CAMPAIGN: REAR BRAKE WHEEL CYLINDER ROTATION REVISION
Model and Year: 1978, 1979, 1980 CHEVROLET MALIBU, MONTE CARLO, -------------- EL CAMINO MODELS AND 1982 S10 LIGHT DUTY TRUCKS
TO: ALL CHEVROLET DEALERS
THIS BULLETIN IS BEING REISSUED TO SUPERSEDE PRODUCT SAFETY CAMPAIGN BULLETIN 82C33 DATED SEPTEMBER, 1985. UPON RECEIPT OF THE REISSUED BULLETIN 82C33(a), DESTROY 82C33.
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 owners 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 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 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 some 1978, 1979, 1980 Chevrolet Malibu, Monte Carlo, El Camino models and 1982 S10 Light Duty trucks. It is possible that a rear brake wheel cylinder could rotate due ,to enlargement of the wheel cylinder pilot hole in the backing plate. If such rotation becomes excessive, contact could be lost between the wheel cylinder piston and the brake shoe and could result in the loss of rear brake fluid and consequently the loss of rear braking action.
These vehicles are equipped with a dual braking system. In the event of a rear system loss, the front brake system would remain functional and the brake warning light on the instrument panel would be lit. Absence of rear braking at a time when minimum stopping distance is required could result in a vehicle crash without prior warning.
DEALER CAMPAIGN RESPONSIBILITY
To prevent the possibility of this condition occurring on vehicles involved, dealers are to install a retaining bracket on both rear wheel cylinders to prevent them from rotating. These parts are available in a parts kit from GMWDD.
Normal maintenance items such as worn brake linings, leaking wheel cylinders, and parking brake cables found during the campaign that require replacement will be at the customer's expense. Customer must be contacted and their consent obtained prior to replacement of any maintenance parts.
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.
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 before reselling or releasing the vehicle.
VEHICLES INVOLVED
All 1978, 1979, 1980 Chevrolet Malibu, Monte Carlo, El Camino models and 1982 S10 Light Duty trucks assembled at the plants listed below:
PLANT YEAR FROM THROUGH ----- ---- ---- ------- Baltimore 1978 8B400001 8B576894 1979 9B400001 9B582686 1980 AB400001 AB507749
Oshawa 1978 81400001 81518668 1979 91400001 91527981 1980 A1400001 A1512589
Doraville 1978 8D400001 8D528942 1979 9D400001 9D526168
Pontiac 1982 C0100001 C0146123
Moraine 1982 C2100001 C2111109
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).
PARTS INFORMATION
Parts for this campaign are to be obtained from GMWDD.
One Wheel Cylinder Retainer Bracket Kit, Part Number 18013604 is required for each vehicle involved in this campaign.
To ensure this kit will be obtained as soon as possible, it should be ordered from GMWDD on a C.I.O. order with no special instructions code, but order on an advise code (2).
BECAUSE OF THE LIMITED NUMBER OF PARTS AVAILABLE AT THE TIME OF CAMPAIGN INITIATION, OWNER NOTIFICATIONS AND PARTS DISTRIBUTION WILL TAKE PLACE ON A REGIONAL BASIS UNTIL SUCH TIME AS AN ADEQUATE SUPPLY IS AVAILABLE.
SERVICE PROCEDURE
Using parts from kit part number 18013604, install a wheel cylinder retaining bracket on both rear wheel cylinders using the following procedure:
1. Hoist and support vehicle.
2. Use a brush or scraper to remove rust and dirt build-up from areas 1, 2, and 3 shown on Figure 1. DO NOT REMOVE WHEEL CYLINDER RETAINER.
3. Place a wheel cylinder bracket over brake pipe with bracket fingers toward the wheel cylinder. Refer to Figure 2.
THE RETAINER BRACKET MUST FIT FLUSH AGAINST THE BACKING PLATE MOUNTING FLANGE WITH ALL FOUR (4) BRACKET FINGERS EXTENDING INTO THE HOLE TO GRASP THE WHEEL CYLINDER.
