CAMPAIGN:FRONT SPINDLE NUT MAY BE OVERTORQUED

SUBJECT: NUT MAY BE OVER TORQUED

MODEL/YEAR: 1994 CAVALIERS

****************************** IMPORTANT

RETAIN THIS DCS ADMINISTRATIVE MESSAGE WITH DEALER CAMPAIGN BULLETINS. A RED TOP DEALER BULLETIN WILL NOT BE PRINTED BY CHEVROLET MOTOR DIVISION.

INVOLVED UNITS CAN BE RELEASED FOR SALE AND DELIVERY IMMEDIATELY AFTER THE CAMPAIGN SERVICE IS COMPLETED.

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 REASONABLE 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 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 CERTAIN 1994 CAVALIERS. SOME OF THESE VEHICLES MAY HAVE BEEN BUILT WITH OVER-TORQUED DRIVE AXLE SPINDLE NUTS. THIS CONDITION COULD CAUSE EXCESSIVE LOAD ON THE SPINDLE NUT AND DRIVE AXLE, AND COULD RESULT IN FAILURE OF THE DRIVE AXLE OR THE SPINDLE NUT. EITHER OF THESE FAILURES COULD RESULT IN SEPARATION OF THE STEERING KNUCKLE/BEARING-HUB/TIRE-WHEEL ASSEMBLY FROM THE DRIVE AXLE. IF THIS WERE TO OCCUR WHILE THE VEHICLE WAS IN MOTION, THE AFFECTED KNUCKLE/HUB/TIRE-WHEEL ASSEMBLY WOULD BECOME UNSTABLE, STEERING CONTROL WOULD BE REDUCED AND A VEHICLE CRASH COULD OCCUR WITHOUT PRIOR WARNING.

TO PREVENT THIS CONDITION FROM OCCURRING, DEALERS ARE TO REPLACE LH AND RH DRIVE AXLES, BEARING-HUB ASSEMBLIES, SPINDLE NUTS, AND WASHERS ON ALL INVOLVED VEHICLES. FOR ANY VEHICLES ALREADY DELIVERED, THE DEALER MUST CONTACT THE OWNER AND ARRANGE FOR THE VEHICLE TO BE REPAIRED AS SOON AS POSSIBLE.

VEHICLES INVOLVED

INVOLVED ARE THE FOLLOWING 1994 CHEVROLET CAVALIER VEHICLES (ALL INVOLVED VEHICLES WERE BUILT AT THE LORDSTOWN ASSEMBLY PLANT - VIN '7'):

DEALER SHIPPED TO VIN ----------------- --- 02145 1G1JC1443R7325818 02145 1G1JC14T0R7325962 04286 1G1JC1449R7325810 04703 1G1JC1446R7325859 04703 1G1JC1441R7325896 07094 1G1JC1446R7325893 08507 1G1JC5442R7325901 08716 1G1JC5442R7325770 10681 1G1JC1448R7325961 10801 1G1JC144XR7325945 13073 1G1JC144XR7325766 13073 1G1JC5448R7325823 13073 1G1JC1444R7325939 13349 1G1JC5442R7325803 13349 1G1JC5443R7325907 13349 1G1JC5447R7325960 13591 1G1JC5442R7325932 15190 1G1JC1443R7325804 16126 1G1JC5441R7326005 16158 1G1JC5447R7325800 16499 1G1JF14T8R7325974 16785 1G1JC1445R7325853 19178 1G1JC5442R7325882 24447 1G1JC1445R7325951 26342 1G1JC144XR7325833 30687 1G1JC54T3R7325865 39023 1G1JC5447R7325828 39023 1G1JC1449R7325908 39156 1G1JC5441R7325839 39305 1G1JC1448R7325863 45051 1G1JC1440R7325824 45051 1G1JC1449R7325869 45051 1G1JC1441R7325915 45051 1G1JC1449R7326004 45060 1G1JC5447R7325814 45127 1G1JC5444R7325849 45697 1G1JC5442R7325798 45756 1G1JC5442R7325946

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). 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 A ADVISE CODE (2).

DRIVE AXLE PART NUMBERS ARE LISTED BELOW AND ARE GROUPED IN RH AND LH SETS ACCORDING TO HOW THEY ARE PAIRED ON VEHICLES. DEALERS WILL NEED TO DETERMINE THE CORRECT DRIVE AXLE PART NUMBERS REQUIRED TO SERVICE THE SPECIFIC VEHICLE(S) INVOLVED IN THE CAMPAIGN. THESE PART NUMBERS CAN BE FOUND IN THE G.M.S.P.O. PART CATALOG.

