CAMPAIGN:TAILGATE GLASS BREAK ELECTRIC R/WINDOW DEFOGGERS

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 ADEQUATLEY 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 A SERVICE DATE WITH EACH OWNER AND TO REPAIR THEIR VEHICLE AS SOON AS POSSIBLE. AS YOU WILL SEE IN READING THE ATTACHED COPY OF THE LETTER WHICH IS BEING SENT TO OWNERS, THE OWNERS ARE BEING INSTRUCTED TO CONTACT THE NEAREST CHEVROLET ZONE OFFICE IF THEIR DEALER DOES NOT REMEDY THE CONDITION WITHIN FIVE DAYS OF THE AGREED SERVICE DATE. IF THE CONDITION IS NOT REMEDIED WITHIN A REASONABLE TIME, THE OWNERS ARE INSTRUCTED HOW TO CONTACT THE NATIONAL HIGHWAY TRAFFICE SAFETY ADMINISTRATION.

DEFECT INVOLVED

THE NATIONAL HIGHWAY TRAFFIC SAFETY ASSOCIATE ADMINISTRATOR HAS MADE AN INITIAL DETERMINATION THAT A DEFECT WHICH RELATES TO MOTOR VEHICLE SAFETY EXISTS WITH RESPECT TO SOME 1979 AND 1980 MALIBU AND MALIBU CLASSIC STATION WAGONS EQUIPPED WITH ELECTRIC REAR WINDOW DEFOGGERS AND ASEMBLED DURING THE 1979 CALENDAR YEAR. SPECIFICALLY, THE ASSOCIATE ADMINISTRATOR BASED HIS INITIAL DETERMINATION ON AN INVESTIGATION REPORT WHICH CONCLUDES THAT:

"THE DEFOGGER BACKLIGHTS (WINDOWS) ...CONTAIN A DEFECT WHICH CAUSES THE GLASS TO SHATTER WITHOUT IMPACT DURING OR SOME TIME AFTER THE USE OF THE DEFOGGER. THE DRIVER DISTRACTION AND THE EXPLOSION OF BROKEN OR HOT GLASS INTO THE PASSENGER COMPARTMENT OF THE VEHICLE CREATES AN UNREASONABLE RISK OF ACCIDENT OR INJUDRY TO THE OCCUPANTS OF THE SUBJECT VEHICLE AS WELL AS PEDESTRIANS AND DRIVERS OF OTHER CARS ON THE ROAD."

A POSSIBILITY EXISTS THAT PORTIONS OF THE VERTICAL ELECTRICAL STRIPS (BUSS BARS) ON THE REAR WINDOW MAY DETERIORATE THROUGH CONTACT WITH A PARTICULAR MAKE OF RUBBER WEATHERSTRIP MATERIAL. DURING OPERATION OF THE DEFOGGER, THIS CAN CAUSE LOCALIZED HOT SPOTS WHICH COULD, IN CERTAIN INSTANCES, RESULT IN BREAKAGE OF THE REAR WINDOW GLASS.

BASED ON THIS INITIAL DETERMINATION, GENERAL MOTORS HAS DECIDED TO REPAIR THESE BUSS BARS, AS NECESSARY, AT NO CHARGE TO OWNERS OF THESE VEHICLES.

DEALERS WILL INSPECT EACH VEHICLE TO SEE IF IT WAS ASSEMBLED WITH A PARTICULAR MAKE OF WEATHERSTRIP (SEE:FIGURE 2). IF IT WAS NOT, NO FURTHER ACTION WILL BE NECESSARY AND DEALERS ARE INSTRUCTED TO SO ADVISE THE OWNER. IF THE PARTICULAR WEATHERSTRIP IS PRESENT, THE BUSS BAR WILL BE REPAIRED BY APPLICATION OF NEW SILVER CONDUCTOR MATERIAL. REPLACEMENT OF THE WEATHERSTRIP WILL NOT BE NECESSARY BECAUSE IT WILLNOT CAUSE THE REPAIRED BUSS BAR TO DETERIORATE.

NOTE: NEAR THE BEGINNING OF THE 1980 CALENDAR YEAR, GENERAL MOTORS RELEASED A SERVICE REAR WINDOW GLASS WHICH MOVED THE BUSS BARS INBOARD (SEE: FIGURE 1). THE SERVICE GLASS IS IDENTIFIED BY A WIDE BLACK-OUT BAND AROUND ITS OUTSIDE EDGE. IF THIS SERVICE GLASS HAS BEEN PREVIOUSLY INSTALLED IN ANY VEHICLE NO FURTHER ACTION IS RE- QUIRED, REGARDLESS OF THE WEATHERSTRIP IDENTIFIED.

