CAMPAIGN:LOWER CONTROL ARM CRACKING
PRODUCT SAFETY CAMPAIGN 93-C-51(A) - LOWER CONTROL ARM CRACKING --- SUPPLEMENT --- 1992-93 G30 VANS WITH 9200 LB. GVWR
******** CANADIAN VERSION APPEARS BELOW THE U.S. VERSION ************
TO: ALL <DIVISION> DEALERS
THIS BULLETIN SUPPLEMENTS 93-C-51 ISSUED AUGUST, 1994. THE SERVICE PROCEDURE AND CLAIMS INFORMATION SECTIONS HAVE BEEN REVISED. SPECIFICALLY, AN INSPECTION HAS BEEN ADDED AND THE CORRESPONDING V-LABOR OPERATION. THE CORRECTED INFORMATION IS REPRINTED BELOW.
SERVICE PROCEDURE
INSPECTION PROCEDURE
1. INSPECT BOTH SIDES OF VEHICLE FOR NEW STYLE LOWER CONTROL ARMS THAT INCORPORATE A SUPPORT PLATE ON THE OUTSIDE OF THE ARM.
2. IF VEHICLE DOES NOT HAVE THE SUPPORT PLATE, IT REQUIRES THE REINFORCEMENT INSTALLATION, PROCEED TO THE INITIAL POSITIONING OF REINFORCEMENT SECTION OF THE SERVICE PROCEDURE.
3. IF VEHICLE DOES HAVE THE SUPPORT PLATE IT WILL NOT REQUIRE REINFORCEMENT INSTALLATION, INSTALL CAMPAIGN IDENTIFICATION LABEL.
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 SIDE BALL JOINTS 115991641 ** SK-00 V9020 1.40 0.1
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
INSPECT ONLY VEHICLE HAS NEW DESIGN CONTROL ARMS - SK-00 V9025 0.2 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.
---------------------------------------------------------------------- ORIGINAL CAMPAIGN
SUBJECT: LH AND RH LOWER CONTROL ARM CRACKING (INSTALL LOWER CONTROL ARM REINFORCEMENT KIT) MODELS: 1992 - 1993 G3 VANS WITH C6W (9200 LB. GVWR) ---------------------------------------------------------------------- SUBJECT: CAMPAIGN 93-C-51 THE SUBJECT SAFETY CAMPAIGN REQUIRES THAT A REINFORCEMENT KIT BE INSTALLED ON ALL INVOLVED UNITS. IT HAS COME TO OUR ATTENTION THAT SOME OF THESE INVOLVED UNITS WERE BUILT WITH A NEW DESIGN LOWER CONTROL ARM THAT HAS A SUPPORT PLATE ON THE OUTSIDE OF THE LOWER CONTROL ARM. WITH THIS NEW DESIGN IT IS NOT NECESSARY TO INSTALL THE REINFORCEMENT KIT. ANY VEHICLES FOUND WITH THIS TYPE OF CONTROL ARM SHOULD BE REPORTED USING THE FOLLOWING LABOR OPERATION NUMBER: LABOR OP DESCRIPTION TIME ALLOWANCE TROUBLE CODE V9025 INSPECT ONLY. NEW DESIGN CONTROL ARM 0.2 HRS 96 ADMINISTRATION ALLOWANCE: 0.1 HR ---------------------------------------------------------------------- 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 ADEQUATELY REPAIR WITHIN 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 APPOINTMENTS WITH OWNERS AND TO REPAIR THEIR VEHICLES AS SOON AS POSSIBLE. AS YOU WILL SEE IN READING THE ATTACHED COPY OF THE LETTER WHICH IS BEING SENT TO OWNERS, THE OWNER IS BEING INSTRUCTED TO CONTACT THE GMC TRUCK DIVISION CONSUMER RELATIONS OFFICE IF THE DEALER DOES NOT REMEDY THE CONDITION WITHIN FIVE DAYS OF THE MUTUALLY AGREED UPON SERVICE DATE. IF THE CONDITION IS NOT REMEDIED WITHIN A REASONABLE TIME, THEY ARE INSTRUCTED 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 G3 VANS WITH 9200 LB. GVWR. 