CAMPAIGN: OMITTED WELDS FRONT SUSPENSION LOWER CONTROL ARM
Dear Chevrolet Dealer:
Attached is Product Safety Campaign 95-C-22 which addresses control arm quality on 1995 Cavalier models. This letter is being included with the bulletin to inform all Chevrolet dealers of some additional services included in this campaign and of some special parts return procedures.
When the campaign service procedure is completed, each owner's vehicle should be filled with fuel and washed. These services should be clearly noted on the repair order and marked "NO CHARGE". This should then be presented to the owner as a gesture of appreciation from the dealership for their cooperation and inconvenience. This service can be charged as part of the campaign expense by using the labor operations shown in the claim table.
IMPORTANT:
Control Arms In Dealer Stock:
Dealers are advised to inspect all right and left control arms (part numbers 22637806-7) in their parts inventory for missing welds or suspect rivets, and to return any defective dealer stock to GMSPO under the "New Defective" return policy for credit.
Dealers should submit an "Application to Return to Servicing PDC" (PC659) and indicate:
Type Of Return: Check The "Defective" Box Comments Column: Enter "missing welds" or "suspect rivets" and "Campaign 95-C-22"
Control Arms Removed From Vehicles:
Also, as part of this campaign, dealers are requested to return all control arms found on vehicles with missing welds or suspect rivets to:
J.R. AULERICH VEHICLE ENGINEERING - CHASSIS LANSING AUTOMOTIVE DIVISION GENERAL MOTORS DIVISION 920 TOWNSEND AVENUE MS 6615 LANSING, MI 48921-6615
Dealers should enter a claim type "F" for credit of shipping expense to return defective control arms removed from involved units.
Thank you in advance for your cooperation in this matter.
R. F. Sobrero General Sales And Service Manager
Subject: PRODUCT SAFETY CAMPAIGN 95-C-22 - OMITTED WELDS - FRONT SUSPENSION LOWER CONTROL ARM
Model and Year: 1995 CAVALIER
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 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 1995 Chevrolet Cavalier models. Some of these vehicles may have been built with some welds omitted from the front suspension lower control arm assemblies. This condition could cause excessive loads on existing control arm welds and could result in separation of the front bushing-sleeve subassembly from the control arm. Separation of the front bushing- sleeve assembly from the control arm may result in reduced steering control. If this were to occur while the vehicle was in motion, a vehicle crash could occur without prior warning.
To prevent this condition from occurring, dealers are to inspect both LH and RH front suspension lower control arm assemblies and replace all control arm assemblies found with omitted welds.
VEHICLES INVOLVED
Involved are certain 1995 Chevrolet Cavaliers built within the following VIN breakpoints:
PLANT YEAR MODEL PLANT CODE FROM THROUGH --------------------------------------------------------------- 1995 J-Car Lordstown "7" S7100008 S7117124 1995 J-Car Ramos Arizpe "S" SS800040 SS812990
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.
PARTS INFORMATION
NOTICE
DEALERS ARE TO INSPECT ALL CONTROL ARM ASSEMBLY PIN'S 22637806-7 IN THEIR PARTS INVENTORY FOR ANY MISSING WELDS AND SUSPECT RIVETS (SEE ILLUSTRATION AND STEP 13 OF THE SERVICE PROCEDURE) . ANY OF THESE PARTS FOUND IN STOCK WITH MISSING WELDS OR SUSPECT RIVETS SHOULD BE RETURNED TO GMSPO UNDER PROVISIONS OF THE "NEW-DEFECTIVE" PARTS RETURN POLICY FOR CREDIT.
DEALERS SHOULD SUBMIT AN "APPLICATION TO RETURN TO SERVICING PDC" (PC659) AND INDICATE:
o TYPE OF RETURN: CHECK THE "DEFECTIVE" BOX
o COMMENTS COLUMN: ENTER "MISSING WELDS" OR "SUSPECT RIVETS" AND "CAMPAIGN 95-C-22"
NOTICE: ESTIMATES INDICATE THAT A VERY SMALL NUMBER OF CONTROL ARM ASSEMBLIES WILL REQUIRE REPLACEMENT (APPROXIMATELY 1%). AS A RESULT OF THIS ESTIMATE, GMSPO 1S NOT INCREASING INVENTORY LEVELS OF THESE CONTROL ARM ASSEMBLIES, AND AVAILABILITY WILL BE A EXTREMELY LIMITED.
DEALERS SHOULD NOT ATTEMPT TO STOCK ADDITIONAL PARTS FOR THIS CAMPAIGN. EXCESSIVE DEALERS STOCKING OF CONTROL ARM ASSEMBLIES COULD LEAD TO UNNECESSARY PARTS SHORTAGES AND CUSTOMER INCONVENIENCE.
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).
As Part Number Description Required ------------------------------------------------------------ 22649351 Front Suspension Lower Control Arm 1 Assembly - RH 22649352 Front Suspension Lower Control Arm 1 Assembly - LH 12337997 Cotter Pin 2
RETURN ALL CONTROL ARM ASSEMBLIES FOUND ON VEHICLES WITH MISSING WELDS AND/OR SUSPECT RIVETS TO:
J.R. AULERICH VEHICLE ENGINEERING - CHASSIS LANSING AUTOMOTIVE DIVISION GENERAL MOTORS DIVISION 920 TOWNSEND AVENUE MS 6615 LANSING, MI 48921-6615
OWNER NOTIFICATION
Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division via both telephone contact and the customary letter of notification (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.
