CAMPAIGN: EXCESSIVE BRK. PEDAL TRAVEL (VACUUM PWR. BRK. SYS.)
SUBJECT: PRODUCT SAFETY CAMPAIGN 92C25 - EXCESSIVE BRAKE PEDAL TRAVEL
MODEL and YEAR: 1992 G-VANS WITH VACUUM POWER BRAKE SYSTEMS (JB5 OR JB7) BUILT AT SCARBOROUGH ASSEMBLY PLANT
To: Select 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 certain 1992 G-Vans built at the Scarborough Assembly Plant and equipped with vacuum power brake systems (RPO's JB5 or JB7) have an incorrect brake pedal assembly. This incorrect brake pedal assembly has a pushrod pin that is both too small and installed in the incorrect location relative to the brake pedal pivot. The incorrect location of the pushrod pin causes an increased brake pedal ratio that results in a decreased master cylinder stroke. Although a vehicle with a decreased master cylinder stroke will meet the full system stopping requirements of Federal Motor Vehicle Safety Standard (FMVSS) 105, "Hydraulic Brake Systems", it will not meet the partial system failure requirements. A further reduction of braking ability at a time when partial system failure has occurred could result in a vehicle crash without prior warning.
To correct this condition, dealers are to inspect for an incorrect brake pedal assembly and, if necessary, replace the brake pedal assembly.
VEHICLES INVOLVED
Involved are certain 1992 G-Vans built at the Scarborough Assembly Plant and equipped with vacuum power brake systems (RPO's JB5 or JB7) and built within the following VIN breakpoints: PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ----- ---- ------- 1992 G-Van Scarborough "4" N4135677 N4136277
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 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 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 an advise code (2). Quantity/ Part Number Description Vehicle ----------- ----------- --------- 15641698 Brake Pedal Assembly 1
DUE TO THE SMALL VEHICLE POPULATION (217 VEHICLES) AND THE SMALL NUMBER OF VEHICLES ESTIMATED TO REQUIRE BRAKE PEDAL ASSEMBLY REPLACEMENT (10%), DEALERS ARE NOT TO ORDER BRAKE PEDAL ASSEMBLIES FOR USE AS SHELF STOCK. ONLY ORDER A REPLACEMENT BRAKE PEDAL ASSEMBLY AFTER INSPECTION (SEE BELOW) HAS VERIFIED THAT AN INVOLVED VEHICLE REQUIRES CAMPAIGN REPAIR.
SERVICE PROCEDURE - Figures referenced are located on pages 4 and 5.
Inspection
Inspect left side of brake pedal assembly to verify stamping number (Figure 1) . If the number 698 is stamped into the brake pedal assembly, no further action is required. Install "Campaign Identification Label" and return vehicle to owner or dealer stock.
If the number 698 is not stamped into the brake pedal assembly, it will be necessary to replace the brake pedal assembly with the correct brake pedal assembly following the "Brake Pedal Replacement" procedure which follows.
Brake Pedal Replacement
Stoplamp Switch Removal
1. Disconnect negative battery cable.
2. Remove lower steering column trim panel.
3. Disconnect electrical connectors from stoplamp switch (Figure 2).
4. Remove stoplamp switch from retainer.
Bracket And Brake Pedal Assembly Removal
Notice: Brake pedal bracket assembly and brake pedal assembly must be removed as a complete assembly.
1. Remove retainer, two washers and pushrod from brake pedal pivot pin (Figure 1).
2. Remove capsule nuts from steering column brace and let steering column rest on seat (Figure 3).
3. Remove relay from left side of brake pedal bracket.
4. Remove 4 nuts from vacuum booster studs (Figure 4).
5. Remove 2 bolts from dash crossmember (Figure 4).
6. Carefully remove brake pedal bracket assembly.
7. Remove brake pedal retaining pivot bolt from brake pedal bracket assembly and remove pedal.
8. Remove existing thread locking compound from pivot bolt threads.
9. Coat pivot bolt threads with Medium Strength Thread Locking Compound (P/N 12345382 or equivalent).
10. Install new brake pedal assembly into bracket assembly and torque retaining pivot bolt to 40-55 Nm (30-41 lb. ft.).
11. Reinstall brake pedal bracket assembly onto vacuum booster studs.
12. Reinstall 4 nuts removed in step 4 and torque to 29 Nm (21 lb. ft.).
13. Reinstall 2 bolts removed in step 5 into dash crossmember and torque bolts to 12 Nm (16 lb. ft.).
14. Reinstall 2 washers and pushrod removed in step 1 to brake pedal pivot pin (Figure 1).
15. Reinstall retainer into pivot pin (Figure 1).
16. Reinstall stoplamp switch into retainer on brake pedal bracket (Figure 1).
17. Connect stoplamp switch connectors to stoplamp switch.
18. Adjust stoplamp switch using the following procedure:
A. Apply brake pedal and press switch until it firmly seats in the retainer.
Notice: "Clicks" will be heard as threaded portion of switch is pushed through the retainer.
B. Pull brake pedal against pedal stop until "clicks" are no longer heard.
Notice: Electrical contact should be made when brake pedal is applied 11-24 mm (0.45-0.95 in.) from fully released position.
19. 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. 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 CC-FC LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS ---------------- -- -------- ----- ----- ----- --- ---- Inspect Brake Pedal - No Further Action -- - - - - SK-00 V7590 0.2 0.1 Required
Inspect & Replace 1 15641698 ** SK-00 V7591 1.0 0.1 Brake Pedal
* 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.
COPY OF LETTER TO OWNERS
(Notification Used By Chevrolet Motor Division)
September 25, 1992
Dear 1992 Chevrolet G-Van 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 certain 1992 G-Vans built at the Scarborough Assembly Plant and equipped with vacuum power brake systems have an incorrect brake pedal assembly. This incorrect brake pedal assembly has a pushrod pin that is both too small and installed in the incorrect location relative to the brake pedal pivot. The incorrect location of the pushrod pin causes an increased brake pedal ratio that results in a decreased master cylinder stroke. Although a vehicle with a decreased master cylinder stroke will meet the full system stopping requirements of Federal Motor Vehicle Safety Standard (FMVSS) 105, "Hydraulic Brake Systems", it will not meet the partial system failure requirements. A further reduction of braking ability at a time when partial system failure has occurred could result in a vehicle crash without prior warning.
WHAT WE WILL DO
To correct this condition, your dealer will inspect your vehicle for an incorrect brake pedal assembly and, if necessary, replace the brake pedal assembly. 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 inspection/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 inspection/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.
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.