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 G3 WITH C6W BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS: GMC VEHICLES: ============= MODEL PLANT FROM THROUGH G3 L05, C6W SCARBOROUGH SOP 1992 P4516232 G3 LL4/L19, C6W SCARBOROUGH SOP 1992 P4516546 G3 L05, C6W FLINT SOP 1993 PF520331 G3 LL4/L19, C6W FLINT SOP 1993 PF518321 CHEVROLET VEHICLES: =================== 1992 G3 SCARBOROUGH N4126718 N4168759 1993 G3 SCARBOROUGH P4100082 P4144127 1993 G3 FLINT PF304142 PF352046 THE SPECIFIC VEHICLES INVOLVED IN THIS CAMPAIGN HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER (VIN) COMPUTER LISTINGS. THESE LISTINGS ARE FURNISHED TO ALL INVOLVED DEALERS WITH THE CAMPAIGN. DEALERS SHOULD CONFIRM ELIGIBILITY THROUGH VISS (VEHICLE INFORMATION SERVICE SYSTEM) OR SERVICENET PRIOR TO BEGINNING CAMPAIGN REPAIRS. DEALER CAMPAIGN RESPONSIBILITY 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. DEALERS ARE TO INSPECT AND CORRECT ALL AFFECTED VEHICLES IN NEW AND USED VEHICLE STOCK PRIOR TO THEIR SALE. WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN IS TAKEN INTO YOUR NEW OR USED VEHICLE INVENTORY, OR IT IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, YOU SHOULD TAKE THE STEPS NECESSARY TO ENSURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE RESELLING 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. IF THE NAME AND ADDRESS OF THE OWNER OF AN INVOLVED VEHICLE WAS UNAVAILABLE TO GM DIVISION AT THE TIME OF CAMPAIGN INITIATION, THE DEALER MUST DETERMINE THE OWNER'S NAME AND ADDRESS FROM THE DEALERSHIP SALES RECORDS. PLEASE PROVIDE THIS INFORMATION DIRECTLY ON THE SECOND COPY OF THE LISTING NEXT TO THE APPLICABLE VIN SO THAT OUR RECORDS MAY BE UPDATED AND THE APPROPRIATE NOTIFICATION MAILED TO THE OWNER. THIS SECOND COPY SHOULD THEN BE SUBMITTED TO THE ADDRESS LISTED BELOW IN THE PREVIOUSLY SUPPLIED YELLOW CAMPAIGN ENVELOPES. GMC TRUCK DIVISION GENERAL MOTORS CORPORATION 101 UNION STREET PLYMOUTH, MICHIGAN 48170 OWNER NOTIFICATION OWNERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY GM DIVISION (SEE COPY OF OWNER LETTER INCLUDED WITH THIS BULLETIN). A LISTING OF OWNER NAMES AND ADDRESSES HAS BEEN FURNISHED TO THE INVOLVED DEALERS TO ENABLE DEALERS TO FOLLOW UP WITH OWNERS INVOLVED IN THIS CAMPAIGN. THIS LISTING 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 THIS CAMPAIGN. SERVICE PROCEDURE INITIAL POSITIONING OF THE REINFORCEMENT 1. RAISE THE FRONT OF VEHICLE AND SUPPORT IT WITH SUITABLE SAFETY STANDS. 2. CLEAN THE LEFT AND RIGHT LOWER CONTROL ARM OF ALL DIRT, RUST, GREASE, AND UNDERCOATING FROM THE SPRING POCKET OUTBOARD TO THE FLANGE SURROUNDING THE BALL JOINT. CLEAN BOTH THE TOP AND BOTTOM AREAS OF THE 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 THE CONTROL ARMS AND THE REINFORCEMENT ARE NOT THOROUGHLY CLEANED, THE U-BOLT MAY "WALK OFF" THE BOTTOM OF THE BALL JOINT WHEN IT IS TIGHTENED. 