Product Safety - Bendix Air Brake ABS Unwanted Activation - Release of Final Phase and Revised VIN Breakpoints

This Campaign Bulletin is being updated to revise the beginning VIN breakpoints as well as complete the final phase of this campaign. Please discard Campaign Bulletin Number 00076.

DUE TO THE AVAILABILITY OF PARTS, THIS CAMPAIGN IS BEING ADMINISTERED IN TWO PHASES. THE FIRST PHASE WAS RELEASED IN DECEMBER, 2000, AND CONSISTED OF SCHOOL BUS VEHICLES. THIS SECOND AND FINAL PHASE CONSISTS OF C AND T SERIES VEHICLES.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1998-2001 Chevrolet and GMC C Series, T Series, and School Bus chassis medium duty vehicles equipped with Bendix ABS air brakes (JE5). Some of these vehicles may have unwanted temporary ABS activation at low speeds. If this occurred when minimum stopping distance was required, it could result in a vehicle crash.

Dealers are to replace the air brake ECU module and inspect the wheel sensor cables and wire harnesses for proper routing.

Involved are certain 1998-2001 Chevrolet and GMC C Series, T Series, and School Bus chassis medium duty vehicles equipped with ABS air brakes (JE5) and built within these VIN breakpoints:

(The beginning VIN breakpoints have been revised for the 1998 model year. Refer to the table below for the new breakpoints. The revised breakpoints are in bold.)

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC Only) before beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

Important: Due to the small number of vehicles involved and due to limited initial parts availability, dealers are encouraged not to order campaign parts for use as shelf stock. Parts should only be ordered when a vehicle is brought in for service.

1. Disconnect the battery negative cable.

Figure 1 -- Typical Location




2. Disconnect the two wiring connectors from the electronic control unit (ECU). Refer to Figure 1.

•	On the C Series and School Bus chassis, the ECU is located on the left-hand radiator support

•	On the T Series, the ECU is located underneath the cab at the rear support.

3. Remove the four bolts retaining the ECU to the mounting plate.
4. Install the new ECU to the plate with the four bolts.

Tighten
Tighten the bolts to 11 N·m (98 lb in).

5. Connect the two wiring connectors to the ECU.
6. Beginning at the ABS speed sensor cables at the ECU module, trace the wires to each front wheel and verify the following:

•	Verify that all connectors in line are fully engaged.

•	Verify that all secondary locks are engaged.

•	Verify that all speed sensor wires passing through any frame member are encased in conduit.

Figure 2





•	Verify that cables are secured to the front brake air lines and axles at 152 mm (6 in) intervals. Refer to Figure 2.

•	Verify that cables have a minimum clearance of 38 mm (1.5 in) from all moving parts. Secure all cables that exhibit the minimum clearance of 38 mm (1.5 in). Wind, snow, and other road hazards can exert force on the wires and decrease the clearance if not properly secured.

7. Ensure that the wheel speed sensor wires are secured against the rear brake slack adjuster shafts with two tie wraps and with one tie wrap at the front brake slack adjuster shafts.
8. Beginning in the engine compartment, trace the rear wheel speed sensor cables to the wheel hubs and verify the following:

•	Verify that the cables are secured to the frame at 305 mm (12 in) intervals.

•	Verify that the cables are routed to avoid sharp edges, heat sources, and moving or rotating parts.

•	Verify that all cables passing through any frame member are encased in conduit.

•	On shorter wheelbase vehicles, verify that any additional length of cable tied up underneath the vehicle is well secured with several tie straps.

Figure 3





•	On vehicles with limited clearance between the rotating brake drum and the sensor wires, secure the sensor wires to the axle end to eliminate the free motion of the sensor wires. Refer to Figure 3.

•	Verify that all connectors in line are fully engaged.

•	Verify that all secondary locks are engaged.

•	Verify all wires exiting connectors are allowed to come out straight for 75 mm (3 in) before bending, and that the wires are secured with a tie wrap at the 75 mm (3 in) point.

9. Install the GM Campaign Identification Label.

FOR US AND IPC

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. 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.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels for US dealers can be obtained from Dealer Support Material by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Additional Campaign Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

FOR CANADA

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. 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.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering.

Submit a Product Campaign Claim with the information indicated below:

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

FOR US AND CANADA

Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin).

FOR IPC

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached suggested dealer letter.

FOR US AND IPC (US States, Territories, and Possessions)

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty 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 customer 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 remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall campaign notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the campaign is not completed within a reasonable time.

FOR ALL

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 customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer 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.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1998-2001 Chevrolet and GMC C Series, T Series, and School Bus chassis medium duty vehicles equipped with Bendix ABS air brakes. Some of these vehicles may have unwanted temporary ABS activation at low speeds. If this occurred when minimum stopping distance was required, it could result in a vehicle crash.

Your dealer will replace the air brake electronic control unit module and inspect the wheel sensor cables and wire harnesses for the proper routing. This service will be performed for you at no charge .

Please contact us as soon as possible to arrange a service date.

We sincerely regret any inconvenience this causes you; however, we have taken this action in the interest of your continued satisfaction with our products.

GMODC

General Motors Corporation

00076

Dear General Motors Customer:

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

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1998-2001 Chevrolet and GMC C Series, T Series, and School Bus chassis medium duty vehicles equipped with Bendix ABS air brakes. Some of these vehicles may have unwanted temporary ABS activation at low speeds. If this occurred when minimum stopping distance was required, it could result in a vehicle crash.

Your dealer will replace the air brake electronic control unit module and inspect the wheel sensor cables and wire harnesses for the proper routing. This service will be performed for you at no charge .

The length of time required to perform this inspection and service correction is approximately 40 minutes. Additional time may be required to schedule and process your vehicle. If you dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed to schedule, process and repair your vehicle.

Please contact your dealer as soon as possible to arrange a service date. Parts are available and instructions for making this correction have been sent to your dealer.

Your dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the number listed below:

If, after contacting the appropriate customer assistance center, 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 SW, Washington, DC 20590 or call 1-888-327-4236.

The attached customer 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 no longer own this vehicle, please let us know by completing the attached and mailing it in the postage paid envelope.

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 Corporation

Enclosure