Product Safety - Brake Lamp Continous Illumination

This bulletin is being revised to include an inspection procedure. Please discard all copies of bulletin 05011 issued February 2005.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2004-2005 model year Chevrolet Epica and Optra vehicles. Some of these vehicles have a brake lamp switch that may become misadjusted if an upward force is applied to the underside of the pedal. If this were to occur, the ABS brake system and regular brake system would operate normally, however, the brake lamps may stay illuminated after the driver's foot is removed from the pedal. A constant illuminated of the brake lamp may fail to warm a following driver when the vehicle is braking and could lead to a vehicle accident.

This can also cause the battery to become discharged once the engine is off, the traction and cruise control systems to be disabled, and the brake-transmission shift interlock to be disabled.

Dealers are to replace the brake lamp switch.

Involved are certain 2004-2005 model year Chevrolet Epica and Optra vehicles built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

For Canada

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a Campaign Initiation Detail Report.

For Export

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin.

The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program.

For Canada

Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO=Customer Special Order.

For Export

Parts required to complete this program are to be obtained through the normal parts supply system.

1. Visually inspect the brake lamp switch.

•	If the switch has a threaded shaft as shown above, no further action is required.

•	If the switch DOES NOT have a threaded shaft, proceed to the next step and replace the brake lamp switch.




2. Disconnect the negative battery cable.
3. Remove the trim panel screws.
4. Remove the trim panel.



5. Turn the stop lamp switch and the connector assembly, and pull it from the brake pedal bracket.
6. Separate the stop lamp switch from the connector to replace the stop lamp switch.
7. Install the connector to the new stop lamp switch.
8. Turn the stop lamp switch and the connector assembly, and twist it into the brake pedal bracket.
9. Press the brake pedal and pull the switch plunger to its maximum setting to adjust the switch.
10. Release the plunger and pull up on the pedal.
11. Install the trim panel screws.

Tighten
Tighten the trim panel screws to 7 N·m (62 lb in).

12. Press the brake pedal and pull the switch plunger to its maximum setting to adjust the switch.

The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

Submit a Product Recall Claim with the information indicated below:

Note: Canadian dealers should refer to the Canadian distribution of the bulletin for detailed claim information.

Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission.

General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.

All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 and 2005 model year Chevrolet Epica and Optra vehicles. Some of these vehicles have a brake lamp switch that may become misadjusted if an upward force is applied to the underside of the pedal. If this were to occur, the ABS brake system and regular brake system would operate normally, however, the brake lamps may stay illuminated after the driver’s foot is removed from the pedal. A constant illumination of the brake lamps may fail to warn a following driver when the vehicle is braking and could lead to a vehicle accident.

This can also cause the battery to become discharged once the engine is off, the traction and cruise control systems to be disabled, and the brake-transmission shift interlock to be disabled.

Your GM dealer will replace the brake lamp switch. This service will be performed for you at no charge .

This service correction will take approximately 15 minutes. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

To limit any possible inconvenience, we recommend that you contact your GM dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date.

The enclosed customer reply form identifies your vehicle. Presentation of this form to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us.

If your vehicle is within the New Vehicle Limited Warranty your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner’s Manual and your dealer for details on Courtesy Transportation.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products.

General Motors Corporation

Enclosure

05011