CAMPAIGN: INTERMEDIATE STEERING SHAFT DETACHMENT. Chevrolet S10 Pickup

NOTE: GM OF CANADA CAMPAIGN 96061 IS LOCATED BELOW THE U.S. VERSION

PRODUCT SAFETY CAMPAIGN

SUBJECT: 96061 - INTERMEDIATE STEERING SHAFT DETACHMENT ----------------------------------------------

MODELS: 1987-95 CHEVROLET POSTAL VEHICLES (LLV) ---------------------------------------

The Highway 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 customer has tendered it for repair. A failure to repair within sixty (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 customer may be entitied 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 remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the divisional letter that is being sent to customers, the customers are being instructed to contact the appropriate Customer Assistance Center if their dealer does not remedy the condition within five (5) 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 decided that a defect which relates to motor vehicle safety exists in certain 1987-95 S 10507 Postal Office Vehicles (LLV). These vehicles may exhibit a condition in which the intermediate steering shaft may become loose at the steering shaft to steering gear coupling. With this looseness, the yoke pinch bolt that passes through the "whistle" slot in the steering gear shaft can wear on the splines of the shaft until there is no longer an interference between the splines and the bolt. When this occurs, body to chassis movement can cause the steering shaft to separate from the steering gear resulting in a total loss of steering control.

If this were to occur while the vehicle was in motion, a vehicle crash could result without prior warning.

To prevent the possibility of this condition occurring, dealers are to torque the upper bolt and the lower bolt to 48 Nm.

VEHICLES INVOLVED

Involved are certain 1987-95 S 10507 Postal Office Vehicles (LLV) built within the following VIN breakpoints:

YEAR DIVISION MODEL PLANT CODE FROM THROUGH ------- --------- ----- ------- ---- ---- ------- 1987-95 Chevrolet LLV Moraine "2" SOP EOP

NOTICE: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) prior to beginning campaign repairs.

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The Customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer 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.

PARTS INFORMATION

No parts are required for this campaign.

CUSTOMER NOTIFICATION

Customers will be notified of this campaign on their vehicles by General Motors (see copy of divisional customer letter included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

All unsold new vehicles in dealers' possession and subject to this campaign m@u be held and inspected/repaired per the service procedure of this campaign bulletin before customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign 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. This could be done by mailing to such customers a copy of the appropriate divisional customer letter accompanying this bulletin. Campaign 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 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.

SERVICE PROCEDURE

- Set front wheels in the straight-ahead position and the steering wheel in the "LOCKED" position.

- Mark the lower intermediate shaft joint to steering gear input shaft relationship to ensure proper installation if intermediate shaft becomes disconnected.

1. Loosen the upper and lower pinchbolts of the intermediate shaft and retorque pinchbolts to 48 Nm (34 lbs. ft.).

2. Install the GM 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 by the customer for periodic servicing. When installing the Campaign Identification Label, be sure to install the clear protective covering. Additional Campaign Identification Labels can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday-Friday, 8:00 a.m. to 4:30 p.m. EST). Ask for Item Number S-1015 when ordering.

Apply the "Campaign Identification Label" only on a clean, dry surface.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below: * REPAIR PART FAILED PARTS LABOR LABOR PERFORMED COUNT PART NO. ALLOW CC-FC 0P HOURS ---------------- ----- -------- ----- ----- ----- ----- Torque Upper And - - - MA-96 V9969 0.2 Lower Bolt

* For Campaign Administrative Allowance, add 0.1 hours to the "Labor Hours".

Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission.

October 1996

Dear Chevrolet Customer:

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

REASON FOR THIS RECALL

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1987-95 S 10507 Postal Office Vehicles (LLV) . These vehicles may exhibit a condition in which the intermediate steering shaft may become loose at the steering shaft to steering gear coupling. With this looseness, the yoke pinch bolt that passes through the 'whistle' slot in the steering gear shaft can wear on the splines of the shaft until there is no longer an interference between the splines and the bolt. When this occurs, body to chassis movement can cause the steering shaft to separate from the steering gear resulting in a total loss of steering control. If this were to occur while the vehicle was in motion, a vehicle crash could result without prior warning.

