CAMPAIGN: TRANS SHIFT CABLE ADJUSTMENT (RESET ADJUSTMENT). GMC Truck GMC G Van 1992

SUBJECT: AUTOMATIC TRANSMISSION CONTROL CABLE

MODELS: 1992 G1, G2, AND G3 VANS

DEALERS NOTIFIED VIA DCS MESSAGE ON SEPTEMBER 12,1991 TO STOP DELIVERY OF INVOLVED MODELS.

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 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 appointments with owners and to repair their vehicles as soon as possible. As you will see in reading the attached copy of the letter which is being sent to owners, the owner is being instructed to contact the nearest GMC Zone Office if the 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 how to contact the National Highway Traffic Safety Administration.

DEFECT INVOLVED

General Motors has determined that certain 1992 G-Vans, equipped with an automatic transmission, fail to conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 102, "Transmission Shift Lever Sequence, Starter Interlock, and Transmission Braking Effect." Some of these vehicles may have a mis-adjusted transmission control cable that, under a certain sequence of operation, allow the engine to be started with the transmission in gear. This condition could cause the vehicle to move in an unexpected direction and cause a vehicle crash without prior warning.

In order to comply with FMVSS 102, and to correct this condition, the shift cable routing will be inspected and the cable adjustment reset using a revised procedure.

VEHICLES INVOLVED

Involved are certain 1992 G1, G2, and G3 models equipped with 4L60/4L80E automatic transmission, built within the following VIN breakpoints:

Model Year Plant From Through --------- ---------- ---- -------- 1992 Scarborough SOP N4501761 Lordstown SOP N7501735

The specific vehicles involved in this campaign have been identified by Vehicle Identification Number Computer Listings. These listings are furnished to all involved dealers with the campaign bulletin.

DEALER CAMPAIGN RESPONSIBILITY

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. Dealers are to correct all affected vehicles in new and used vehicle stock prior to their sale.

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 ensure the campaign correction has been made before reselling or releasing the vehicle, Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer and arrangements made to make the required correction according to instructions contained in this bulletin.

This bulletin is notice to you that the new motor vehicles involved in this campaign may not comply with the standard identified above. Under Section 108 of the National Traffic and Motor Vehicle Safety Act, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the campaign correction, your dealership may be subject to a civil penalty up to $1,000 for each such sale.

If the name and address of the owner of an involved vehicle was unavailable to GMC Truck Division at the time of campaign initiation, the dealer must determine the owner's name and address from the dealership sales records. Please provide this information directly on the second copy of the listing next to the applicable VIN so that our records may be updated and the appropriate notification mailed to the owner. This second copy should then be submitted to the address listed below in the previously supplied yellow campaign envelopes.

GMC Truck Division General Motors Corporation 101 Union Street Plymouth, Michigan 48170

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by GMC Truck Division (see copy of owner letter included with this bulletin). A listing of owner names and addresses has been furnished to the involved dealers to enable dealers to follow up with owners involved in this campaign. This listing 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 this campaign.

SERVICE PROCEDURE INSPECTION:

Inspect for a red/orange round sticker on the right hand side (passenger side) of the radiator support, next to the hood latch. If sticker is present, proceed to Step 28 below. If sticker is not present, proceed to "Repair Section" below.

REPAIR:

1. Inspect the cable routing past the brake pipes in the engine compartment to ensure routing is as shown in Figure 1.

NOTE: If the cable is routed correctly, proceed to Step 9.

2. If the cable is routed incorrectly, it will be necessary to remove the shift cable at the transmission end.

3. Remove the shift cable from the transmission manual shaft per Step 16 below.

4. Loosen the locking tab from the cable conduit per Step 17 below.

5. Using pliers, compress the cable conduit top and bottom, retaining barbs until the cable can be removed from the transmission retaining bracket. See Figure 2, Note 1.

6. Remove the cable from the retaining clips in the engine compartment.

7. Reroute the cable per Figure 1.

8. Reinstall the cable in the engine compartment clips, and into the transmission retaining bracket.

9. Remove instrument panel extension screws "A" (Qty 2). See Figure 3.

10. Remove engine cover screws "B" (Qty 2). See Figure 3.

11. Release engine cover over center latches "C" (Qty 2). See Figure 3.

12. Slide engine cover rearward until the seats restrict rearward movement.

13. Shift cable must be routed above spark plug retainer and bracketry and outboard past such items as rear a/c pipes, c/c servo and bracket, as applicable. Cable must be allowed to assume its natural routing.

14. Place steering column transmission shift lever in NEUTRAL position. For tilt steering columns, adjust the column 2 detents down from the full up detent position.

15. Observe and ensure transmission cable assembly is routed freely from the front of dash, past the brake pipes, and in the engine compartment as shown in Figure 1.

