CAMPAIGN:RIGHT-HAND FRAME & BODY MOUNT CRACKS
Subject: PRODUCT CAMPAIGN 93-C-53 - RIGHT-HAND FRAME AND BODY MOUNT CRACKS
Model and Year: 1991-93 P30 COMMERCIAL MODELS WITH 9L6 LOW PROFILE CHASSIS
To: All Chevrolet/Geo Dealers
General Motors has determined that certain 1991-93 Chevrolet P30 Commercial low profile chassis vehicles (RPO 9L6) may exhibit a cracking condition of the right-hand front body mounting bracket and/or the right-hand frame rail in the area of the body mounting bracket. If a crack develops in the bracket or frame, and is not repaired, it may propagate and cause additional cracks to other frame attachments. This condition is caused by "bottoming out" of the front suspension that causes high impact loads to be transmitted to the right-hand frame and body mount bracket.
To correct this condition, dealers are to install a Front Air Bag Suspension Kit on all involved vehicles. on vehicles exhibiting a crack in the right-hand body mount or frame, it will be necessary to install a right-hand body mount kit and repair the cracks.
VEHICLES INVOLVED
Involved are certain 1991-93 Chevrolet P30 Commercial low profile chassis vehicles built within the following VIN breakpoints:
PLANT YEAR MODEL PLANT CODE FROM THROUGH ------------------------------------------------------------------ 1991 P30842 Detroit "3" M3312665 M3316948 1992 P30842 Detroit "3" N3303792 N3321708 1993 P30842 Detroit "3" P3300749 P3321558
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 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.
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 ----------- ----------- --------- 15988948 Front Air Bag Suspension Kit 1 (All Vehicles) Right-Hand Front Body Mount Kit 1 (If Required)
NOTICE
DUE TO A LIMITED AMOUNT OF RIGHT-HAND FRONT BODY MOUNT KITS, DO NOT ORDER MOUNT KIT UNLESS INSPECTION INDICATES A NEED FOR THE KIT
SERVICE PROCEDURE
INSPECTION:
---------- FRONT BODY MOUNT BRACKET ASSEMBLY OR FRAME CRACKING ---------------------------------------------------
1. Raise front of vehicle. Refer to 1994 P30 and P/G Chassis Service Manual (NAPT-9432) General Information Section 0A-8 entitled "General Vehicle Lifting and Jacking".
2. Remove right and left front wheel assemblies.
3. Refer to Figure 1 below. Access right-hand front wheel house area and locate right-hand body mount bracket assembly (Item 1) attached to front frame rail. Inspect frame rail and right-hand body mount bracket assembly for looseness or cracking.
4. If no cracks are detected in either the right front body mount bracket or the frame rail, proceed to "Suspension Kit Installation" procedure beginning on page 5 of this bulletin.
If cracks are detected, proceed to "Front Body Mount Kit Installation" procedure on page 4.
Notice: Due to a limited amount of right-hand front body mount kits. Do not order mount kit unless inspection indicates a need for the kit
FRONT BODY MOUNT KIT INSTALLATION
1. If a crack exists in the right-hand front body mount bracket or frame rail, it will be necessary to remove the body mount bracket.
2. Refer to Figure 1, Items 5, 6, 7 and 8. Remove bolt and nut assembly from the right-hand front body mount bracket and return. When removing bolt assembly, the body may move ' Relieving most of the pressure on the body mount bracket. This will allow easier removal of the rivets and body mount bracket. Depending on the body builder, there may also be a radiator support bracket attached to the right-hand body mount.
3. Remove right-hand body mount bracket. Use a #5 center drill to aid in removal of the six (6) body mount attaching rivets. After rivets have been center drilled, use a chisel and remove the head of the rivet and drive the shaft of the rivet through the frame rail with a drift. Discard rivets and the old bracket assembly.
4. Inspect right-hand front frame rail for any cracks that may have been hidden by the bracket assembly. Repair all cracks in the frame rail as necessary. Refer to Service Manual, Section 2A-5, for welding instructions.
5. Refer to Figure 1. Install new right-hand front body mount bracket (item 1) and inside frame reinforcement (Item 2). Loosely install bolts (Item 3) and nuts (Item 4). Do not tighten assembly at this time.
6. Re-install and partially tighten body bolt and nut assembly (Items 5,6,7 and 8). This will assist technician with aligning the total assembly.
