CAMPAIGN: STEEL WHEELS CRACK (INSTALL REDESIGNED WHEELS)

SUBJECT: PRODUCT SAFETY CAMPAIGN 92C19 - STEEL WHEELS CRACKING

MODEL and YEAR: 1991-92 CHEVROLET CAPRICE POLICE SEDANS (SEO 9C1) AND POLICE WAGONS (SEO 1A2)

To: All Chevrolet Dealers

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 Chevrolet Fleet Service Operations 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 1991-92 Chevrolet Caprice Police vehicles (sedans and wagons) equipped with 15" X 7" steel wheels with the wheel code "RDL". These wheels could fracture and become separated from the vehicle due to a combination of lug nut over-torquing and wheel distortion caused by tire mounting equipment. Multiple tire changes and the severe police duty cycle tend to aggrevate the condition. If wheel separation were to occur while a vehicle was in motion, steering and braking control of the vehicle could be affected and a vehicle crash without prior warning could result.

To prevent the possibility of this condition occurring, redesigned 15" X 7" steel wheels are to be installed to replace the suspect (wheel code "RDL") 15" X 7" steel wheels.

VEHICLES INVOLVED

Involved are 1991-92 Chevrolet Caprice Police vehicles (sedans and wagons) equipped with 15" X 7" steel wheels with the wheel code RDL and built within the following VIN breakpoints: PLANT YEAR MODEL PLANT CODE FROM THROUGH ----- ----- ----- ----- ----- -------- 1991 B-Car Arlington "R" MR100001 MR152643

1991 B-Car Willow Run "W" MW234954 MW264781

1992 B-Car Arlington "R" NR1OO001 NR133789

1992 B-Car Willow Run "W" NW100003 NW134400

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 as parts become available to service complete police fleets (see copy of owner letter included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

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 owners take possession of these vehicles.

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.

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.

Notice: Dealers should contact appropriate fleet locations indicated on the Vehicle Identification Number Computer Listings (see "Vehicles Involved" section) to ensure location of vehicles.

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.

SPECIAL TOOLS

Each dealer will be shipped a Torque Stick (J-39544) tool for use in this campaign and for future use in tightening police wheel nuts. This tool is being furnished at no charge to dealers and will be sent to dealers during the week of July 6, 1992. Additional tools, if required, may be purchased by contacting the Kent-Moore tool company at 1-800-345-2233.

Notice: Chevrolet dealers which are "dualed" with either Buick or Pontiac divisions will not be sent this special tool since it is an essential (required) tool for their dealership.

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). since replacement wheel availability is currently limited, each fleet will be notified by owner letter when wheels for their fleet are available.

Quantity/ Part Number Description Vehicle ----------- ----------- -------- 12521214 Wheel Kit 1

Contains: 5 Replacement Wheels 20 Wheel Nuts 5 Valve Stems

Notice: Dealers should contact appropriate fleet locations indicated on the Vehicle Identification Number Computer Listings (see "Vehicles Involved" section) to ENSURE LOCATION OF VEHICLES PRIOR TO PLACING ORDERS FOR WHEELS.

SERVICE PROCEDURE

WHEEL INSPECTION

1. Remove wheel covers.

2. Inspect wheel code on each wheel INCLUDING THE SPARE (see illustration, figure 1).

- If a vehicle has any wheels with "RDL" wheel codes, the "RDL" wheels must be replaced with new design wheels following the "New Wheel Replacement" procedures in this bulletin.

- If no wheels (INCLUDING THE SPARE) have the "RDL" wheel code, no wheels require replacement. Reinstall wheel covers and continue to step 10 of the "New Wheel Installation" procedure.

(PERFORM THIS PROCEDURE FOR ALL WHEEL CODE "RDL" WHEELS)

1. Raise vehicle (remove spare prior to raising if it must be replaced).

2. Remove valve core to allow all air to escape.

NOTICE: 70 seconds is required for air to completely exhaust from a police tire. Always allow all air to escape prior to breaking tire bead.

3. Remove tire/wheel assembly from vehicle.

Notice: Do not use torque stick to remove wheel nuts.