3. CENTER THE REINFORCEMENT (FIGURE 1) BETWEEN THE FLANGES. THE TECHNICIAN SHOULD DO ONE SIDE AT A TIME. GAPS A, B (FIGURE 1) ARE TO BE EQUAL WI THIN 0.060 INCH (1.5 MM). SECURE THE REINFORCEMENT WITH A "C" CLAMP (FIGURE 2). IMPORTANT: THE REINFORCEMENT IS INSTALLED CORRECTLY WHEN THE BALL JOINT MAKES FULL CONTACT WITH THE REINFORCEMENT RADIUS (FIGURE 1, ITEM 2), NOT JUST IN THE CENTER SECTION OF THE REINFORCEMENT. THE REINFORCEMENT IS DESIGNED TO FIT BALL JOINTS WITH A BOTTOM DIAMETER OF 2.60 INCHES (66 MM) OR GREATER. THE TECHNICIAN MAY FIND THAT THE BALL JOINT DOES NOT MAKE FULL CONTACT WITH THE RADIUS OF THE REINFORCEMENT WHEN THE REINFORCEMENT IS CENTERED CORRECTLY BETWEEN THE FLANGES. FURTHERMORE, IT MAY BE POSSIBLE THAT AN AFTER MARKET BALL JOINT WITH THE 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 THE BALL JOINT IS CLEAN AS DESCRIBED IN STEP 1. MEASURE THE BOTTOM DIAMETER OF THE BALL JOINT WITH A CALIPER. IF THE MEASUREMENT IS LESS THAN 2.6 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 THE 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, THE U-BOLT, WILL BE ABOUT EVEN WITH BOTTOM OF THE BALL JOINT. THE U-BOLT IS NOT DESIGNED TO FIT INTO THE GALLEY OF THE CONTROL ARM. ON SOME VEHICLES THE U-BOLT MAY CONTACT THE FLANGE EDGE OF THE CONTROL ARM AND INTERFERE WITH THE CORRECT INSTALLATION. IF THIS HAPPENS, LOCATE AND MARK THE AREA WHERE THE U-BOLT COMES IN CONTACT WITH THE CONTROL ARM. YOU MAY REMOVE ONLY ENOUGH MATERIAL (LIGHTLY GRIND) (FIGURE 2A) FROM THE OUTER RADIUS OF THE U-BOLT TO ALLOW CLEARANCE BETWEEN THE U-BOLT AND THE CONTROL ARM (FIGURE 2, ITEM 7). 5. DRILL A CENTER HOLE WITH A 3/8 INCH (9.5 MM) DRILL. THE REINFORCEMENT (FIGURE 2) HAS BEEN DESIGNED TO BE USED AS A DRILL TEMPLATE. WHEN DRILLING, KEEP THE 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 THE CENTER HOLE AND TORQUE TO APPROXIMATELY 18 NM (13 LB. FT.). 7. REMOVE "C" CLAMP. 8. DRILL THE REMAINING HOLES IN ANY SEQUENCE. 9. DISASSEMBLE THE REINFORCEMENT (FIGURE 2, ITEM 1) AND U-BOLT (FIGURE 2, ITEM 7) FROM THE CONTROL ARM AND REMOVE ALL OF THE CHIPS AND BURS FROM THE LOWER CONTROL ARM AND REINFORCEMENT. INSTALLATION OF REINFORCEMENT 1. REINSTALL THE REINFORCEMENT (FIGURE 3, ITEM 1) AND U-BOLT (FIGURE 3, ITEM 7). HAND START ALL OF THE BOLTS AND NUTS. TIGHTEN THE U-BOLT NUTS (FIGURE 3, ITEM 5) TO APPROXIMATELY 22 NM (16 LB. FT.)M MAKE SURE THE U-BOLT IS ALIGNED WITH THE BOTTOM EDGE OF THE BALL JOINT AND IS NOT COCKED WHILE CONTINUING TO TORQUE. NOTICE: IF THE REAR MOST BOLT HEAD INTERFERES WITH THE BUMP STOP BRACKET, INSTALL THE BOLT FROM THE BOTTOM OF THE CONTROL ARM. 2. TORQUE THE 3/8-16 BOLTS (FIGURE 3) TO 37 - 43 NM (27 - 32 LB. FT.). TORQUE THE CENTER BOLT FIRST AND THE REMAINDER IN ANY SEQUENCE. 3. TORQUE THE U-BOLT NUTS (FIGURE 3) TO 40 - 46 NM (30 -34 LB. FT.). 4. CONTINUE TO THE OTHER SIDE OF VEHICLE AND FOLLOW THE SAME PROCEDURES THAT HAVE BEEN LISTED ABOVE. 5. ONCE BOTH LOWER CONTROL ARM REINFORCEMENTS HAVE BEEN INSTALLED AND TORQUED LOWER THE VEHICLE. 