CAMPAIGN: EXCESSIVE BRK. PEDAL TRAVEL (VACUUM PWR. BRK. SYS.)
SUBJECT: EXCESSIVE BRAKE PEDAL TRAVEL
MODELS: 1992 G-VANS WITH VACUUM POWER BRAKE SYSTEMS (JB5/JB7) BUILT AT THE SCARBOROUGH ASSEMBLY PLANT
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 some 1992 G-Vans produced at the Scarborough Assembly plant and equipped with vacuum power brake systems (JB5/JB7) have an incorrect brake pedal assembly. This incorrect brake pedal assembly has a pushrod pin that is both too small and installed in the incorrect location relative to the brake pedal pivot. The incorrect location of the push rod pin causes an increased brake pedal ratio that results in a decreased master cylinder stroke. Although a vehicle with a decreased master cylinder stroke will meet the full system stopping requirements of Federal Motor Vehicle Safety Standard (FMVSS) 105, "Hydraulic Brake Systems" it will not meet the partial system failure requirements. A further reduction of braking ability at a time when partial system failure has occurred could result in a vehicle crash without prior warning.
To correct this condition, dealers will inspect for an incorrect brake pedal assembly and replace as required.
VEHICLES INVOLVED
Involved are certain 1992 G-Vans built at the Scarborough Assembly Plant built within the following VIN breakpoints:
Model Year Plant Division From Through ----- ----- -------- ---- -------- 1992 Scarborough GMC N4516762 N4517227 Truck
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
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 owners take possession of the these vehicles.
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.
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.
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.
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 lefter 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.
PRELIMINARY INSPECTION
1. Inspect the left side of the brake pedal assembly to verify the stamping number (Figure 1). If the number 698 (Figure 1) is stamped into the pedal assembly no further action is required. Install a "Campaign Identification Label" and submit a Warranty Repair Order as described in the WARRANTY INFORMATION section of this bulletin.
2. If the number 698 is not stamped into the brake pedal assembly it will be necessary to replace the brake pedal assembly with the correct assembly. Continue to the SERVICE PROCEDURE for instructions on replacing this assembly.
SERVICE PROCEDURE REMOVING THE STOP LAMP SWITCH
1. Disconnect the negative battery cable.
2. Remove the lower steering column trim panel.
3. Disconnect the electrical connectors from the stoplamp switch (Figure 2).
4. Remove the stoplamp switch from the retainer.
REMOVING THE BRACKET AND THE BRAKE PEDAL ASSEMBLY
Note: The bracket and brake pedal assembly must be removed as a complete assembly.
1. Remove the retainer, the two washers and the pushrod from the brake pedal pivot pin (Figure 1).
2. Remove the capsule nuts from the steering column brace and let the steering column rest on the seat (Figure 3).
3. Remove the relay from the left side of the brake pedal bracket.
4. Remove the 4 nuts from the vacuum booster studs (Figure 4).
5. Remove the two bolts from the dash cross-member (Figure 4).
6. Carefully remove the brake pedal bracket assembly.
7. Remove the brake pedal retaining pivot bolt from the brake pedal bracket assembly and remove the pedal (Figure 1).
8. Remove the existing thread locking compound from the pivot bolt threads.
9. Coat the pivot bolt threads with Medium Strength Thread Locking Compound (P/N 12345382).
10. Install the correct brake pedal into the bracket assembly (P/N 15641698) and torque the retaining pivot bolt to 40-55 N-m (30-41 lbs.ft.).
11. Reinstall the brake pedal bracket assembly onto the vacuum booster studs.
12. Reinstall the 4 nuts and torque them to 29 N-m (21 lb.ft.)
13. Reinstall the 2 bolts into the dash cross- member and torque the bolts to 12 N-m (16 lb.ft.).
Use Figure 1 for steps 14 thru 19.
14. Reinstall the washer, the pushrod and the washer on the brake pedal pivot pin.
15. Reinstall the retainer into the pivot pin.
16. Reinstall the stoplamp switch into the retainer on the brake pedal bracket.
17. Connect the stoplamp switch connectors to the stoplamp switch.
18. Adjust the stoplamp switch.
The stoplamp switch will self adjust the first time the brake pedal returns to its "stopped" position after the switch is installed.
A. Apply the brake pedal and press the switch in until it firmly seats in the retainer.
Note: "Clicks" can be heard as the threaded portion of the switch is pushed through the retainer.
B. Pull the brake pedal against the pedal stop until the click can no longer be heard.
Note: Electrical contact should be made when the brake pedal is applied 11-24 mm (0.45-0.95 in) from the fully released position.
19. Install Campaign Identification Label, on the radiator core support.
PARTS INFORMATION
Due to the small quantity of parts that are estimated to be required (10%), it is important to inspect the left side of the brake pedal assembly to verify the stamping number prior to ordering parts. It is estimated that the possibility of vehicles requiring the brake pedal assembly is extremely remote.
Parts are to be obtained from General Motors Service Parts Operations (GMSPO). To insure that these parts will be obtained as soon as possible, they should be ordered from GMSPO on a C.I.O. order with no special instruction code but order under advise code (2).
Part Number Description Qty./Veh. ------ ----------- --------- 12345382 Thread Locking Compound As Required 15641698 Brake Pedal Assembly 1
WARRANTY INFORMATION
Dealers should submit a warranty claim on each vehicle completed under this campaign.
Labor Operation *Time Trouble Number Description Allowance Code --------- ----------- ---------- ------- V7590 Inspection - No 0.2 hrs. 96 Further Action Required
V7591 Replace the brake 1.0 hrs. 96 Pedal
*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.
COPY OF LETTER TO OWNERS
Dear GMC Truck Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
General Motors has determined that some 1992 G-Vans produced at the Scarborough Assembly plant and equipped with vacuum power brake systems (JB5/JB7) have an incorrect brake pedal assembly. This incorrect brake pedal assembly has a pushrod pin that is both too small and installed in the incorrect location relative to the brake pedal pivot. The incorrect location of the push rod pin causes an increased brake pedal ratio that results in a decreased master cylinder stroke. Although a vehicle with a decreased master cylinder stroke will meet the full system stop- ping requirements of Federal Motor Vehicle Safety Standard (FMVSS) 105, "Hydraulic Brake Systems" it will not meet the partial system failure requirements. A further reduction of braking ability at a time when partial system failure has occurred could result in a vehicle crash without prior warning.
To correct this condition, your dealer will inspect for an incorrect brake pedal assembly and replace as required. This service will be completed for you at no charge.
Instructions for performing this service have been sent to your GMC dealer. Please contact your dealer to arrange a service date. The labor time necessary to perform this correction will vary from one hour and fifteen minutes to one hour and thirty minutes. Please ask your dealer how much additional time will be needed to process your vehicle.
Your GMC 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 shortest 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.
GMC TRUCK DIVISION GENERAL MOTORS CORPORATION
92C16 Enclosure
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.
