LH LOWER CONTROL ARM CRACKING (INSTALL REINFORCEMENT)
Subject: PRODUCT SAFETY CAMPAIGN 86C25(e)-LH LOWER CONTROL ARM CRACKING
-- REISSUE --
Model and Year: 1985-86 C30, G30 AND P30 TRUCKS (SEE "VEHICLES INVOLVED" SECTION FOR SPECIFIC MODEL AND RPO INVOLVEMENT DETAILS)
To: All Chevrolet Dealers
# THIS BULLETIN CANCELS AND SUPERSEDES CAMPAIGN BULLETIN 86C25(d) ISSUED JANUARY, 1992. THE SERVICE PROCEDURE AND CLAIM INFORMATION SECTIONS HAVE BEEN REVISED. ALL COPIES OF BULLETIN 86C25(d) SHOULD BE DESTROYED. REVISED INFORMATION IS SHOWN IN BOLD TYPE AND DENOTED WITH AN #.
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 was 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. I f 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 1985-86 P30 commercial model trucks with 350 gas or 6.2L diesel engines, 1985-86 G30 model vans with 350 gas or 6.2L diesel engines, and 1985-86 C30 model trucks built without heavy duty front suspensions. The left hand lower control arm can crack starting at the rear flange and progress to the ball joint mounting hole and eventually cause the lower ball joint to separate from the control arm. If this happens, a loss of vehicle steering control can occur which could result in a vehicle crash without prior warning.
To prevent this condition from occurring, dealers are to install a reinforcement brace to the left hand lower control arm.
VEHICLES INVOLVED
Involved are certain:
- 1985-86 P30 commercial model trucks with 350 gas (LT9) or 6.2L diesel (LL4) engines,
- 1985-86 G30 model vans with 350 gas (LT9) engines or 6.2L diesel (LL4) engines with or without school bus equipment (B3D) and without recreational vehicle chassis modification (9A2) or heavy duty front suspension (F42), and
- 1985-86 C30 model trucks built without heavy duty front suspensions (F42).
Following are the VIN breakpoints these vehicles were built within:
PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ----- ---- ------- 1985 C30 Janesville "J" FJ100040 FJ188396
1985 C30 Oshawa "1" F1100036 F1145169
1985 C30 Pontiac "V" FV100006 FV206417
1985 C30 St. Louis "S" FS100012 FS200260
1985 G30 Scarborough "4" F4100003 F4170037
1985 G30 Lordstown "7" F7100015 F7213033
1985 P30 Detroit "3" F3300019 F3347195
1986 C30 Janesville "J" GJ100007 GJ186078
1986 C30 St. Louis "S" GS100003 GS203037
1986 G30 Lordstown "7" G7100151 G7198163
1986 G30 Scarborough "4" G4100003 G4172866
1986 P30 Detroit "3" G3300003 G3334844
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 were furnished to involved dealers with the original campaign bulletin or supplements. 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 original campaign bulletin or supplements has no involved vehicles currently assigned.
OWNER NOTIFICATION
Owners have been 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 are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin.
In summary, whenever a vehicle subject to this campaign is enters your vehicle inventory, or it 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 an advise code (2).
NOTICE: Disregard instructions enclosed in kit P/N 15624685. Use procedures from "Service Procedure" portion of this bulletin instead.
Quantity/ Part Number Description Vehicle ----------- ----------- 15624685 Lower Control Arm Reinforcement Kit 1
09766424 Ball Joint If Required
# SERVICE PROCEDURE ------------------- FIGURES REFERENCED IN PROCEDURE ARE LOCATED ON PAGES 6 THROUGH 9.
NOTICE: Disregard instructions enclosed in kit P/N #15624685. Use procedures listed in this Service Procedure instead.
# PRELIMINARY INSPECTION OF THE CONTROL ARM
# 1. Raise left front of vehicle and support with suitable safety stands.
# 2. Inspect left hand lower control arm to determine if subject vehicle requires modification. Arms subject to kit installation will have a small radius of 0.1 inch (2.54 mm) at flange-to-nose transition (Figure 1) instead of the intended 1.0 inch (25.4 mm) nominal radius (Figure 2). All right hand lower control arms have proper radius and may be used for comparison.
NOTICE: Some 1985 and 1986 vehicles may have had their lower control arms replaced. If inspection of left hand lower control arm indicates 1.0 inch (25.4 mm) nominal radius as shown in Figure 2, control arm does NOT require reinforcement kit. If this is the case, install a Campaign Identification Label and submit a Product Campaign Claim for "Inspect Control Arm - No Action Required".
# INITIAL POSITIONING OF THE REINFORCEMENT
# 1. Clean left hand lower control arm of all dirt, rust, grease and undercoating from spring pocket outboard. Clean both top and bottom areas of the control arm. This will ensure good mechanical contact of reinforcement and U-bolt to control arm and ball joint flange. Use appropriate solvents and/or a wire brush as required.