PART NUMBER DESCRIPTION QUANTITY/VEHICLE ------------------------------------------------------------------------ 7470014 KIT 2 467146 WASHER-FRT WHL SPINDLE 2

26022784 KIT-AXLE ASM-RH* AS REQUIRED 26018515 KIT-AXLE ASM-LH* -

26018516 KIT-AXLE ASM-RH* AS REQUIRED 26018517 KIT-AXLE ASM-LH* -

26018518 KIT-AXLE ASM-RH* AS REQUIRED 26018524 KIT-AXLE ASM-LH* -

FLUID 12345881 AUTO TRANSAXLE FLUID DEXTRON II-E 1 QUART

SERVICE PROCEDURES

REFER TO SECTION 3C AND 4D OF THE 1994 SERVICE MANUAL.

DEALERS ARE TO REPLACE BOTH LH AND RH COMPLETE DRIVE AXLE ASSEMBLIES INCLUDING CONSTANT VELOCITY (CV) JOINTS, BOTH LH AND RH BEARING/HUB ASSEMBLIES, AND BOTH LH AND RH SPINDLE NUTS AND WASHERS.

IMPORTANT

THE NEW SPINDLE NUT IS TO BE TIGHTENED TO 220NM (162 LBS. FT.). THIS IS LOWER THAN THE TORQUE SPECIFIED IN SECTION 4D OF THE SERVICE MANUAL. THE TORQUE LEVEL REQUIRED FOR THIS JOINT IS BEING EVALUATED AND A SERVICE MANUAL UPDATE BULLETIN WILL BE ISSUED WHEN A REVISED TORQUE IS DETERMINED.

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

DEALERS ARE TO HOLD WARRANTY CLAIMS UNTIL JUNE 7, 1994.

OR

SUBMIT A PRODUCT CAMPAIGN CLAIM WITH THE INFORMATION INDICATED BELOW: ** * REPAIR PC FAILED PARTS LABOR LAB OTH NET PERFORMED PART NO. ALLOW CC-FC OP HRS HRS AMT ---------------------------------------------------------------------------- 7 7470014 SK-00 V9050 2.3 0.1

*CAMPAIGN ADMINISTRATIVE ALLOWANCE.

**THE "PARTS ALLOWANCE" SHOULD BE THE SUM TOTAL OF THE CURRENT GMSPO DEALER NET PRICE PLUS 40% OF ALL PARTS REQUIRED FOR THE REPAIR.

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.

DEAR CHEVROLET CAVALIER OWNER:

THIS NOTICE IS SENT TO YOU IN ACCORDANCE WITH THE REQUIREMENTS OF THE NATIONAL TRAFFIC AND MOTOR VEHICLE SAFETY ACT.

REASON FOR RECALL

GENERAL MOTORS HAS DETERMINED THAT A DEFECT WHICH RELATES TO MOTOR VEHICLE SAFETY EXISTS IN CERTAIN 1994 CHEVROLET CAVALIERS. SOME OF THESE VEHICLES MAY HAVE BEEN BUILT WITH OVER-TORQUED DRIVE AXLE SPINDLE NUTS. THIS CONDITION COULD CAUSE EXCESSIVE LOADS ON THE SPINDLE NUT AND DRIVE AXLE, AND COULD RESULT IN FAILURE OF THE DRIVE AXLE OR THE SPINDLE NUT. EITHER OF THESE FAILURES COULD RESULT IN SEPARATION OF THE STEERING KNUCKLE/BEARING-HUB/TIRE-WHEEL ASSEMBLY FROM THE DRIVE AXLE. IF THIS WERE TO OCCUR WHILE THE VEHICLE WAS IN MOTION, STEERING CONTROL WOULD BE REDUCED AND A VEHICLE CRASH COULD OCCUR WITHOUT PRIOR WARNING.

WHAT WE WILL DO

TO PREVENT THIS CONDITION FROM OCCURRING, DEALERS ARE TO REPLACE LH AND RH DRIVE AXLES, BEARING=HUB ASSEMBLIES, SPINDLE NUTS, AND WASHERS ON ALL INVOLVED VEHICLES.

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. INSTRUCTIONS FOR MAKING THIS CORRECTION HAVE BEEN SENT TO YOUR DEALER AND PARTS ARE CURRENTLY AVAILABLE. THE LABOR TIME NECESSARY TO PERFORM THIS SERVICE IS APPROXIMATELY THREE (3) HOURS. PLEASE ASK YOUR DEALER IF YOU WISH TO KNOW HOW MUCH ADDITIONAL TIME WILL BE NECESSARY TO SCHEDULE AND PROCESS YOUR VEHICLE.

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 WITH 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 CORRECTIONS 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 PRODUCT.

CHEVROLET MOTOR DIVISION GENERAL MOTOR 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.