AREA.

8. Install seat using retaining bolts removed in Step 3 and torque bolts to 35 N.m (26 lbs. ft.). Verify retaining bolts are seated properly.

9. Reconnect electrical connectors if vehicle is equipped with power seat.

10. Install seat belt guide, if applicable.

11. Repeat procedure for passenger seat.

12. Install Campaign Identification Label.

SERVICE PROCEDURE - M/L VAN: --------------------------- 1. Disconnect the electrical connectors if vehicle is equipped with power seats.

2. Remove seat belt guide, if applicable.

3. Remove the seat from the vehicle by removing four seat riser to floor retaining nuts (do not discard). To provide support, lay seat on its side on a workbench or equivalent.

4. Remove seat adjuster knob cover.

5. Remove the adjuster knob from the seat by holding the knob while using a pair of needle nose pliers or equivalent to rotate the clip.

6. Remove the recliner trim cover from seat by inserting a screwdriver or equivalent behind the cover and pushing out on die retainer clips (Figure 2).

NOTICE: BE CAREFUL WHEN REMOVING THE COVER THAT THE CLIPS ARE NOT DAMAGED.

7. Remove two (2) seat back recliner retaining bolts (Figure 3, Item 2), to gain access to the vinyl/foam. The bolts will not be reused.

8. Cut the vinyl/foam material back using the markings left by the recliner as guides. Be careful when cutting the vinyl/foam to ensure that it is cut back from the bolt area (Figure, 3 Item 1).

9. Install two (2) new seat back recliner retaining bolts (Figure 3, Item 2) and torque to 28 N.m (21 lbs. ft.). New bolts are coated with a shiny finish to allow easy identification.

NOTICE: WHEN REINSTALLING BOLTS, ALL VINYL AND FOAM MUST BE CLEAR OF BOLT AREA.

10. Reinstall trim cover.

11. Reinstall adjuster knob and rotate knob clip to secure.

12. Reinstall adjuster knob cover.

13. Reinstall seat into the vehicle and torque bolts to 35 N.m (26 lbs. ft.)

14. Reconnect the electrical wires if equipped with electric seats.

15. Reinstall seat belt guide, if applicable.

16. Install Campaign Identification Label.

INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

Dear General Motors Customer

General Motors of Canada Limited has determined that a defect relating to motor vehicle safety exists in certain 1985-91 2-Wheel Drive Safari/Astro Vans, 1990-91 All Wheel Drive Safari/Astro Vans, and 1989-90 R/V Suburbans equipped with bucket seats with knob type recliner. A front seat recliner bolt may fatigue and break. This may allow the seat back to suddenly recline, which can lead to sudden loss of vehicle control.

To prevent this condition from occurring, your dealer will remove the foam, cloth or vinyl from between the recliner mechanism and the seat frame "soft" joint and replace the recliner bolts.

This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department General Motors of Canada Limited

Object Number: 85845 Size: FS

Object Number: 84112 Size: FS

Object Number: 85168 Size: FS

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.