SERVICE PROCEDURE
1. Raise vehicle on frame type hoist. See section OA of appropriate service manual.
2. Remove lower bolt from right engine strut and loosen upper bolt. Move strut to gain access to right front control arm bolt.
3. Remove suspension support brace (two bolts) to gain access to left front control arm bolt.
4. Remove front tire & wheel assembly.
5. Unclip antilock brake system speed sensor harness from control arm at two locations on front edge of control arm.
6. Disconnect lower suspension ball joint from steering knuckle using tool J-28892.
7. Remove front stabilizer bar link.
8. Remove lower control arm front attaching bolt (horizontal).
9. Loosen lower control arm rear fastener (vertical). Do not remove bolt.
10. Pull front of lower control arm assembly outward and clear of the suspension support pocket.
11. Clean control arm to assure accurate inspection of all weld positions.
12. Inspect the ball joint attachment to the control arm to verify that all three (3) rivets are fully seated.
13. Carefully inspect the control arm for the presence of all twenty (20) welds (see illustration). Welds fill slots shown as XXX on illustration.
On the left (driver's) side, seventeen (17) of the welds will be located on the underside of the control arm assembly, with three (3) of the welds located on the top side of the control arm.
On the right (passenger's) side, seventeen (17) of the welds will be located on the top of the control arm assembly, with three (3) of the welds located on the bottom side of the control arm.
IMPORTANT: --------- The welds that attach the front bushing sleeve to the control arm must be very carefully inspected for presence on all three sides (welds right 5, 6 and 7, or left 8, 9 and 10) See Illustrations.
14. If any welds are missing, or if any ball joint rivets are not fully seated, the control arm assembly must be replaced following the procedure in Section 3C of the 1995 Service Manual with the following torque values:
Control Arm Front Fastener 120 Nm (89 lb. ft.) + 1/2 Turn Control Arm Rear Fastener 170 Nm (125 lb. ft.) Ball Joint To Knuckle 60 Nm (44 lb. ft.) - (Align Cotter Pin Holes By Tightening Only) Stabilizer Link 17 Nm (13 lb. ft.)
15. Re-attach ABS harness to control arms at two (2) locations.
16. Install wheel & tire assembly. Torque wheel nuts to 125 Nm (92 lb. Ft.) using torque stick J39544-15.
17. Repeat steps 4 through 15 for the opposite side of the vehicle.
18. Reinstall suspension support brace. Tighten bolts to 66 Nm (48 lb. Ft.).
19. Reinstall lower attaching bolt to engine strut. Tighten bolts to 120 Nm (89 lb. Ft.)
20. Lower Vehicle.
21. Set vehicle toe-in to 0.1 degree total tow-in (0.1 degree sum toe), making sure steering wheel is correctly set to straight ahead position.
22. Install Campaign Identification Label.
23. Wash vehicle and fill fuel tank before returning to owner.
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 LABOR LABOR OTHER NET REPAIR PERFORMED PC PART NO. ALLOW CC-FC OP HOURS HOURS AMOUNT ---------------------------------------------------------------------------- Inspect LH And RH Control Arm 2 12337997 ** SK-00 V9535 1.6 0.1 - - Assemblies. Set Vehicle Toe-in. Inspect LH And RH Control Arm Assemblies. 3 22649351 ** SK-00 V9536 1.7 0.1 - - Replace 1 Control Arm Assembly. Set Vehicle Toe-in. Inspect LH And RH Control Arm Assemblies. Replace Both 4 22649351 ** SK-00 V9537 1.7 0.1 - - Control Arm Assemblies. Set Vehicle Toe-in. Fuel Top Off - - - -- SP-95 T2010 - - - - & Wash Vehicle - - - -- SP-95 T2011 - - - - && Alternate - - - -- SP-95 T2012 - - - - @ Transportation
* 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.
& The amount to be entered in the "Net Amount" column for labor operation T2010 should represent the cost of fuel required to fill the vehicle's tank for a customer. Note that the amount submitted is limited to the current allowance for P.D.I. fueling of these vehicle, or a maximum of 11.2 gallons at $1.10 per gallon.
&& The amount to be entered in the "Net Amount" column for labor operation T2011 should represent the cost of washing the owner's vehicle up to $6.00.
@ The amount to be entered in the "Net Amount" column for labor operation T2012 should represent the cost of alternate transportation following guidelines previously provided.
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 THIS RECALL
General Motors has determined that a defect which relates to motor vehicle safety exists in certain 1995 Chevrolet Cavalier models. Some of these vehicles may have been built with some welds omitted from the front suspension lower control arm assemblies. This condition could cause excessive loads on existing control arm welds and could result in separation of the front bushing-sleeve subassembly from the control arm. Separation of the front bushing-sleeve assembly from the control arm may result in reduced steering control. If this were to occur while the vehicle was in motion, a vehicle crash could occur without prior warning.
WHAT WE WILL DO
To prevent this condition from occurring, your dealer will inspect both right and left front suspension lower control arm assemblies and replace all control arm assemblies found with omitted welds. 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. 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.
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.
Your Chevrolet dealer is best equipped to 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).
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.