In some cases, it may be necessary to reposition the wheel cylinder to properly install the bracket. If you cannot properly reposition the wheel cylinder, brake drum removal may be necessary. Contact your Area Service Manager or Zone Office for instructions regarding these additional procedures.
NOTE: Zone approval is required for this additional labor.
4. Insert the bolt from kit through the hole in the bracket and start into the clipped-on nut. Using a #8 external head socket, tighten bolt to 6.72 Nm. (60 in. lbs.).
The bracket may tend to walk inward down the axle tube as the bolt is tightened.
AFTER THE BRACKET HAS BEEN INSTALLED, INSPECT TO MAKE SURE THAT THE BRACKET FINGERS GRASP THE WHEEL CYLINDER, AS SHOWN IN ILLUSTRATION. IF FINGERS DO NOT GRASP THE CYLINDER, REMOVE THE BRACKET AND REPEAT STEPS 2, 3, AND 4 OF THE SERVICE PROCEDURE.
WHEN THE BRACKET IS PROPERLY INSTALLED, THE GAP BETWEEN THE BRACKET AND MOUNTING FLANGE MUST NOT EXCEED 3&M (7/64"). REFER TO FIGURE 3. IF CAP EXCEEDS 3MM, REMOVE BRACKET AND REPEAT STEPS 2, 3, AND 4.
5. Grasp the retaining bracket by hand and twist. Bracket should not move. If the bracket can be moved, it should be reinstalled, repeating steps 2, 3, and 4.
6. Repeat steps 2, 3, 4, and 5 to install a bracket on opposite side of vehicle.
7. Install the campaign completion label.
CLAIM INFORMATION
Submit a Product Campaign Claim with the information indicated below:
Parts Failed Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- -------- ---------- -------- ---------- ------ ------ 2 18013604 00 V2860 .4 .1
DESCRIPTION: Install Bracket Retainer kit.
Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- ------- ---------- ------- ---------- ----- ------ 2 18013604 00 V2861 .6 .1
DESCRIPTION: Install Bracket Retainer kit and remove one (1) rear brake drum.
Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- --------- ---------- -------- ---------- ----- ----- 2 18013604 00 V2862 .7 .1
DESCRIPTION: Install Bracket Retainer kit and remove two (2) rear brake drums.
Parts Failed **Parts Failure Labor Labor *Other ***Net Count Part No. Allowance Code Operation Hours Hours Amount ----- -------- ---------- -------- --------- ------ ----- ------ 3 18012303 00 V2863 1.0 .1 3.20
DESCRIPTION: Install Bracket Retainer kit and replace one (1) rear wheel cylinder, includes bleeding rear brakes.
AREA SERVICE MANAGER'S APPROVAL REQUIRED. -----------------------------------------
Parts Failed **Parts Failure Labor Labor *Other ***Net Count Part No. Allowance Code Operation Hours Hours Amount ----- -------- --------- ------- --------- ----- ------ ------ 4 18012303 00 V2864 1.4 .1 3.20
DESCRIPTION: Install Bracket Retainer kit and replace two (2) rear wheel cylinders, includes bleeding rear brakes.
Parts Failed **Parts Failure Labor Labor *Other ***Net Count Part No. Allowance Code Operation Hours Hours Amount ------ ------- --------- ------- --------- ----- ------ ----- 3 18012972 00 V2865 1.5 .1 3.20
$ DESCRIPTION: Install Bracket Retainer kit. Replace one (1) rear brake backing plate. Includes REPLACING ONE wheel cylinder and bleeding rear brakes.
AREA SERVICE MANAGER'S APPROVAL REQUIRED. ----------------------------------------
Parts Failed **Parts Failure Labor Labor *Other ***Net Count Part No. Allowance Code Operation Hours Hours Amount ----- -------- --------- ------- --------- ----- ----- ----- 4 18012973 00 V2866 2.4 .1 3.20
$ DESCRIPTION: Install Bracket Retainer kit. Replace two (2) rear brake backing plates. Includes REPLACING both wheel cylinders and bleeding rear brakes.
