CAMPAIGN: FRT. AIR BRAKE HOSE MAY RAPTURE/SERVICE PROCEDURE
SUBJECT: BRAKE HOSE CAN CONTACT INNER FENDER EXTENSION
MODELS: 1985-1990 C7D MEDIUM TRUCKS WITH HIGH CAB MODELS (EPG) AND 7,000# AIR BRAKE FRONT AXLES (FS2/FT2)
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 a defect which relates to motor vehicle safety exists on certain 1985-90 C7D medium conventional high cab models (EPG) equipped with 7,000# air brake front axles (FS2/FT2). The front air brake hoses can contact the inner fender extensions. If this occurs, the inner fender extension can chafe the brake hoses and eventually wear the hoses to the point that a rupture would occur, resulting in a loss of front brakes. Tbese vehicles are equipped with a dual braking system; part of the system will still work and allow the vehicle to be stopped, but over a greater distance. Loss of front braking at a time when minimum stopping distance is required could result in a vehicle crash, without prior warning.
To prevent this condition from occurring, it will be necessary to cut out a portion of the inner fender extensions on both sides of the vehicle. Additionally, both front brake hoses will be inspected for chafing and replaced if chafing has occurred.
VEHICLES INVOLVED
Involved are certain 1985-90 C7D medium conventional high cab models (EPG) equipped with 7,000# air brake front axles (FS2/Fr2) built within the following VIN breakpoints:
MODEL YEAR FROM THROUGH --------- ---------- -------- GMCTRUCK 1985 FV622391 FV626374 1986 GV502332 GV538071 1987 HV505286 HV539953 1988 JV501148 JV535041 1989 KV501508 KV521933 1990 LV500415 LV500633
CHEVROLET 1985 FV212016 FV217206 1986 GV102593 GV120867 1987 HV105429 HVI16257 1988 JV101602 JV116823 1989 KV105803 KV114515 1990 LV100057 LV100995
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 inspect and 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.
If no owner's name and address were available to GMC Truck Division at the time of campaign initiation, the dealer will 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 name 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. Ac- cordingly, you are urged to limit the use of this listing to this campaign.
SERVICE PROCEDURE
The following service procedure consists of making a clearance cut-out in the inner fender extension and mud splash shield. Additionally, air brake hoses must be inspected for damage and replaced if necessary.
A. Inspection Procedure (See Figure 1)
1. Set parking brake.
2. Inspect air brake hoses on both sides of vehicle. If there is any sign of chafing or damage to the hoses at the inner fender area, remove and replace hoses as described in Paragraph "C."
B. Making Clearance Cut-Out In Inner Fender Extension and Mud Splash Shield
1. A template for the cut-out has been furnished. In addition, Figure 2 gives the dimensions for making a template, if necessary.
2. Using the template, mark the areas on the inner fender extension and mud splash shield on both the right and left sides of the vehicle. The location of the cut-out areas is shown in Figure 1.
3. The cut-out can be made using an electric saber saw with a metal cutting blade which will cleanly cut both the fiber glass inner fender extension and the rubber mud splash shield.
NOTE: Fiber glass dust can be very irritating to the skin and eyes. When cutting the fiber glass, wear long sleeved shirt and goggles.
C. Removal and Replacement of Front Air Brake Lines
1. Remove access panel section of engine noise shield to gain access to front air line and elbow fitting.
2. Remove clamps holding right and left front brake lines to inside of frame near elbow fittings.
3. Remove front brake lines from elbow fittings.
4. Remove elbow fittings from frame.
5. Remove plastic connecting hoses connecting front brake chambers to bracket elbows from the elbow at bracket.
6. Remove elbow fittings from brackets.
7. Remove front brake hoses and replace with new hoses.
8. Installation is reverse of removal.
NOTE: Apply sealer to all thread surfaces.
PARTS INFORMATION
Parts are to be obtained from General Motors Service Parts Operation (GMSPO). To ensure 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 an advise code (2).
Part Number Description Quantity ----------- ------------------- -------- 2023204 Brake Hose (LH & RH) AR
WARRANTY INFORMATION
Dealers should submit an accurately filled out Warranty Repair Order on each vehicle completed under this campaign.
LABOR OPERATION *TIME TROUBLE NUMBER DESCRIPTION ALLOWANCE CODE -------- ----------------------- --------- -------- V5700 Rework Inner Fender Shields .2 Hr 96 V5701 Replace LH Brake Hose .7 Hr 96 V5702 Replace RH Brake Hose .7 Hr 96
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 five (5) digit dealer code of this 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" #P 8919.
Dear GM 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 a defect which relates to motor vehicle safety exists on certain 1985-90 C7D medium conventional high cab models (EPG) equipped with 7,000# air brake front axles (FS2/FT2). The front air brake hoses can contact the inner fender extensions. If this occurs, the inner fender extension can chafe the brake hoses and eventually wear the hoses to the point that a rupture would occur, resulting in a loss of front brakes. These vehicles are equipped with a dual braking system; part of the system will still work and allow the vehicle to be stopped, but over a greater distance. Loss of front braking at a time when minimum stopping distance is required could result in a vehicle crash, without prior warning.
To prevent this condition from occurring, it will be necessary to cut out a portion of the inner fender extensions on both sides of the vehicle. Additionally, both front hoses will be inspected for chafing and replaced if chafing has occurred. This service will be performed for you at no charge.
Instructions for performing this service have been sent to your GM dealer. Parts are available. Please contact your dealer to arrange a service date. The labor time necessary to perform this correction may vary from 15 min. to 1-1/2 hours. Please ask your dealer how much additional time will be needed to process your vehicle.
Your GM dealer is best equipped to obtain parts and 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. Tbe 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 that we have done our best to remedy this condition without charge 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 800-424-9393 (Washington, D.C. residents use 366-0123).
The enclosed 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 let us know by completing the postage paid owner reply card and returning it 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.
***************************************************************************** *STG DISCLAIMER*
"THE TEMPLATE DISPLAYED IN THIS SERVICE PUBLICATION IS NOT INTENDED FOR USE" (Please refer to the actual publication for an accurate "TEMPLATE" to use in this service procedure.) *****************************************************************************
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.
