CAMPAIGN: EXCESSIVE BRK. PEDAL TRAVEL (VACUUM PWR. BRK. SYS.)
SUBJECT: EXCESSIVE BRAKE PEDAL TRAVEL
MODELS: 1992 GMC and Chevrolet G-Vans with vacuum power brake systems (JB5 or JB7) built at Scarborough Assembly Plant.
TO: ALL GENERAL MOTORS DEALERS
General Motors of Canada Limited has determined that certain 1992 GMC and Chevrolet 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 push rod 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 Canada Motor Vehicle Safety Standard (CMVSS) 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 the following 1992 GMC and Chevrolet G-Vans built at the Scarborough Assembly Plant and equipped with vacuum power brake systems (RPO's JB5 or JB7):
2GDEG25KXN4517044 2GTEG25H3N4516777
2GDEG25K0N4516890 2GTEG25H5N4516764
2GDEG25K2N4517006 2GTGG35K3N4516840
2GDEG25K3N4516771 2GTGG35K8N4517109
2GDEG25K3N4516821 2GCEG25H6N4135747
2GJGG39K4N4516946 2GCGG35K3N4135862
2GJGG39K5N4517037 2GCGG35K6N4135919
2GKEG25K2N4517192 2GNGG35K0N4135745
2GTEG25HXN4517036
All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.
DEALER CAMPAIGN RESPONSIBILITY:
All unsold new vehicles in dealer's 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 perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, age of vehicle, or ownership, from this time forward.
Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service, you are to ensure the campaign correction has been made before selling or releasing the vehicle.
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 taken into your new or used 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.
CAMPAIGN PROCEDURE:
Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.
OWNER NOTIFICATION:
All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors. The listings provided are for campaign activity only and should not be used for any other purpose.
PARTS INFORMATION:
Parts required to complete this campaign should be ordered through regular channels, as follows:
Part Number Description Quantity/Vehicle
15641698 Brake Pedal Assembly 1
DUE TO THE SMALL VEHICLE POPULATION (17 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.
PARTS AND LABOUR CLAIM INFORMATION:
Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:
Repair Code Description Time Allowance
1A Inspect Brake Pedal - No Further Action Required .3 2A Inspect & Replace Brake Pedal 1.1
Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 30% to cover parts handling.
SERVICE PROCEDURE:
Inspection Procedure
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 the 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.
INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL
Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.
General Motors of Canada bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer." They are written to inform these 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 your General Motors dealer for information on whether your vehicle may benefit from the information.
Dear General Motors Customer:
General Motors of Canada Limited has determined that certain 1992 GMC and Chevrolet 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 push rod 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 Canada Motor Vehicle Safety Standard (CMVSS) 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, your dealer will inspect your vehicle for an incorrect brake pedal assembly and, if necessary, replace the brake pedal assembly.
This service will be provided for you at no charge.
Please contact your GM dealer as soon as possible to arrange a service date.
If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.
This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.
Customer Support Department General Motors of Canada Limited
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.