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1979 AND 1980 MALIBU AND MALIBU CLASSIC STATION WAGONS EQUIPPED WITH RPO C49 (REAR WINDOW DEFOGGERS) WITHIN THE FOLLOWING VEHICLE BREAKPOINTS:

PLANT MODEL YEAR FROM THROUGH

BALTIMORE 1979 1T35M9B471206 1T35M9B582673 1980 1W35JAB400010 1W35JAB446985

LEEDS 1979 1W35H9K482662 1W35M9K635166 1980 1W35JAK400015 1W35HAK450551

DORAVILLE 1979 1T35J9D456901 1T35M9D52617

ARLINGTON 1979 1W35H9R446269 1W35J9R500899

FREMONT 1979 1T35H9Z433465 1W35J9Z472855

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 THE 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 WAS NOT SHIPPED ANY INVOLVED VEHICLES.

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

DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN, REGARDLESS OF MILEAGE, 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 IN THE FUTURE, YOU SHOULD TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE.

INSPECTION PROCEDURE 1. DETERMINE THE WEATHERSTRIP SUPPLIER. OPEN THE LIFT GLASS, LIFT OUTER LIP OF WEATHERSTRIP AND INSPECT THE UPPER RIGHT OR LEFT CORNER OF THE WEATHERSTRIP IN THE AREA OF THE RADIUS. (FIGURE 2.) 2. ONE (1) HOLE INDICATES SHELLER GLOBE WEATHERSTRIP. THE INSPECTION IS COMPLETE AND NO FURTHER ACTION IS NECESSARY. 3. THREE (3) HOLES INDICATE GENERAL TIRE WEATHERSTRIP. THE COMPLETE REWORK IS TO BE PERFORMED ON THESE CARS.

BACK GLASS ASSEMBLY

FOR REFERENCE PURPOSES FIGURE 3 SHOWS COMPONENTS OF BACK GLASS ASSEMBLY.

REPAIR PROCEDURE

1. REMOVE BACK GLASS ASSEMBLY FROM THE CAR AND PLACE ON A CLEAN PROTECTED SURFACE.

2. WORKING ON THE INSIDE OF THE GLASS, APPLY MASKING TAPE TO GLASS 3/8" INBOARD OF BUSS BAR MATERIAL AND TO THE TOP OF METAL WINDOW FRAME ON EACH SIDE OF GLASS (FIGURE 4).

3. REMOVE BACK RESIDUE FROM BOTH BUSS BARS AND EXPOSED GRIDS USING THE 3M SCOTCH BRIGHT (GRAY) PAD PROVIDED. LIGHT PRESSURE SHOULD BE APPLIED TO THE PAD UNTIL THE BUSS BARS TURN A SILVER-GRAY COLOR. REMOVE ONLY AS MUCH BUSS BAR MATERIAL AS NECESSARY TO ASSURE A REASONABLY CLEAN SURFACE. THE GRIDS ARE ESPECIALLY DELICATE AND CARE SHOULD BE TAKEN TO ASSURE THE SCOTCH BRITE CLEANING WILL NOT CAUSE BREAKS OR OPENS IN THE GRID LINES NEXT TO THE BUSS BAR.

4. REMOVE MASKING TAPE FROM GLASS AND GLASS FRAME. THEN CLEAN GLASS SURFACE WITH A WAX AND GREASE REMOVER SUCH AS PREP-SOL, PRE-KLEANO, ACRYLIC-CLEAN, SHER-WILL-CLEAN OR EQUIVALENT. WIPE SURFACE WITH A CLEAN CLOTH AND ALLOW TO DRY.

5. WITH SCISSORS, ROUND CORNERS OF COPPER TAPE (SUPPLIED IN THE KIT) AS SHOWN ABOVE. REMOVE BACKING FROM 1/2" X 6" COPPER TAPE AND APPLY TO INBOARD EDGE OF BOTH BUSS BARS FROM THE THIRD TO THE EIGHTH GRID LINE (FIGURE 5). APPLY PRESSURE TO TAPE SURFACE TO REMOVE AIR POCKETS.

6. MASKS SUPPLIED IN KIT ARE TO BE APPLIED TO LEFT AND RIGHT SIDES. CUT MASK AT POINTS "A" AND "B" (FIGURE 6). APPLY LARGE PORTION OF MASK TO GLASS 3/8" INBOARD OF BUSS BAR. THEN APPLY SMALL 3/16" STRIP PORTION TO THE GLASS WITH EDGE OF MASK ALONG THE OUTER EDGE OF BUSS BAR.

