CAMPAIGN: LOWER CONTROL ARM BALL JOINT. Chevrolet Impala 1995

SUBJECT: Lower Control Arm Ball Joint ----------------------------

MODELS: 1995 Chevrolet Caprice Police Sedans (SEO 9C1), Taxi Cab (SEO 9C6) and Special Service Wagon (SEO 1A2) and 1995 Cadillac Fleetwood with RPO B9Q (Conversion Hearse) or RPO V4U (Coach Builder Limousine) AND 1995-1996 Chevrolet Caprice/Impala, Buick Roadmaster and Cadillac Fleetwood (Retail Passenger) ------------------------------------------------------------------

TO: ALL GENERAL MOTORS DEALERS

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THIS BULLETIN REPLACES PRODUCT CAMPAIGN BULLETIN 5D38 ISSUED FEBRUARY 1996. SPECIFICALLY, THE VEHICLES INVOLVED SECTION HAS BEEN REVISED TO REFLECT THE ADDITION OF RETAIL PASSENGER UNITS, THE PARTS INFORMATION SECTION HAS BEEN REVISED TO REFLECT THE ADDITION OF PART NUMBERS FOR CADILLAC AND BUICK MODEL VEHICLES AND THE SERVICE PROCEDURE HAS BEEN REVISED TO REFLECT A FINAL BALL JOINT TORQUE RANGE.

PLEASE DESTROY ALL OLD COPIES OF PRODUCT CAMPAIGN BULLETIN 5D38.

General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in CERTAIN 1995 Chevrolet Caprice Police Sedans (SEO 9CI), Taxi Cab (SEO 9C6) and Special Service Wagon (SEO IA2) and 1995 Cadillac Fleetwood with RPO B9Q (Conversion Hearse) or RPO V4U (Coach Builder Limousine) AND 1995-1996 Chevrolet Caprice/Impala, Buick Roadmaster and Cadillac Fleetwood (Retail Passenger) model vehicles. The lower control arm ball joint attachment nut may be loose.

To correct this condition, all involved vehicles will have both front lower control arm ball joint attachment nuts inspected for proper torque. If the ball joint has loosened from the knuckle, both the ball joint and knuckle will be replaced.

VEHICLES INVOLVED:

Involved are CERTAIN 1995 Chevrolet Caprice Police Sedans (SEO 9Cl), Taxi Cab (SEO 9C6) and Special Service Wagon (SEO IA2) and 1995 Cadillac Fleetwood with RPO B9Q (Conversion Hearse) or RPO V4U (Coach Builder Limousine) AND 1995-1996 Chevrolet Caprice/Impala, Buick Roadmaster and Cadillac Fleetwood (Retail Passenger) model vehicles built within the following VIN breakpoints:

Year Model Plant Plant Code From Through ---- ----- ----- ---------- ---- -------

1995 Chevrolet Caprice Arlington R SOP EOP (SEO 9C1, 9C6,1A2) 1995 Chevrolet Caprice/Impala Arlington R SR145136 EOP 1996 Chevrolet Caprice/Impala Arlington R SOP TRI08199 1995 Buick Roadmaster Arlington R SR418849 EOP 1996 Buick Roadmaster Arlington R SOP TR402787 1995 Cadillac Fleetwood Arlington R SOP EOP (RPO B9Q, V4U) 1996 Cadillac Fleetwood Arlington R SOP TR701778

NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

All additional 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:

Additional involved vehicles are shown on the attached computer listing and owners of record 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:

IT IS ANTICIPATED THAT APPROXIMATELY 5% OF THE KNUCKLE/BALL JOINT ASSEMBLIES WILL REQUIRE REPLACEMENT FOR THIS CONDITION DURING THE LIFE OF THE VEHICLE. DUE TO THE SMALL NUMBER OF VEHICLES REQUIRING KNUCKLE/BALL JOINT REPLACEMENT, DEALERS ARE ENCOURAGED NOT TO ORDER CAMPAIGN PARTS FOR USE AS SHELF STOCK. PARTS SHOULD ONLY BE ORDERED WHEN INSPECTION DETERMINES THAT IT IS NECESSARY TO REPLACE THE KNUCKLE/BALL JOINT.

