CAMPAIGN:LOWER CONTROL ARM CRACKING
Subject: PRODUCT SAFETY CAMPAIGN 93-C-51 - LOWER CONTROL ARM CRACKING
Model and Year: 1992-93 G30 VANS WITH 9200 LB. GVWR
To: All Chevrolet/Geo 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 1992-93 Chevrolet G30 vans with 9200 lb. GVWR (Gross Vehicle Weight Rating - RPO C6W). These vehicles may exhibit lower control arm cracking during the life of the vehicle. If the vehicle usage is predominately at or near the rated GVW, either of the lower control arms could eventually develop a crack in the flange on the end of the control arm near the ball joint pad. With continued use, the ball joint could separate from the control arm resulting in loss of steering control.
If this condition occurs, 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 on each of the front lower control arms.
VEHICLES INVOLVED
Involved are certain 1992-93 Chevrolet G30 vans with 9200 lb. GVWR and built within the following VIN breakpoints:
PLANT YEAR MODEL PLANT CODE FROM THROUGH --------------------------------------------------------------- 1992 G30 Van Scarborough "4" N4126718 N4168759 1993 G30 Van Scarborough "4" P4100082 P4144127 1993 G30 Van Flint "F" PF304142 PF352046
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
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 ----------- ----------- --------- 15991641 Lower Control Arm Reinforcement Kit 1 09766424 Ball Joint As Required 112546009 Lower Control Arm - LH As Required 112546010 Lower Control Arm - RH As Required
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 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 - Figures Referenced Are Located On Pages 5 & 6.
INITIAL POSITIONING OF REINFORCEMENT
1. Raise front of vehicle and support it with suitable safety stands.
2. Clean left and right lower control arms of dirt, rust, grease and undercoating from the spring pocket outboard to the flange surrounding the ball joint. Clean both top and bottom areas of control arms. This will insure good mechanical contact of the reinforcement and U-bolt to the control arm and ball joint flange. Use appropriate solvents and/or a wire brush as required. If control arms and reinforcement are not thoroughly cleaned, the U-bolt may "walk off" the bottom of the ball joint when it is tightened.
3. Center reinforcement between flanges (Figure 1). The technician may want to do one side at a time. Gaps A & B (Figure 1) are to be equal to within 0.060 inch (1.5 mm) Secure reinforcement with a "C" clamp (Figure 2).
NOTICE: Reinforcement is installed CORRECTLY when ball joint makes full contact with reinforcement radius (Figure 1, Item 2) not just in center section of reinforcement.
Reinforcement is designed to fit ball joints with a bottom diameter of 2.60 inches (66 mm) or greater. Technician may find that ball joint does not make full contact with radius of reinforcement when reinforcement is centered correctly between flanges.
It may be possible that an after market 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 the radius of the reinforcement. When this condition happens, only a small section of the ball joint will come in contact with the reinforcement. If this occurs, make certain ball joint is clean as described in step 1 and measure bottom diameter of ball joint with a caliper. If measurement is LESS THAN 2.60 INCHES (66 MM) the ball joint must be replaced with a GM ball joint.
If an after market lower control arm has been installed, it will be necessary to remove the aftermarket control arm, install a GM designed control arm and perform the installation of the reinforcement per the campaign service procedure.
4. Install U-bolt (Figures 1 & 3) and torque nuts to approximately 10 Nm (7 lb. Ft.).
IMPORTANT: This step must be performed before proceeding to step 5.
NOTICE: 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. If this happens, locate and mark area where U-bolt comes in contact with control arm. You may remove only enough material (LIGHTLY grind) (Figure 2A) from OUTER radius of U-bolt to allow clearance between U-bolt and control arm (Figure 2, Item 7).
5. Drill a center hole with a 3/8 inch (9.5 mm) drill. Reinforcement has been designed to be used as a template. When drilling keep drill as perpendicular as possible.
6. Install a 3/8-16 bolt (Figure 2, Item 6), nut (Figure 2, Item 3) and washer (Figure 2, Item 2) in center hole and torque to approximately 18 Nm (13 lb. ft.).
7. Remove "C" Clamp.
8. Drill remaining holes in sequence.
9. Disassemble reinforcement (Figure 2, Item 1) and U-bolt (Figure 2, Item 7) from control arm and remove all chips and burs from lower control arm and reinforcement.
INSTALLATION OF REINFORCEMENT
1. Reinstall reinforcement (Figure 3, Item 1) and U-bolt (Figure 3, Item 7). Hand start all bolts and nuts. Tighten U-bolt nuts (Figure 3, Item 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 interferes with bump stop bracket, install bolt from bottom of control arm.
2. Torque 3/8-16 bolts (Figure 3) to 37-43 Nm (27-32 lb. ft.) Torque center bolt first and remainder in any sequence.
3. Torque U-bolt nuts (Figure 3) to 40-46 Nm (30-34 lb. ft.).
4. Continue to other side of vehicle and follow steps 1-3 above for that lower control arm.
5. Once both lower control arm reinforcements have been installed and torqued, lower vehicle.
6. 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 LABOR LABOR OTHER REPAIR PERFORMED PC PART NO. ALLOW CC-FC OP HOURS HOURS -------------------------------------------------------------------------- Install Reinforcement Kit & Measure Left And Right 1 15991641 ** SK-00 V9020 1.4 0.1 Side Ball Joints
Install One Ball Joint Install Reinforcement Kit 2 09766424 ** SK-00 V9021 2.4 0.1
Install Two Ball Joints & Install Reinforcement Kit 3 09766424 ** SK-00 V9022 3.1 0.1
Replace One Control Arm 1 12546009 ** SK-00 V9023 1.1 0.1
Replace Both Control Arms 2 12546009 ** SK-00 V9024 2.0 0.1
* 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 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 a defect which relates to motor vehicle safety exists in certain 1992-93 Chevrolet G30 vans with 9200 lb. GVWR (Gross Vehicle Weight Rating - RPO C6W) . These vehicles may exhibit lower control arm cracking during the life of the vehicle. If the vehicle usage is predominately at or near the rated GVW, either of the lower control arms could eventually develop a crack in the flange on the end of the control arm near the ball joint pad. With continued use, the ball joint could separate from the control arm resulting in loss of steering control.
If this condition occurs, 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, your dealer will install a reinforcement brace on each of the front lower control arms. 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 may take up to 3 hours. 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
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.