7. APPLY MASKING TAPE OVER GLASS FRAME AND OUTBOARD EDGE OF MASK TO ELIMINATE EXCESS CLEAN UP (SECTION A-A).

8. FORM A PIECE OF MASKING TAPE (FIGURE 8) AND APPLY OVER TOP OF EACH BRASS CONTACT PLATE (FIGURE 7).

9. TO INCREASE THICKNESS OF EPOXY WHICH WILL BE APPLIED OVER BUSS BAR, APPLY MAKSING TAPE OVER MASK FROM SECOND GRID LINE TO NINTH GRID LINE (FIGURE 7).

MIX ONE PACKAGE OF EPOXY MATERIAL FOR TWO MINUTES AND APPLY TO TOTAL CUT OUT AREA OF MASK USING A STIFF 2" OR 3" PUTTY KNOFE. THE KNIFE MUST MAINTAIN LIGHT PRESSURE AGAINST THE MASK SURFACE DURING APPLICATION OF THE EPOXY MATERIAL TO ASSURE A SMOOTH LEVEL APPLICATION OF MATERIAL (FIGURE 7).

11. REMOVE MASK AND MASKING TAPE FROM GLASS AND GLASS FRAME.

12. CURE THE EPOXY BY PASSING A HAND-HELD HEAT GUN (WITH A RANGE OF 350 DEG) BACK AND FORTH FOR FIVE MINUTES. EPOXY IS CURED WHEN LIGHT FINGERNAIL PRESSURE WILL NOT MAKE AN IMPRESSION IN THE MATERIAL.

13. REPEAT PROCEDURE ON OPPOSITE SIDE, AFTER MATERIAL HAS CURED CLEAN EXCESS EXPOXY MATERIAL FROM AROUND NEW BUSS BARS.

14. REINSTALL GLASS ASSEMBLY TO THE VEHICLE.

15. TEST ALL GRID LINES TO DETERMINE IF THEY ARE OPERATIONAL AND REPAIR GRIDS AS REQUIRED USING REMAINING SILVER EPOXY MATERIAL, FOLLOWING STANDARD PROCEDURE OUTLINED IN SECTION 10 OF THE FISHER SERVICE MANUAL.

PART INFORMATION

THE PARTS REQUIRED TO COMPLETE THIS CAMPAIGN ON ALL INVOLVED VEHICLES CAN BE ORDERED FROM GENERAL MOTORS WAREHOUSING AND DISTRIBUTION DIVISION AS FOLLOWS: PART NUMBER DESCRIPTION

9636066 GRID DEFOGGER REPAIR KIT

NOTE: TO INSURE THESE PARTS WILL BE OBTAINED AS SOON AS POSSIBLE THEY SHOULD BE ORDERED FROM GMWDD ON A C.I.O. ORDER WITH NO SPECIAL INSTRUCTION CODE, BUT ORDER ON AN ADVISE CODE (2). TO INSURE ADEQUATE AVAILABILITY OF THIS PART DO NOT ORDER PARTS UNTIL AFTER MARCH 1, 1981.

CLAIM INFORMATION

SUBMIT A PRODUCT CAMPAIGN CLAIM WITH THE INFORMATION INDICATED BELOW:

PARTS FAILED **PARTS FAILURE LABOR LABOR *OTHERS COUNT PART NO. ALLOWANCE CODE OPERATION HOURS HOURS

00 V0750 .2 .1

DESCRIPTION: INSPECT WEATHERSTRIP TO IDENTIFY SUPPLIER. NOT INVOLVED, NO FURTHER ACTION REQUIRED.

1 9626066 00 V0751 1.5 .1

DESCRIPTION: INSPECT, APPLY KIT AND CHECK GRIDS. APPLY GRID DEFOGGER REPAIR KIT ACCORDING TO THE INSTRUCTIONS OUTLINED IN THIS BULLETIN.

* CAMPAIGN ADMINISTRATIVE ALLOWANCE **THE PARTS ALLOWANCE SHOULD BE THE SUM TOTAL OF THE CURRENT GMWDD DEALER NET PLUS 30% OF ALL PARTS REQUIRED FOR THE REPAIR.

DEALERS WILL AUTOMATICALLY RECEIVE THE CORRECT PARTS AND LABOR ALLOWANCE BASED ON THE LABOR OPERATION PERFORMED.

REFER TO THE CHEVROLET CLAIMS PROCESSING MANUAL FOR DETAILS ON PRODUCT CAMPAIGN CLAIM SUBMISSION.

CAMPAIGN IDENTIFICATION LABEL

EACH VEHICLE MODIFIED 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 FIVE DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR BALLPOINT 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 CLEAN DRY SURFACE.

ADMINISTRATIVE PROCEDURE

REFER TO THE CURRENT CHEVROLET SERVICE POLICIES AND PROCEDURES MANUAL AND CLAIMS PROCESSING MANUAL FOR CAMPAIGN HANDLING AND ADMINISTRATIVE PROCEDURES.

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.