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- ----------- ---------------- CHEVROLET ---------

9767113 Ball Joint (9/16) As Required 18021052 Knuckle, Left-Hand (9/16) As Required 18021053 Knuckle, Right-Hand (9/16) As Required 9766421 Ball Joint (5/8) As Required 18021377 Knuckle, Left-Hand (5/8) As Required 18021378 Knuckle, Right-Hand (5/8) As Required 12337997 Cotter Pin 3 Per Side 3965092 Seal, Spindle 1 Per Side

CADILLAC/BUICK --------------

9767113 Ball Joint (9/16) As Required 18016023 Knuckle, Left-Hand (9/16) As Required 18016024 Knuckle, Right -Hand (9/16) As Required 9766421 Ball Joint (5/8) As Required 18021054 Knuckle, Left-Hand (5/8) As Required 18021055 Knuckle, Right-Hand (5/8) As Required 12337997 Cotter Pin 3 Per Side 3965092 Seal, Spindle 1 Per Side

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 ----------- ----------- -------------- AA Inspect Only .5 - BOTH Ball Stud Nuts Torqued Coffectly

2A Inspect Only .6 - Ball Stud Nut Torqued Correctly ONE SIDE - Check ONE SIDE For Nut Gap

3A Inspect Only .7 - Check BOTH SIDES For Nut Gap

4A Inspect/Repair 2.3 - Ball Stud Nut Torqued Correctly ONE SIDE - Check ONE SIDE For Nut Gap & Replace Ball Stud/Knuckle

5A Inspect/Repair 2.4 - Check BOTH SIDES For Nut Gap - Replace ONE SIDE Ball Stud/Knuckle - Torque ONE SIDE

9A Inspect/Repair 3.4 - Check BOTH SIDES For Nut Gap - Replace BOTH SIDES Ball Stud/Knuckle

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus appropriate model year parts handling allowance.

Repair Codes 4A, 5A, 9A include "Time Allowance" for Wheel Alignment and Front Toe Adjustments.

SERVICE PROCEDURE:

INSPECTION - NUT TOROUE

1. Rotate vehicle steering wheel to the extreme right stop position.

2. Gain access to right front lower ball stud attachment area through the forward area of the wheel well, remove lower ball joint cotter pin.

3. Utilizing a clicker type torque wrench set at 60 N.m (44 lb. ft.) and while attempting to tighten lower ball stud nut, determine which of the following conditions exists and proceed as required:

A. Torque Wrench Clicks Prior To Nut Rotation [Nut torqued to more than 60 N.m (44 lb. ft.) as installed].

I. Reset torque wrench between 95 N.m (70 lb. ft.) and 112 N.m (83 lb. ft.). Tighten ball j oint nut until wrench clicks.

II. Install new cotter pin. If pin cannot be installed, tighten nut enough to align slot in nut with hole in ball stud and install new cotter pin. Nut rotation to align cotter pin hole is not to exceed one flat (60 degrees).

III. Proceed to Step 4.

B. Nut Rotates Prior to Torque Wrench Clicking [Nut torqued to less than 60 N.m 44 lb. ft.) as installed].

I. DO NOT perform any further work on this attachment at this time. Proceed to Step 4.

4. Rotate steering wheel to extreme left stop position and repeat Steps 2 and 3 on left ball stud attachment.

5. If either the right/left or both lower ball stud nuts were torqued to LESS than 60 N.m (44 lb. ft.) as determined in Step 3, proceed to Step 6, "Nut Gap Inspection." If both lower ball joints were found to be torqued to MORE than 60 N.m (44 lb. ft.) as determined in Step 3, proceed to Step 10

INSPECTION - NUT GAP

6. Raise and suitably support vehicle in such a manner that front suspension is hanging fully extended (full rebound position).

7. Loosen ball stud nut(s) at suspect attachment(s) four (4) complete revolutions. Inspect gap between nut lower surface and upper contact surface of knuckle (see Figure 1).

8. NO GAP: (Ball stud IS NOT seated in knuckle) Replace knuckle and lower ball stud following applicable Service Manual Procedure, Section 3C-3, Front Suspension. Check and adjust wheel alignment and toe-in after new knuckle and lower ball stud is installed. Proceed to Step 10.

OR

GAP:

--- (Ball stud IS seated in knuckle) Tighten nut and torque between 95 N.m (70 lb. ft.) and 112 N.m (83 lb. ft.), then tighten nut enough to align slot in nut with hole in ball stud and install new cotter pin. Nut rotation to align cotter pin hole is not to exceed one flat (60 degrees).

9. Lower vehicle.

10. 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.

Dear General Motors Customer:

This condition can cause the lower control arm ball joint to loosen, fatigue and separate from the front suspension knuckle. If separation were to occur with the vehicle in motion, loss of vehicle control may occur, which could result in a vehicle crash without prior warning. To correct this condition, all involved vehicles will have both front lower control arm ball joint attachment nuts inspected for proper torque. If the ball joint has loosened from the knuckle, both the ball joint and knuckle will be replaced.

This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date so they may inspect your vehicle and, if necessary, order the parts for the repair.

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

Object Number: 93000 Size: MF

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.