CAMPAIGN: REAR DISC BRAKE CONE CLUTCH PARK BRAKE ADJUSTER

Subject: PRODUCT SAFETY CAMPAIGN 86C28 REAR DISC BRAKE CONE CLUTCH PARK BRAKE ADJUSTER

Model and Year: 1982-86 CHEVROLET CAMAROS WITH REAR DISC BRAKES (RPO J65) AND MANUAL TRANSMISSIONS

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 that is being sent to owners, the owners are being instructed to contact the Chevrolet 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.

DEFECT INVOLVED

General Motors has determined that a defect which relates to motor vehicle safety exists in 1982-86 Chevrolet Camaro model vehicles equipped with rear disc brakes (RPO J65) and manual transmissions. These vehicles may exhibit a lack of park brake automatic adjustment leading to reduced parking brake effectiveness.

To correct this condition, all involved vehicles will have an improved design rear brake caliper actuator installed. Other repairs to restore park brake functions to proper operation may also be made in conjunction with this campaign.

VEHICLES INVOLVED

Involved are 1982-86 Chevrolet Camaro model vehicles equipped with rear disc brakes (RPO J65) and manual transmissions, and built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ------- ---- -------- -------- 1982 F-Car Norwood "N" CN100001 CN168020 " " Van Nuys "L" CL123326 CL221394 1983 " Norwood "N" DN103234 DN165071 " " Van Nuys "L" DL100280 DL168650 1984 " Norwood "N" EN100002 EN200276 " " Van Nuys "L" EL100004 EL260754 1985 " Norwood "N" FN100008 FN176201 " " Van Nuys "L" FL100079 FL503417 1986 " Norwood "N" GN100007 GN188639 " " Van Nuys "L" GL100002 GL203370

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 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 correction according to instructions contained in this bulletin.

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 ----------- ------------------- ---------- 18019028 Rear Brake Caliper 1 Actuator Kit Each Kit Contains: -2 Actuator Assemblies -All Necessary Gaskets & Seals -2 Brake Pad Dampening Springs

12300230 Brake Pads As Required 18010361 Actuator Levers As Required 10200446 Parking Brake Cable As Required - Front

10200448 Parking Brake Cable As Required - Kit (Both Rear Cables) P/N 10200443 Left Rear Cable P/N 10200444 Right Rear Cable 10046472 Parking Brake Apply Handle As Required 10139097 Banjo Washer As Required 01052535 Brake Fluid 1 Pint

DEALERS ARE TO RETURN ALL SERVICE INVENTORY OF SEAL KIT P/N 18010453, ACTUATOR KIT P/N 18016369, AND REAR CALIPER P/N 18016374. PLEASE IDENTIFY THESE PARTS AS SPECIAL RETURNS ON YOUR PC659 DOCUMENT.

SERVICE PROCEDURE

A. Raise vehicle and remove both rear tire/wheel assemblies.

B. Inspect park brake apply system for proper function, corrosion, kinks, etc. Remove nonfunctional cables.

C. spray equalizer and both bleeder screws with Liquid Wrench (or equivalent product). Do not remove screws at this time.

D. Remove both rear calipers following the procedures in the appropriate Service Manual.

E. Remove brake pads.

F. Inspect brake pads f or taper wear or excessive wear. Taper wear can be determined by taking measurements at the four points shown in the diagram below.

Calculate pad taper by subtracting the thinnest point measured from the thickest point measured.

The brake pads should be replaced if taper is greater than .080 inches.

G. Overhaul calipers as follows:

Tools Required:

* J-22269-01 Piston Installer * J-38898 Boot Seal Installer

1. Remove shoe damping spring from end of piston.

2. Remove park brake lever.

3. Remove lever seal and antifriction washer.

4. Remove piston by turning actuator screw with lever or wrench.

NOTICE: DO NOT REUSE OLD PISTON OR OLD BALANCE SPRING.

5. Remove actuator screw by pressing on threaded end.

6. Remove shaft seal and thrust washer from actuator screw.

7. Remove old boot while being careful not to scratch the housing bore.

8. Remove piston seal, using a wood or plastic tool that will not damage the caliper bore.

9. Remove caliper mounting bolts, bushings and sleeves.

10. Remove bleeder screw.

NOTICE: If excessive resistance is encountered, use the following procedure to prevent breakage:

(A) First put a 10mm socket over bleeder screw and tap lightly on it.

(B) If step (A) does not help, use a propane torch to heat the caliper around bleeder screw after assuring that any excess Liquid Wrench has been removed from surface. Apply heat to caliper for approximately 30 seconds to 1 minute (maximum). DO NOT USE AN ACETYLENE TORCH. Overheating the aluminum caliper could cause the bleeder screw to strip its threads.