4. Remove tire from "RDL" wheel.

5. Install new valve stem (supplied in kit) into new replacement wheel.

NOTICE: Suspect wheels ("RDL") must be permanently disfigured so they can not be reused. It is suggested that, if possible, the wheel be cut with an oxygen/acetylene torch or that an air chisel be used to deform the valve stem hole. Note on repair order how the wheel was disfigured and how many "RDL" wheels were found and replaced.

6. Install tire onto new replacement wheel.

NOTICE: Do not stand over tire when inflating. The bead may break when it snaps over the safety hump and cause serious personal injury.

7. Balance tire/wheel assembly.

8. Reinstall tire/wheel assembly onto vehicle using new wide flange wheel nuts (supplied in kit) and the following procedure:

a. Snug wheel nuts down by hand.

b. Following star pattern (see figure on page 6) and using torque stick (J-39544), tighten wheel nuts to approximately half of specified torque (approx. 68 Nm or 50 lb. ft.).

c. Again using star pattern (see figure on page 6) and torque stick, tighten wheel nuts to 135 Nm (100 lb. ft.).

Notice: Never use lubricant or penetrating fluids on wheel studs, nuts or mounting surfaces since this can raise the actual torque on the nut. Wheel nuts, studs and mounting surfaces must be clean and dry.

Also, since a new wide flange wheel nut is being used with the replacement wheel, every effort should be made to assure that during future tire changes the wide flange wheel nuts remain with the replacement wheel.

9. Repeat steps 2 through 8 as required for each wheel code "RDL" tire/wheel assembly.

10. FOR VEHICLES WHICH DO NOT HAVE ALL FIVE WHEELS REPLACED:

Due to individual tire changing procedures, involved vehicles may no longer be equipped with their original set of factory installed wheels. For this reason, whenever an involved vehicle does not have all five wheels replaced, the remainder of the wheels, valve stems and lug nuts from the wheel kit are to be placed in the vehicle (either in the trunk or rear seat) along with a copy of the letter on page 9 (reproduce locally). This will alert fleet personnel to the possibility that an "RDL" wheel from an involved vehicle's original set of wheels may have been installed on another police vehicle outside the involved vehicle VIN range, and will also allow fleet personnel to replace such a wheel. Note that if a fleet discovers an "RDL" wheel which has been installed on another vehicle they are to return the "RDL" wheel to the dealership for disfiguration and proper campaign part disposal.

For vehicles which have no wheels replaced after inspection, include an entire wheel kit and a copy of the letter on page 9 with the vehicle.

Notice: Some involved vehicles were not manufactured with 5 "RDL" wheels. As a result, it is possible that a fleet which is provided extra wheels will not discover additional "RDL" wheels within the fleet.

11. 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 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 for periodic servicing by the owner. Additional "Campaign Identification Labels" can be obtained from DAC.

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 ---------------- -- -------- ----- ----- ----- --- --- --- Inspect/ No Wheels Replaced-Set 1 12521214 ** SK-00 V7570 0.3 0.1 -- Provided To Fleet

Inspect/ One Wheel Replaced-Remainder 1 12521214 ** SK-00 V7571 0.5 0.1 $#.## Of Kit Provided To Fleet

Inspect/ Two Wheels Replaced-Remainder 1 12521214 ** SK-00 V7572 0.7 0.1 $#.## Of Kit Provided To Fleet

Inspect/ Three Wheels Replaced - 1 12521214 ** SK-00 V7573 0.9 0.1 $#.## Remainder of Kit Provided To Fleet

Inspect/Four Wheels Replaced-Remainder 1 12521214 ** SK-00 V7574 1.1 0.1 $#.## Of Kit Provided To Fleet

Inspect/ All Five 1 12521214 ** SK-00 V7575 1.2 0.1 $#.## Wheels Replaced

* Campaign Administrative Allowance.

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of the wheel kit required for the repair.

*** For cases in which all five wheels are not replaced, dealers are to place the remainder of the unused wheel kit in the vehicle so the involved fleet may assure that all "RDL" wheels are accounted for. See step 10 of the service procedure and the letter on page 9 for additional details.