AREA SERVICE MANACER'S APPROVAL REQUIRED. -----------------------------------------
Parts Failed **Parts Failure Labor Labor *Other ***Net Count Part No. Allowance Code - Operation Hours Hours Amount ----- ------- --------- -------- --------- ----- ----- ----- 4 18012973 00 V2867 1.5 .1 3.20
$ DESCRIPTION: Install Bracket Retainer kit. Replace one (1) rear wheel cylinder, replace one (1) rear wheel backing plate (SAME SIDE). Includes bleeding rear brakes.
AREA SERVICE MANAGER'S APPROVAL REQUIRED. -----------------------------------------
Parts Failed **Parts Failure Labor Labor *Other ***Net Count Part No. Allowance Code - Operation Hours Hours Amount ----- -------- ---------- -------- --------- ------ ----- ------ 6 18012972 00 V2868 2.4 .1 3.20
DESCRIPTION: Install Bracket Retainer kit. Replace two (2) rear wheel cylinders, replace two (2) rear wheel backing plates. Includes bleeding rear brakes.
AREA SERVICE MANAGER'S APPROVAL REQUIRED. ----------------------------------------- $ Denotes change.
*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.
***The $3.20 in the "Net Amount Column," represents the material allowance for brake fluid used in conjunction with all labor operation performed, except labor operations V2860, V2861 and V2862.
Dealers will automatically receive the correct labor allowance based on the labor operation performed.
$ In addition to the REVISED dealer claim information a REVISED "Claim Information Chart," has been prepared on page 10 to assist Dealer Personnel in identifying the repair categories of each vehicle involved.
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 a clean dry surface.
$ Denotes change.
Claim Information Chart
Repair Performed ** * *** Asm Rear Brake Failed Parts Lab Oth Net Approval Wheel Cylinder PC Part No. Allow FC LABOP HRS HRS AMT Required -------------- -- -------- ----- -- ----- --- --- --- --------
Install Bracket 2 18013604 00 V2860 .4 .1 No Retainer Kit
Install Bracket Retainer Kit Remove 1 Rear Brake Drum 2 18013604 00 V2861 .6 .1 No
Install Bracket Retainer Kit Remove 2 Rear Brake Drums 2 18013604 00 V2862 .7 .1 No
Install Bracket Retainer Kit Replace 1 Rear Wheel Cylinder Bleed Rear Brakes 3 18012303 00 V2863 1.0 .1 3.20 Yes
Install Bracket Retainer Kit Replace 2 Rear Wheel Cylinders Bleed Rear Brakes 4 18012303 00 V2864 1.4 .1 3.20 Yes
Install Bracket Retainer Kit Replace 1 Rear Backing Plate Replace 1 Wheel Cylinder Bleed Rear Brakes 3 18012972 00 V2865 1.5 .1 3.20 Yes
Install Bracket Retainer Kit Replace 2 Rear Backing Plates Replace Both Wheel Cylinders Bleed Rear Brakes 4 18012972 00 V2866 2.4 .1 3.20 Yes
Install Bracket Retainer Kit Replace 1 Rear Wheel Cylinder Replace 1 Rear Backing Plate (Same Side) Bleed Rear Brakes 4 18012973 00 V2867 1.5 .1 3.20 Yes
Install Bracket Retainer Kit Replace 2 Rear Wheel Cylinders Replace 2 Rear Backing Plates Bleed Rear Brakes 6 18012972 00 V2868 2.4 .1 3.20 Yes
*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.
*** The $3.20 in the "Net Amount Column", represents the material allowance for brake fluid used in conjunction with all labor operations except V2860, V2861, V2862.
Dealers will automatically recieve the correct labor allowance based on the labor operation performed.
Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim submission.
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.