6. INSTALL "CAMPAIGN IDENTIFICATION LABEL". PARTS INFORMATION PARTS ARE TO BE OBTAINED FROM GENERAL MOTORS SERVICE PARTS OPERATION (GMSPO). TO ENSURE THAT 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 ORDER UNDER AN ADVISE CODE (2). PART NUMBER DESCRIPTION QUANTITY 15991641 LOWER CONTROL ARM REINFORCEMENT KIT 1 9766424 BALL JOINT AS REQUIRED WARRANTY INFORMATION DEALERS SHOULD SUBMIT AN ACCURATELY FILLED OUT WARRANTY REPAIR ORDER ON EACH VEHICLE COMPLETED UNDER THIS CAMPAIGN. PROCESS REIMBURSEMENT: IF THE LOWER CONTROL ARM(S) OR BALL JOINTS HAVE BEEN REPLACED PRIOR TO THIS CAMPAIGN, SUBMIT AN ACCURATE WARRANTY REPAIR ORDER USING THE EXISTING "V" LABOR OPERATIONS SHOWN BELOW. THE REINFORCEMENT KIT MUST STILL BE INSTALLED. CHEV LABOR OP. DESCRIPTION *TIME ALLOWANCE TROUBLE CODE CC-FC V9020 INSTALL REINFORCEMENT KIT, MEASURE L, R SIDE BALL JOINT 1.4 HRS. 96. SK-00 V9021 INSTALL ONE BALL JOINT AND INSTALL REINFORCEMENT KITS 2.4 HRS. 96. SK-00 V9022 INSTALL TWO BALL JOINTS AND INSTALL REINFORCEMENT KITS 3.1 HRS. 96. SK-00 CHEV ONLY: V0923 REPLACE ONE CONTROL ARM 1.1 HRS. SK-00 V0924 REPLACE BOTH CONTROL ARMS 2.1 HRS. SK-00 * FOR DEALER TO RECEIVE ADMINISTRATIVE TIME ALLOWANCE ASSOCIATED WITH THIS CAMPAIGN, ADD 0.1 HOUR TO THE LABOR OPERATION TIME ALLOWANCE. 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 FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR 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. APPLY "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. FIGURES: 4 ADMINISTRATIVE PROCEDURE PROCEDURES COVERING THIS CAMPAIGN ARE OUTLINED IN SECTION V OF YOUR DEALERSHIP'S "GMC TRUCK WARRANTY CLAIMS PROCESSING MANUAL" #P9119.
************* CANADIAN VERSION ***************************************
SUBJECT
LH AND RH LOWER CONTROL ARM CRACKING (INSTALL LOWER CONTROL ARM REINFORCEMENT KIT)
Models: 1992 - 1993 Chevrolet/GMC G3 Vans with L05 (5.7L), LL4 (6.2L), L19 (7.4L) and C6W (9200 LB. GVWR)
TO: ALL GENERAL MOTORS DEALERS
General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1992 - 93 Chevrolet/GMC G3 vans with 9200 lb. GVWR. 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 reinforcement brace on each of the front lower control arms.
VEHICLES INVOLVED:
Involved are certain 1992 - 93 Chevrolet/GMC G3 with C6W built within the following VIN breakpoints:
Year Model Plant Plant Code From Through
1992-93 GMC G3 L05 & C6W Scarborough 4 SOP P4516232 1992-93 Chev G3 L05 & C6W Scarborough 4 SOP P4143506 1992-93 GMC G3 LL4/L19 & C6W Scarborough 4 SOP P4516546 1992-93 Chev G3 LL4/L19 & C6W Scarborough 4 SOP P4144198 1993 GMC G3 L05 & C6W Flint F SOP PF520331 1993 Chev G3 L05 & C6W Flint F SOP PF352046 1993 GMC G3 LL4/L19 & C6W Flint F SOP PF518321 1993 Chev G3 LL4/L19 & C6W Flint F SOP PF351740
NOTE: PLEASE CHECK DCS SCREEN 45 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WELL BE PAID.
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.