Notice: If control arm and reinforcement are not thoroughly cleaned, the U-bolt may "walk" off the bottom of the ball joint when it is tightened.
# DENOTES CHANGE
# 2. Center reinforcement (Figure 3B, "1") between flanges. Gaps A & B shown in Figure 3B are to be equal within 0.060 inch (1. 5 mm) . Secure reinforcement with a 4", 5" or 6" C-clamp (Figure 3).
NOTICE: Reinforcement is designed to fit ball joints with a bottom diameter of 2.60 inches (66 mm) or greater, and is installed CORRECTLY when ball joint makes full contact with reinforcement radius (Figure 3B), not just center section of reinforcement.
Technicians may find that ball joint does not make full contact with radius of reinforcement when reinforcement is centered between flanges. In this event, it is possible that an aftermarket ball joint with a bottom diameter which is less than 2.60 inches (66 mm) has been installed. This does not allow for full contact with radius of reinforcement and, when this happens, only a small section of ball joint will be centered on reinforcement.
If this occurs, make certain ball joint is clean as described in Step 1 and then measure bottom diameter of ball joint with calipers. If measurement is LESS THAN 2.60 inches (66 mm), ball joint must be replaced with a Genuine GM ball joint.
# 3. Install U-Bolt (Figure 3, "7") and torque to approximately 10 Nm (7 lb. ft.).
NOTICE: THIS STEP MUST BE PERFORMED BEFORE PROCEEDING TO STEP 4.
When correctly installed, U-bolt will be about even with bottom of ball joint. U-bolt is NOT designed to fit into galley of control arm. On some vehicles U-bolt may contact flange edge of control arm and interfere with correct installation. In these cases you may remove only enough material (LIGHTLY grind) (Figure 3A) from outer radius of U-bolt to allow clearance between U-bolt and control arm (Figure 3, "7").
4. Drill center hole with 3/8 inch (9.5 mm) drill. Reinforcement (Figure 3, "1") has been designed to be used as a drill guide. Keep drill as perpendicular as possible when drilling.
5. Install one 3/8-16 bolt (Figure 3, "6"), nut (Figure 3, "3") and washer (Figure 3, "2") in center hole and torque to approximately 18 Nm (13 lb. ft.).
6. Remove "C" clamp.
7. Drill three remaining holes in any sequence.
# DENOTES CHANGE
# 8. Disassemble reinforcement (Figure 3, "1") and U-bolt (Figure 3, "7") from control arm and remove all chips or burrs from reinforcement.
INSTALLATION OF REINFORCEMENT
# 1. Reinstall reinforcement (Figure 4, "1") and U-bolt (Figure 4, "7"). Hand start all bolts. Tighten U-bolt nuts (Figure 4, "5") to approximately 22 Nm (16 lb. ft.). Make sure U-bolt is ALIGNED with bottom edge of ball joint and is NOT COCKED while continuing to torque.
NOTICE: If rear most bolt head flange interferes with bump stop bracket, install bolt from bottom of control arm.
# 2. Torque 3/8-16 bolts (Figure 4, "6") to 37-43 Nm (27-32 lb. ft.). Tighten center bolt first and remainder in any sequence.
# 3. Torque U-bolt nuts (Figure 4, "5") to 40-46 Nm (30-34 lb. ft.).
# 4. Lower vehicle.
5. 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 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.
# DENOTES CHANGE
# CLAIM INFORMATION ------------------- Submit a Product Campaign Claim with the information indicated below:
FAILED PARTS CC-FC LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW 0P HRS HRS
Inspect Lower Control Arm - No - -- -- SK-00 V4773 0.2 0.1 Action Required
Inspect, Measure Ball Joint, 1 15624685 SK-00 V4774 0.7 0.1 & Install Reinforcement Kit
Inspect - Replace Aftermarket Ball 2 09766424 SK-00 V4775 1.2 0.1 Joint & Install Reinforcement Kit
* Campaign Administrative Allowance.
** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% 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 Truck 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 1985-86 P30 commercial model trucks with 350 gas or 6.2L diesel engines, 1985-86 G30 model vans with 350 gas or 6.2L diesel engines and 1985-86 C30 model trucks built without heavy duty front suspensions. The left hand lower control arm can crack starting at the rear flange and progress to the ball joint mounting hole and eventually cause the lower ball joint to separate from the control arm. If this happens, a loss of vehicle steering control can occur which could result in a vehicle crash without prior warning.
WHAT WE WILL DO
To prevent this condition from occurring, dealers are to install a reinforcement brace to the left hand lower control arm. 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 available. The labor time necessary to perform this service correction is approximately one hour. Please ask your dealer if you wish to know how much additional time will be needed 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 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).
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 safety and continued satisfaction with our products.
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.