7. Tighten body mounting bracket bolts (Item- 3) to 38 Nm (28 lb. Ft.) in an alternating pattern.
8. Tighten upper body mount nut (Item 8). The upper body mount bolt was originally installed by a builder. Check bolt head for identification and refer to Service Manual Section 0A-12, "General Information", for fastener identification and torque information.
9. Continue to "Suspension Kit Installation" procedure on pages 5 and 6.
SUSPENSION KIT INSTALLATION
1. Refer to Service Manual (NATP-9432), section 3C-8. On right-hand and left-hand front suspension, remove stabilizer shaft clamps (Figure 6, Item 42) attached to lower control arms and remove fasteners (Figure 5, Items 21, 22 and 23) from lower portion of shock absorber assembly.
2. Refer to Service Manual, section 3C-13, Figure 15. Disconnect lower ball joints from steering knuckles. This will allow access to coil spring for removal.
3. Refer to Service Manual, section 3C-15, Figure 18. Carefully remove coil spring assembly.
4. After coil springs have been removed, inspect air bag assemblies from Suspension Kit. End pads should be secured to both ends of air bag. If pads are loose, reinstall by snapping pads onto air bag. Refer to 3C-15 and 3C-16 of Service Manual for air bag installation to coil spring.
5. Remove both left-hand and right-hand upper rebound bumpers. Drive existing rebound bumpers out of upper control arm assemblies using a drift. Discard existing bumpers and install new bumper assemblies from Suspension Kit (Refer to Figure 2, Items 1, 2 and 3). Torque bumper nut (Item 1) to 155 Nm (114 lb. ft.).
6. Refer to section 3C-14 Figure 16 and remove jounce bumper nuts (Item 58) and jounce bumpers (Item 33) of both right-hand and left-hand lower control arm assemblies. Retain nut (Item 58) and install new jounce bumpers (Figure 2, Item 4) from Suspension Kit. Torque jounce bumper nut to 35 Nm (26 lb. Ft.) (Figure 2, Item 5).
7. Refer to section 3C-14, "Reinstallation Of Coil Springs With New Air Bags". Reattach lower control arm ball joints (Section 3C-14, Figure 16, Item 35) to steering knuckles. Torque ball joint nuts to 122 Nm (90 lb. Ft.) and install cotter pin (Item 34).
8. Refer to section 3C-8. Reinstall shock absorber lower fasteners (Figure 5, Items 21, 22 and 23). Torque nut (Item 23) to 101 Nm (74 lb. Ft.).
9. Refer to section 3C-8. Reinstall stabilizer shaft clamps (Item 42) and attaching fasteners (Items 38, 39, 41 and 43) Torque nuts to (Item 38) to 33 Nm (24 lb. Ft.).
Notice: Refer to Service Manual page 3C-32 for Fastener Tightening Specifications - Independent Front Suspension.
10. Refer to Service Manual section 3E-9, Figure 10. Reinstall wheel assemblies.
11. Lower vehicle.
12. Inflate air bags to 70 PSI.
13. Align front end. Alignment specifications are provided in Section 3A of the Service Manual.
Notice: Alignment procedures should be performed with vehicle loaded (under normal operating conditions).
14. 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 Front Air 1 15988948 ** SK-00 V9190 2.4 0.1 Bag Suspension Kit Install Right-Hand Front Body Mount Kit 2 15988333 ** SK-00 V9191 3.6 0.1 & Air Bag Suspension Kit Install Right-Hand Front Body Mount Kit & Air Bag Suspension 2 15988333 ** SK-00 V9192 4.3 0.1 Kit And Repair Front Frame Rail Cracks
* 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.
Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim Submission.
Dear Chevrolet Truck Owner:
This notice is sent to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.
REASON FOR THIS RECALL
General Motors has determined that certain 1991-93 Chevrolet P30 Commercial low profile. chassis vehicles may exhibit a cracking condition of the right-hand front body mounting bracket and/or the right-hand frame rail in the area of the body mounting bracket. If a crack develops in the bracket or frame, and is not repaired, it may propagate and cause additional cracks to other frame attachments. This condition is caused by "bottoming out" of the front suspension that causes high impact loads to be transmitted to the right-hand frame and body mount bracket.
WHAT WE WILL DO
To correct this condition, dealers are to install a Front Air Bag Suspension Kit on all involved vehicles. on vehicles exhibiting a crack in the right-hand body mount or frame, it will be necessary to install a right-hand body mount kit and repair the cracks. 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 performing this service have been sent to your dealer and parts are available. Please contact your dealer to arrange a service date as soon as possible. You may ask your dealer if you wish to know how much time will be needed to schedule and process your vehicle.
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 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.
