Product Safety - Upper Ball Joint Separation

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1996-1997 4-wheel drive Chevrolet Blazer, GMC Jimmy and Oldsmobile Bravada vehicles registered in CT, DE, IL, IN, IA, ME, MD, MI, MN, MO, NH, NJ, NY, OH, PA, RI, VT, Washington, D.C, WV and WI. Some of these vehicles have a condition where the front suspension upper ball joint may separate without prior warning. If this were to occur while the vehicle was moving, the top of the front tire would lean inward and a very noticeable noise would be heard. The vehicle would pull in the direction of the separated ball joint but the vehicle control could be maintained using a steering correction in these circumstances. If the driver were surprised by the sudden change in the vehicle handling and was unable to control the vehicle, there could be a crash.

Dealers are to replaced both upper ball joints.

Involved are certain 1996-1997 4-wheel drive Chevrolet Blazer, GMC Jimmy, and Oldsmobile Bravada model vehicles registered in CT, DE, IL, IN, IA, ME, MD, MI, MN, MO, NH, NJ, NY, OH, PA, RI, VT, Washington, D.C, WV and W and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before 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 Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. 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" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

Removal Procedure

Important: Perform the following procedure on both upper ball joints.

1. Raise and suitably support the vehicle with safety stands.
2. Remove the tire and wheel.
3. Remove the wheel speed sensor electrical connector from the upper control arm.
4. Disconnect the wheel speed sensor electrical connector.
5. Remove the cotter pin from the upper ball joint stud.
6. Remove the upper ball joint stud nut.
7. Using a pry bar, placed under the upper control arm and on top of the frame, pry upward.
8. With the aid of a helper, carefully hammer on the steering knuckle in the area of the upper ball joint stud in order to release the stud from the steering knuckle.



9. Remove the upper ball joint from the steering knuckle.

9.1.	Place a block under the upper control arm to keep the control arm and the steering knuckle out of the way.

9.2.	Suspend the steering knuckle to prevent straining the brake line.

10. Using an air chisel, carefully remove the heads of the rivets that are retaining the ball joint to the upper control arm.
11. Remove the rivets using a pin punch and hammer.
12. Remove and discard the upper ball joint.
13. Using a 6 mm (¼ in) drill bit, enlarge the upper control arm ball joint attaching holes.

Installation Procedure

1. Install the upper ball joint to the upper control arm.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound of sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the upper ball joint retaining bolts and the nuts.

Tighten
Tighten the upper ball joint retaining nuts to 18 N·m (13 lb ft).




3. Install the upper ball joint to the steering knuckle.
4. Install the upper ball joint to the steering knuckle nut.

Tighten

•	Tighten the upper ball joint to steering knuckle nut to 83 N·m (61 lb ft).

•	Tighten the upper ball joint to steering knuckle nut in order to align for the cotter pin. Do not tighten the nut more than 1/6 turn.

5. Install the new cotter pin to the upper ball joint stud. Bend the pin ends against the nut.
6. Connect the wheel speed sensor electrical connector.
7. Install the wheel speed sensor electrical connector to the upper control arm.
8. Lubricate both upper ball joints.
9. Install the tire and wheel.
10. Lower the vehicle.
11. Check the front wheel alignment. Align if necessary. Refer to Wheel Alignment Specifications in the appropriate Service Manual.
12. Install the GM Campaign Identification Label.

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. 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.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. 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 for US dealers can be obtained from Dealer Support Material by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Submit a Product Campaign Claim with the information indicated below:

Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submission.

Customer requests for reimbursement of previously paid repairs to replace upper ball joints are to be submitted by September 30, 2002 (this time limit may be longer depending upon the law in your state). The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

When a customer requests reimbursement, they must provide the following:

Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS.

Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification.

Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin).

The US National Traffic and Motor Vehicle Safety Act 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 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. In the recall campaign notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the campaign is not completed within a reasonable time.

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.

Dear General Motors 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 1996-1997 4-wheel drive Chevrolet Blazer, GMC Jimmy and Oldsmobile Bravada vehicles. Some of these vehicles have a condition where the front suspension upper ball joint may separate without prior warning. If this were to occur while the vehicle was moving, the top of the front tire would lean inward and a very noticeable noise would be heard. The vehicle would pull in the direction of the separated ball joint but the vehicle control could be maintained using a steering correction in these circumstances. If the driver were surprised by the sudden change in the vehicle handling and was unable to control the vehicle, there could be a crash.

Your dealer will replace both upper ball joints. This service will be performed for you at no charge .

The length of time required to perform this service correction is approximately one hour and twenty minutes to two hours and fifteen 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 to schedule, process and repair your vehicle.

Reimbursement

If you have already paid for some or all of the cost to have your upper ball joints replaced, you should contact your GM dealer to seek reimbursement. Please provide your dealer with your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair. Your request for reimbursement, including the information and documents mentioned above, must be received by your dealer by September 30, 2002.

For California, Connecticut, Virginia and Wisconsin:

To seek reimbursement, write to your Divisional Customer Assistance Center. Please provide your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair. This information must be provided within two (2) years after the date on which you paid for the repair.

Please contact your 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.

Your 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 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 1-888-327-4236.

The attached 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 attached and mailing it in the postage paid envelope.

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.

Chevrolet/Pontiac-GMC/Oldsmobile Division

General Motors Corporation

Enclosure