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 instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner 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 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 (see copy of owner letter included with this bulletin). 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
15991641 Lower Control Arm Reinforcement Kit 1
9766424 Ball Joint As required
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
2A Install Reinforcement Kit & 1.4 Measure L & R side Ball Joint
3A Install One Ball Joint and 2.4 Install Reinforcement Kits
4A Install Two Ball Joints and 3.1 Install Reinforcement Kits
7A Previously replaced Lower Control Arm(s) or Ball Joint(s)
NOTE: THE REINFORCEMENT KIT MUST STILL BE INSTALLED.
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:
INITIAL POSITIONING OF THE REINFORCEMENT
1. Raise the front of vehicle and support it with suitable safety stands.
2. Clean the left and right lower control arm of all dirt, rust, grease, and undercoating from the spring pocket outboard to the flange surrounding the ball joint. Clean both the top and bottom areas of the control arms. This will ensure 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 the control arms and the reinforcement are not thoroughly cleaned, the U-bolt may "Walk off" the bottom of the ball joint when it is tightened.
3. Centre the reinforcement (Figure 1) between the flanges. The technician should do one side at a time. Gaps A & B (Figure 1) are to be equal within 0.060 inch (1.5 nun). Secure the reinforcement with a "C" clamp (Figure 2).
IMPORTANT: The reinforcement is installed CORRECTLY when the ball joint makes full contact with the reinforcement radius (Figure 1, Item 2) not just in the centre section of the reinforcement
The reinforcement is designed to fit ball joints with a bottom diameter of 2.60 inches (66 mm) or greater. The technician may find that the ball joint does not make full contact with the radius of the reinforcement when the reinforcement is centered correctly between the flanges.
Furthermore, it may be possible that an after market ball joint with the 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 the ball joint is clean as described in step 1. Measure the bottom diameter of the ball joint with a caliper. If the measurement is LESS THAN 2.6 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 after market control arm, install a GM designed control arm and perform the installation of the reinforcement per the campaign service procedure.
4. Install the U-bolt (Figures 1 & 3) and torque nuts to approximately 10 N.m (7 lb. ft.).
IMPORTANT: This step must be performed before proceeding to step 5.
NOTICE: When correctly installed, the U-bolt, will be about even with the bottom of the ball joint. The U-bolt is NOT designed to fit into the galley of the control arm. On some vehicles the U-bolt may contact the flange edge of the control arm and interfere with the collect installation. If this happens, locate and mark the area where the U-bolt comes in contact with the control arm. You may remove only enough material (LIGHTLY grind) (Figure 2A) from the OUTER radius of the U-bolt to allow clearance between the U-bolt and the control arm (Figure 2, Item 7).
5. Drill a centre hole with a 3/8 inch (9.5 mm) drill. The reinforcement (Figure 2) has been designed to be used as a drill template. When drilling, keep the 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 the centre hole and torque to approximately 18 N.m (13 lb. ft.).
7. Remove "C" clamp.
8. Drill the remaining holes in any sequence.
9. Disassemble the reinforcement (Figure 2, Item 1) and U-bolt (Figure 2, Item 7) from the control arm and remove all of the chips and burs from the lower control arm and reinforcement.
INSTALLATION OF REINFORCEMENT
1. Reinstall the reinforcement (Figure 3, Item 1) and U-bolt (Figure 3, Item 7). Hand start all of the bolts and nuts. Tighten the U-bolt nuts (Figure 3, Item 5) to approximately 22 N.m (16 lb. ft.). Make sure the U-bolt is ALIGNED with the bottom edge of the ball joint and is not cocked while continuing to torque.
NOTICE: If the furthest rear bolt head interferes with the bump stop bracket, install the bolt from the bottom of the control arm.
2. Torque the 3/8-16 bolts (Figure 3) to 37 - 43 N.m (27 - 32 lb. ft.). Torque the centre bolt first and the remainder in any sequence.
3. Torque the U-bolt nuts (Figure 3) to 40 - 46 N.m (30 - 34 lb. ft.).
4. Continue to the other side of vehicle and follow the same procedures that have been listed above.
5. Once both lower control arm reinforcements have been installed and torqued lower the vehicle.
6. 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.
Customer Support Department General Motors of Canada Limited
September 1994
Dear General Motors Customer
General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1992 - 93 Chevrolet/GMC G3 vans with 9200 lb. GVWR. 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, your dealer will install a reinforcement brace on each of the front lower control arms.
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.