WHAT WE WILL DO

To prevent the possibility of this condition occurring, your dealer will torque the upper bolt and the lower bolt to 48 Nm. 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. Instructions for making this correction have been sent to your dealer. The labor time necessary to perform this service correction is approximately 15 minutes. Please ask your dealer if you wish to know how much additional 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.

Your Chevrolet dealer is best equipped to provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within five (5) days, we recommend you contact the Chevrolet Customer Assistance Center by calling 1-800- 222-1020.

After contacting your dealer and the Customer Assistance Center, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call 1-800-424-9393 (Washington D.C. residents use 202-366-0123).

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.

Chevrolet Motor Division GENERAL MOTORS CORPORATE

** CANADIAN VERSION **

PRODUCT SAFETY CAMPAIGN

SUBJECT: CAMPAIGN 96061 - INTERMEDIATE STEERING SHAFT DETACHMENT -------------------------------------------------------

MODELS: 1991-1994,4995 CHEVROLET POSTAL VEHICLES (LLV) ----------------------------------------------

DEFECT INVOLVED

General Motors of Canada Limited has decided that a defect which relates to motor vehicle safety exists in certain 1991-1993-1994-1995 S 10507 Postal Office Vehicles (LLV). These vehicles may exhibit a condition in which the intermediate steering shaft may become loose at the steering shaft to steering gear coupling. Vrith this looseness, the yoke pinch bolt that passes through the "whistle" slot in the steering gear shaft can wear on the splines of the shaft until there is no longer an interference between the splines and the bolt. When this occurs, body to chassis movement can cause the steering shaft to separate from the steering gear resulting in a total loss of steering control. If this were to occur while the vehicle was in motion, a vehicle crash could result without prior warning.

To prevent the possibility of this condition occurring, dealers are to torque the upper bolt and the lower bolt to 48 N.m (34 lbs. ft.).

VEHICLES INVOLVED

Involved are certain 1991-1993-1994-995 S 10507 Postal Office Vehicles (LLV) built within the following VIN breakpoints: PLANT YEAR DIVISION MODEL PLANT CODE FROM THROUGH ------------- --------- ----- ------- ----- ---- ------- 1991-93-94-95 Chevrolet LLV Moraine "2" SOP EOP

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.

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

PARTS INFORMATION

No parts are required for this campaign.

CUSTOMER NOTIFICATION

All customers of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors (see copy of customer letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.

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 customers take possession of these vehicles.

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

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

SERVICE PROCEDURE

- Set front wheels in the straight-ahead position and the steering wheel in the "LOCKED" position.

- Mark the lower intermediate shaft joint to steering gear input shaft relationship to ensure proper installation if intermediate shaft becomes disconnected.

1. Loosen the upper and lower pinchbolts of the intermediate shaft and retorque pinchbolts to 48 N.m (34 lbs. ft.).

2. 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 by the customer for periodic servicing. Additional Campaign Identification Labels can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. Apply the "Campaign Identification Label" only on a clean, dry surface.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

* REPAIR PERFORMED PART FAILED PARTS LABOUR LABOUR COUNT PART NO. ALLOW CC-FC 0P HOURS Torque Upper And Lower Bolt - - - MA-96 V9969 0.2

* For Campaign Administrative Allowance, add 0. I hours to the "Labour Hours".

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

October 1996

Dear General Motors Customer:

General Motors of Canada Limited has decided that a defect which relates to motor vehicle safety exists in certain 1991-1993-1994-1995 S 10507 Postal Office Vehicles (LLV). These vehicles may exhibit a condition in which the intermediate steering shaft may become loose at the steering shaft to steering gear coupling. With this looseness, the yoke pinch bolt that passes through the "whistle" slot in the steering gear shaft can wear on the splines of the shaft until there is no longer an interference between the splines and the bolt. When this occurs, body to chassis movement can cause the steering shaft to separate from the steering gear resulting in a total loss of steering control. If this were to occur while the vehicle was in motion, a vehicle crash could result without prior warning.

To prevent the possibility of this condition occurring, your GM dealer will torque the upper bolt and the lower bolt to 48 N.m.

This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date. 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

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.