11. Inspect caliper bore and seal groove. If necessary, use crocus cloth to polish out any light corrosion.

12. Clean all parts with GM brake parts cleaner P/N 12345754 (or equivalent).

13. Dry parts with unlubricated compressed air.

14. Blow out all passages in housing and bleeder screw.

15. Clean internal passage in bleeder screw, reinstall bleeder screw and torque to 6-9 Nm. (80-140 lb. in.).

16. Install new piston seal. Lubricate seal and bore with brake fluid.

NOTICE: Make sure that seal is not twisted.

17. Install lubricated new boot onto new piston with inside lip of boot in piston groove and boot fold toward end of piston which contacts inboard brake pad.

18. Install thrust washer on actuator screw with copper side of washer toward the piston assembly and gray surface toward the caliper housing.

19. Install lubricated shaft seal on actuator screw.

20. Install actuator screw into piston.

21. Install new balance spring into piston recess.

22. Guide lubricated piston assembly into lubricated bore of caliper.

NOTICE: Excessive force is not required to install the piston assembly into the caliper bore.

DO NOT ALLOW PISTON TO COCK IN BORE AS SEAL WILL BE DAMAGED.

23. When resistance (seal engagement) is met, rotate piston assembly back and forth to insure it is square to seal.

24. Use #J-22269-01 to install piston through piston seal. Shake tool to align piston to the seal while gently turning the jack screw to push piston through the seal to the bottom of the caliper bore. See illustration below.

25. Install lubricated antifriction washer and lever seal over end of actuator screw.

NOTICE: The sealing bead on the lever seal should be against the housing.

26. Install lever on actuator screw. Rotate lever away from stop slightly and hold while installing nut to 48 Nm (35 lb. ft.). Then, rotate lever back to contact stop.

27. Seat boot into caliper housing counter bore using new Kent-Moore tool # J-38898.

28. Install new dampening spring (included in kit) in groove on end of piston.

29. Clean, lubricate and reinstall sleeves, bushings and caliper mounting bolts.

30. Install brake shoes.

H. Reinstall calipers, per the appropriate shop manual.

I. Install hydraulic fitting and bolt, using 2 new brass washers, and torque to 33Nm (24 lb. ft.).

J. Bleed brake system as required (power or manual), per shop manual.

K. Apply approximately 778N (175 lb.) force 3 times to the brake pedal to seat the linings.

L. Clinch outboard shoe to caliper, per shop manual.

M. Readjust park brake cable, per shop manual.

N. Reinstall wheels and tire assemblies.

O. 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.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

* *** FAILED PARTS CC-FC LABOR LAB OTH NET REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS AMT ------------------- --- -------- ----- ----- ----- --- --- --- **** Install New Actuator 1 18019028 ** SK-00 V6620 2.0 0.1 $#.## Kit ***** Supplemental Repairs # ######## ** SK-00 T1749 #.# 0.0 -.- For Campaign 86C28

Reimburse Owner For - - - - 02-95 T1750 - - - - - - Previous Repair

* Campaign Administrative Allowance.

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair. For V6620, this amount should include the parts allowance for any replaced banjo washers when applicable.

*** The $#.## identified in the "Net Amount" column represents the cost plus 30% for one (1) pint of brake fluid used in conjunction with labor operations.

**** Labor hours required to replace tapered pads, install actuator levers, and adjust park brake cables are included in the standard campaign labor hours (V6620). No additional time is needed as procedures to perform these repairs are part of the campaign actuator installation procedure.

***** The Labor Hours required for supplemental repairs needed to complete this campaign are listed below. If multiple repairs were required, add appropriate times together. Failed Part Number information can be selected from the "Parts Information" section of this bulletin.

Labor Description Hours ------------------ ----- Replace Front Park 0.7 Brake Cable

Replace Both Rear 0.2 Park Brake Cables

Replace All Park 0.9 Brake Cables

Replace Park Brake Handle 0.5

Remove And Reinstall 0.1 Wheel Lock Nuts

Replace Tapered Brake (The labor hours to perform this Pads repair are included in V6620. Use T1749 only to claim the applicable parts allowance.)

Replace Actuator Levers (The labor hours to perform this repair are included in V6620. Use T1749 only to claim the applicable parts allowance.)

Dealers will automatically receive the correct labor and material allowance for labor operation V6620.

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

REIMBURSEMENT

Customer request for reimbursement of a prior repair to correct a previous parking brake adjuster condition are to be submitted according to the instructions in this bulletin using the attached "Request For Reimbursement" form. Additional copies of the form are to be reproduced by the dealer.

