Special Policy Adjustment - Tailgate Support Cable Replacement

The service procedure and labor time in this bulletin have been revised because of feedback received from GM dealership service technicians. Discard all copies of bulletin 06020, issued July 2006.

Due to part availability, this Special Policy is being mailed to customers in phases. You will be notified as parts become available and phases are released.

To minimize customer inconvenience, encourage customers to have their cables replaced rather than returning for annual inspections.

If a customer is concerned that the inspection procedure is not an appropriate way to assure the intended performance of the cables, or is unwilling to perform the required inspection, dealers are instructed to assist the customer by replacing the galvanized support cables with stainless steel support cables.

Some customers of 2000-2003 Chevrolet S10 and GMC Sonoma vehicles may experience broken galvanized steel tailgate support cables.

This special policy covers the condition described above for a period of 12 years from the date the vehicle was originally placed in service, regardless of mileage. The repairs will be made at no charge to the customer.

For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after July 21, 2006 are covered by this special policy and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to July 21, 2006 must be submitted to the Service Contract provider.

Involved are certain 2000-2003 Chevrolet S10 and GMC Sonoma vehicles built within the following VIN breakpoints:

Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO).

General Motors will notify customers of this special policy on their vehicles (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly).

1. Open and support the endgate.
2. Disconnect the endgate cable from the bolt head of the endgate striker bolt.




Important: Insert the gasket removal tool or equivalent (1) behind the center latch assembly fastener to avoid damaging endgate paint.

3. Insert the gasket removal tool or equivalent (1) behind the center latch assembly fastener.



4. Drill out the rivet (1) on the latch assembly using a 9.5 mm (3/8 in) drill bit.



5. Ream the latch assembly hole (2) using a 9.5 mm (3/8 in) drill bit.
6. Remove the latch assembly fastener (3) from the latch assembly.
7. Loosen but do not remove the latch assembly fastener (1).
8. Apply two thin coats of rust penetrating lubricant (corrosion inhibitor) to the area around the latch assembly fastener hole (2).



9. Install the new fastener and new cable (2) to the latch assembly.

Tighten
Tighten the fastener to 9 N·m(80 lb in).

10. Install and tighten the fastener (3) and tighten the fastener (1).

Tighten
Tighten fasteners (1) and (3) to 25 N·m(18 lb ft).

11. Attach the new cable onto the bolt head of the endgate striker bolt.
12. Perform Steps 2-11 for the opposite side of the endgate.
13. Close the endgate.

For vehicles repaired under the terms of this special policy, submit a claim with the information indicated below:

All customer requests for reimbursement for previous repairs for the special policy condition will be handled by the Customer Assistance Center, not by dealers.

A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter.

Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.

Customer requests for reimbursement of previously paid repairs for the special policy condition are to be submitted the dealer prior to or by November 30, 2007. Repairs must have occurred within the 12 years of the date the vehicle was originally placed in service, regardless of mileage.

When a customer requests reimbursement, they must provide the following:

Dear General Motors Customer:

As the owner of a 2000, 2001, 2002, or 2003 model year Chevrolet S10 or GMC Sonoma vehicle, your satisfaction with our product is very important to us.

This letter is intended to make you aware that some 2000, 2001, 2002, and 2003 model year Chevrolet S10 and GMC Sonoma vehicles equipped with galvanized steel tailgate support cables may have a condition where the cables can corrode and fracture when loads are applied to them. If one or both tailgate support cables were to break, cargo and/or individuals positioned on the tailgate could drop to the ground, possibly resulting in cargo damage and/or personal injury.

Owners should NEVER permit an individual to sit on the opened (horizontal) tailgate when a vehicle is in motion. Even when the vehicle is operated at low speeds, individuals seated on the tailgate can easily lose their balance in response to vehicle maneuvers, unexpected jolts due to road conditions, etc. Individuals who fall to the ground or pavement from a moving vehicle may be seriously injured or killed.

General Motors is providing you with additional warranty coverage to cover corrosion on galvanized steel tailgate support cables. If this condition occurs on your vehicle within 12 years of the date that your vehicle was originally placed in service, regardless of vehicle mileage, the condition will be repaired for you at no charge .

You should determine which of the two options below better suits your preference and vehicle usage.

Option 1: You may choose to have your galvanized steel tailgate support cables inspected yearly. You can perform this inspection yourself according to the inspection procedure included with this letter, or as shown on the online video at www.gm.com/cables, or you can take your vehicle to your GM dealer and they will inspect the cables for you at no charge. If a cable shows signs of corrosion, both cables will be replaced with stainless steel cables at no charge to you. If you choose this option, and would like your dealer to perform the inspection, you should contact the service department to schedule an appointment that is convenient for you. Keep this letter with your other important glove box literature for future reference.

Option 2: If you have any concerns about frequency or effectiveness of the inspection procedure, discuss them with your dealer. If you are not satisfied that regular inspection is an appropriate way to assure the intended performance of your cables, or you are unwilling to inspect the cables, your dealer will replace your galvanized support cables with stainless steel support cables.

The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid to have your galvanized steel tailgate support cable replaced because of corrosion.

All replacement tailgate support cables that had been purchased prior to August 2006 were made of galvanized steel and will need to be inspected annually as outlined in the enclosed inspection procedure.

We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products.

Scott Lawson

General Director,

Customer and Relationship Services

Enclosure

06020