**** The $#.## identified in the "Net Amount" column represents dealer cost plus 30% for balance weights used in conjunction with labor operations V7571, V7572, V7573, V7574 and V7575.

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.

NOTICE TO FLEET PERSONNEL

ATTENTION

FLEET PERSONNEL

This vehicle has been inspected in accordance with Chevrolet product safety recall 92C19. Inspection indicates that not all of the wheels were suspect "RDL" code wheels and any suspect wheels found have been replaced. However, it is possible that this vehicle was built with 5 suspect wheels (including spare) and that as a result of tire changing procedures the original wheels may have been instared on another police vehicle outside the recall parameters.

For this reason, we have provided you the remaining wheel(s), valve stem(s) and wheel nuts from the replacement 5 wheel kit obtained for this vehicle. Please use these wheels to assure that your police vehicles do not have a suspect wheel from this vehicle. Police vehicles with the last eight digits of the Vehicle Identification Number (VIN) prior to MR100001 or MW234954, or after NR133789 or NW134400 are outside the recall parameters and should be checked. The VIN is located at the upper left of the instrument panel and can be viewed from outside of the vehicle (see Owner's Manual page 205 for 1991 vehicles or page 269 for 1992 vehicles).

Notice: Please be certain to remove any additional wheels provided by your Chevrolet dealer from this vehicle as soon as possible.

The diagram in fig. 4 shows the location of the wheel code ("RDL") which identifies the suspect wheels. If a suspect wheel is found and replaced, be certain to retum the suspect wheel to your dealership for proper disposal. DO NOT REUSE A SUSPECT WHEEL.

If no suspect wheels are found, your fleet may keep the replacement wheel(s) for your service use. Note that it is possible that this vehicle was not built with five suspect wheels.

Notice: Since a new wide flange wheel nut is being used with the replacement wheels, every effort should be made to assure that during future tire changes the wide flange wheel nuts remain with the replacement wheels.

Thank you for your cooperation and for assisting us in this important matter. We apologize for any inconvenience we may have caused; however, we have taken this action in the interest of your safety and continued satisfaction with our products.

Chevrolet Motor Division General Motors Corporation

COPY OF LETTER TO POLICE FLEETS

To All Chevrolet Police Fleets:

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

REASON FOR THIS RECALL

General Motors has determined that a defect which relates to motor vehicle safety exists in 1991-92 Chevrolet Caprice Police vehicles (sedans and wagons) equipped with 15" X 7" steel wheels with the wheel code "RDL". These wheels could fracture and become separated from the vehicle due to a combination of lug nut over-torquing and wheel distortion caused by tire mounting equipment. Multiple tire changes and the severe police duty cycle tend to aggravate the condition. If wheel separation were to occur while a vehicle was in motion, steering and braking control of the vehicle could be affected and a vehicle crash without prior warning could result.

WHAT WE WILL DO

To prevent the possibility of this condition occurring, redesigned 15" X 7" steel wheels are to be installed to replace the suspect (wheel code "RDL") 15" X 7" steel wheels. 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. The wheels to correct the involved vehicles in your fleet are currently available and instructions for making this correction have already been sent to your dealer. The labor time necessary to perform this service inspection/correction is approximately 15 minutes to one hour and 15 minutes. You may wish to ask your dealer how much additional time will be needed to schedule and process your vehicle.

Your vehicle will be inspected for suspect "RDL" code wheels (see illustration on reverse side of this letter) and any suspect wheels found will be replaced as described above. It is possible, however, that your vehicle was built with 5 suspect wheels (including spare) and that as a result of tire changing procedures some original wheels may have been installed on another police vehicle not involved in this recall.

For this reason, if we inspect your vehicle and discover less than five suspect wheels, we will provide you the remainder of the five wheel kit obtained to correct your vehicle. These remaining wheels can then be used to replace any suspect wheels that may have been installed on vehicles not involved in this recall (Note that it is possible that less than five suspect wheels were installed on your vehicle when it was manufactured).

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 Chevrolet Fleet Service Operations by calling 1-800-334-5370.

After contacting your dealer and Chevrolet Fleet Service Operations, 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).

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 Motor Division GENERAL MOTORS CORPORATION

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.