Owners must submit original repair invoices along with proof of payment (charge card receipt, copy of cancelled check, or a receipt marked "PAID" if paid-in-cash). The customer repair invoice should provide a description of the repair made and the person or facility performing the repair. These documents are to be retained by the dealer with the dealer repair order and supporting warranty records.

REQUEST FOR REIMBURSEMENT INSTRUCTIONS PRODUCT SAFETY CAMPAIGN 86C28 1982 - 1986 CHEVROLET CAMARO W/REAR DISC BRAKES & MANUAL TRANSMISSION

1 R.O. # & DATE The dealership should enter the repair order number and date of the owner's or dealer's paid receipt or invoice.

2 REQUEST DATE Date owner or dealer requested reimbursement. (MONTH, DAY)

3 VEHICLE IDENTIFICATION NUMBER VIN involved.

4 MILEAGE Enter mileage at time of transaction. (If not available, enter "0".)

5 CC/FC Code is preprinted on form.

6 LABOR OPERATION Labor Operation as referenced in bulletin.

7&8 SUBLET DMN & Enter total amount of reimbursement. (Do not LINE TOTAL enter parts or labor hours on claim.)

9 AUTH CODE If the amount of reimbursement approved is $300 or less, no authorization is needed. If the amount exceeds $300, advise customer to contact Chevrolet Customer Assistance at 1-800-222-1020.

10 REQUESTED Dealer Service Manager enter amounts REIMBURSE determined from owner supplied invoices or paid receipts, which are covered. (Maximum amount is $300.)

11 APPROVED AMOUNT Dealer Service Manager to detemiine based on reimbursement policy of this bulletin. (Maximum amount is $300.)

12 740 STAMP Dealer Service Manager is to stamp reimbursement form including date and signature. (No Authorization Code is required.)

13 DEALER REFERENCE INFORMATION A Enter Document Number & Line Number on which claim was submitted.

B Enter Claim Memo Number and Date when claim is credited.

C Enter number of dealer check to owner, if applicable. Date check was written, if applicable. Date copy of check was attached to OWNER REQUEST FOR REIMBURSEMENT file.

14 OWNER INFORMATION Must include telephone number.

15 DEALER INFORMATION Includes Dealer Code, Dealer Name, Service Manager's signature and social security number. To be completed by Service Manager.

16 EXPLAIN Should the dealer Service Manager determine, after review of owner's invoices/receipts, that the reimbursement case is not eligible; Service Manager should write reason on worksheet, explain to owner, and place a copy of the worksheet in the file.

17 The dealer is then to issue the owner a check for the reimbursement in the approved amount. A copy of the check issued to the owner is to be attached to the dealer's file copy of the request and retained for 24 months from date of credit.

Dear Chevrolet Camaro Owner:

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

REASON FOR THIS RECALL

As we informed you in our previous letter, General Motors has determined that a defect which relates to motor vehicle safety exists in 1982-86 Chevrolet Camaro Model Vehicles equipped with rear disc brakes and manual transmissions. As we explained in that letter, the parking brake system of these vehicles may contain a nonfunctional parking brake adjuster in the rear disc brake assemblies. This condition may result in a gradual loss of parking brake effectiveness as the rear disc brake pads wear during normal brake usage. As a result, the parking brake system may not be able to hold the vehicle on a steep incline. If the vehicle is parked or left unattended with the transmission in neutral or a gear other than "reverse" the vehicle may roll away and result in personal injury or property damage.

In our previous letter, we informed you that a new parking brake adjuster was in the process of being developed. Development of that new parking brake adjuster is now complete, and parts to repair the affected vehicles are now available.

WHAT WE WILL DO

To improve parking brake performance in your Camaro, your Chevrolet dealer will install the new design parking brake adjusters in your vehicle. This service will be performed for you at no charge.

WHAT YOU SHOULD DO

Please contact your Chevrolet dealer as soon as possible to arrange a service date and so the dealer may order the necessary parts for the repair. Instructions for making this correction have been sent to your dealer and parts are available. The labor time necessary to perform this service correction is approximately two (2) hours. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

Be certain to continue to follow the cautions mentioned in our last letter until your vehicle is repaired. Specifically, the manual transmission must be placed in "reverse" gear each time your vehicle is parked and the vehicle's front wheels must be turned into the curb according to your parking conditions.

Also, when exiting your vehicle, check to see that the vehicle remains stationary after removing your foot from the regular brake pedal. If the vehicle moves when the regular brakes are released, do not leave the vehicle in this position. The vehicle must be moved to a less steep grade in order to park safely.

Your Chevrolet dealer is best equipped to obtain parts and provide service to ensure 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 Chevrolet Customer Assistance Center by calling 1-800-222-1020.

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.

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.