CAMPAIGN: HORN PADMAY NOT BE PROPERLY RETAINED & MAY SEP.

SUBJECT: Product Campaign 94-C-63 - Horn Pad May Not Be Properly Retained and May Separate From Steering Wheel -------------------------------------------------------

MODEL/YEAR: 1993-94 Chevrolet Cavalier --------------------------

TO: All Chevrolet/Geo Dealers

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General Motors has determined that certain 1993-94 Chevrolet Cavalier model vehicles may have been built with insufficient retention of the horn pad. In vehicles which exhibit this condition, the horn pad may separate from the steering wheel. I this were to occur, the horn pad assembly could fall between the steering wheel spokes. This causes us a safety concern, since during a vehicle turn, the horn pad could become jammed between the steering wheel spokes and the turn signal lever. Under these conditions, much more effort would be required to maintain control of the vehicle. This could result in damage to the turn signal lever, horn pad, and horn wiring, rendering the turn signal and horn controls inoperative.

To correct this condition, dealers will modify the horn pad retention clips, install horn pad retention brackets to the steering wheel, re-install the horn pad and assure that the horn pad is properly retained.

VEHICLES INVOLVED

Involved are certain 1993-94 Chevrolet Cavalier models built within the following VIN breakpoints: PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ----- ---- -------

1993 J-Car Lordstown "7" P7257665 P7352044 1994 J-Car Lordstown "7" R7100001 R7373816 1994 J-Car Ramos "S" RS800001 RS800005

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

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 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 the instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owners 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 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.

PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicle listing, prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO Customer Special Order.

Quantity/ Part Number Description Vehicle ----------- ------------ --------- 12360474 Kit-Insert, Horn Pad Retention 1

SERVICE PROCEDURE

1. Remove CTSY (Horn) fuse.

2. Remove horn pad and horn wire from steering wheel.

3. Cut away raised vinyl ribs (#2) on the back of horn pad (#1) as shown in Figure 1.

4. Rework horn pad clips (#1), as shown in Figure 2. Perform bends in sequence shown by arrows #2, #3, and #4 in Figure 2 using needle nose pliers. Complete these bends until clip marked "A" looks like "B" in Figure 2.

5. Using a T-20 Torx driver, remove only the top (3) screws on the steering wheel (marked #2) in Figure 3.

Important: Do not remove all six retaining screws at the same time.

6. Install new support bracket from kit, P/N 12360474, and fasten with the (3) top screws (previously removed). Thread locking compound is not required with original screws. Tighten screws to 3 Nm (25 lb in.).

(If it is necessary to replace any of the retaining screws, use P/N 12337853. A thread locking compound, P/N 12345493, is required with these replacement screws.)

Important: Cut away steering wheel foam as necessary to allow bracket to seat on steering wheel plate. Use a razor knife or other appropriate tool to cut foam.

7. Repeat steps 5 and 6 above for the bottom (3) screws on the steering wheel (marked #3) in Figure 3.

8. Install horn wire.

9. Put steering wheel in full down tilt position (if equipped).

10. Install horn pad by: * Aligning lower clips to lower bracket. * Push horn pad down until upper clips can be engaged. * Push horn pad to engage upper clips to bracket on steering wheel.

11. Install CTSY (Horn) fuse, (15 amp) and ensure horn works properly.

12. Tilt steering wheel in full up position.

13. 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. When installing the new Campaign Identification Label, be sure to install the clear protective covering. Additional Campaign Identification Labels can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday-Friday, 8:00 a.m. to 4:30 p.m. EST). Ask for Item Number S-1015 when ordering.

Apply "Campaign Identification Label", only on a clean, dry surface.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

PART FAILED PARTS LABOR LABOR REPAIR PERFORMED COUNT PART NO. ALLOW CC-FC OP HOURS* ---------------- ----- -------- ----- ----- ----- ------

Install Horn Pad 1 12360474 -- MA-96 V9883 0.8 Retention Kit

* For Campaign Administrative Allowance, add 0.1 hours to the "Labor Hours".

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net Price plus 30% for 1993 models and 40% for 1994 models of all parts required for the repair.

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

March, 1996

Dear Chevrolet Customer:

This notice is sent to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.

REASON FOR THIS RECALL

General Motors has determined that certain 1993-94 Chevrolet Cavalier model vehicles may have been built with insufficient retention of the horn pad. In vehicles which exhibit this condition, the horn pad may separate from the steering wheel. If this were to occur, the horn pad assembly could fall between the steering wheel spokes. This causes us a safety concern, since during a vehicle turn, the horn pad could become jammed between the steering wheel spokes and the turn signal lever. Under these conditions, much more effort would be required to maintain control of the vehicle. This could result in damage to the turn signal lever, horn pad, and horn wiring, rendering the turn signal and horn controls inoperative.

WHAT WE WILL DO

To correct this condition, dealers will modify the horn pad retention clips, install horn pad retention brackets to the steering wheel, re-install the horn pad and assure that the horn pad is properly retained. 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 performing this service have been sent to your dealer and parts are available. Please contact your dealer to arrange a service date as soon as possible. You may ask your dealer if you wish to know how much time will be needed to schedule and process your vehicle.

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 continued satisfaction with our products.

Chevrolet Motor Division GENERAL MOTORS CORPORATION

Enclosure

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.