16. Remove shift cable nylon ball receiver from transmission manual shaft lever ball stud. See Figure 2 "B". Use screwdriver to snap receiver from stud.

17. With a stubby screwdriver inserted into slot at Point A, pry upward against the cable release until the cable is free to move in the adjust body. Locking tab will move outward approximately 1/2 inch. It is not necessary to completely remove the locking tab. See Figure 2.

18. Install a #64 (3 1/2" x 1/4" x 1/32") rubber band on the steering column shift lever as shown in Figure 4 to preload it while ensuring it is in the NEUTRAL detent to its maximum clockwise position.

19. It is essential that the shift cable conduit slides freely in the adjust body. See Figure 2, Note 2. If the conduit does not slide freely, route the cable past any obstructions such as air conditioning pipes, spark plug retainer, etc.

20. At the transmission manual shaft, place the lever into NEUTRAL position (2 detents from PARK; PARK is full clockwise). See Figure 2 " B ".

21. Attach plastic shift cable ball stud receiver onto transmission manual shaft ball stud with the flat side toward the lever as shown in Figure 2.

22. Push transmission shift cable locking tab back into its seated position. DO NOT touch conduit while locking the tab.

23. The shift cable system is now properly adjusted.

24. Remove rubber band from shift lever, and ensure vehicle will start only in PARK and NEUTRAL.

25. Reinstall engine cover.

NOTE: DURING STEPS 26 THROUGH 37 APPLY SERVICE BRAKE AND FEATHER RELEASE TO VERIFY VEHICLE IS NOT IN GEAR.

26. Position gear shift selector in Park.

27. Turn ignition switch to start engine. Engine should start, but vehicle must not move.

28. Position gear shift selector in Reverse.

29. Move selector toward Neutral to remove free play. Do not move out of detent.

30. Attempt to turn ignition switch to the start position. Switch should not turn.

31. Move selector to Neutral.

32. Repeat Step 27.

33. Move selector to Drive.

34. Repeat Step 29.

35. Repeat Step 30.

36. Repeat Step 31.

37. Repeat Step 27.

38. Verify PRNDL needle alignment. If adjustment of the PRNDL needle is required place steering column shift lever in NEUTRAL position. DO NOT change the alignment by readjusting the transmission shift cable or moving the PRNDL housing. The tilt steering column needle is adjusted by tapping the steel retainer sideways with a screwdriver; the standard (non-tilt) column needle is adjusted by loosening the pointer retainer screw and adjusting as required and retightening the screw.

39. Install Campaign Identification Label.

PARTS INFORMATION

No parts required.

WARRANTY INFORMATION

Dealers should submit a warranty claim on each vehicle completed under this campaign.

Labor Operation *Time Trouble Number Description Allowance Code --------- ----------------- -------- -------- V7060 Inspection only. No 0.2 Hr. 96 further action required.

V7061 Shift cable adjust- 0.5 Hr ment

Add: Reroute cable 0.1 Hr. PRNDL alignment 0.1 Hr.

For dealer to receive Administrative Time Allowance associated with this campaign, add 0.1 hour to the Labor Operation Time Allowance.

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 five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or 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 for periodic servicing by the owner.

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

ADMINISTRATIVE PROCEDURE

Procedures covering this campaign are outlined in Section V of your dealership's "GM Truck Claims Processing Manual" #P9119.

Dear GMC Truck Owner:

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

In order to comply with FMVSS 102, and to correct this condition, the shift cable muting will be inspected and the cable adjustment reset using a revised procedure. This service will be completed for you at no charge.

Instructions for performing this service have been sent to your GMC Truck dealer. Please contact your dealer to arrange a service date. The labor time necessary to perform this correction will vary from 15 minutes to 1 hour. Please ask your dealer how much additional time will be needed to process your vehicle.

Your GMC Truck dealer is best equipped to provide service to ensure your vehicle is corrected as promptly as possible. However, if you take your vehicle to your dealer on the agreed service date and they do not service this condition on that date or within five days, we recommend you contact your nearest GMC Truck Zone Office by telephone. The Zone Office will assist you and your dealer in getting your vehicle corrected. The telephone numbers of the Zone Offices are listed in your Warranty and Owner Assistance Information Manual.

After contacting your dealer and the Zone Office, if you are still not satisfied with the action we have taken to remedy this non-compliance, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street S.W., Washington, D.C. 20590, or call the toll free Auto Safety Hotline at 1-800-424-9393 (Washington D.C. residents may call 366-0123).

The enclosed postage paid owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction to your vehicle in the shonest possible time. If you have sold or traded your vehicle, please furnish us complete name and address of the person you sold or traded your vehicle to and return the card to us.

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.

Object Number: 87669 Size: MF

Object Number: 85247 Size: FS

Object Number: 87897 Size: MF

Object Number: 86814 Size: MF

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.