General Motors has determined that certain early shipped 1992 TopKick/Kodiak medium duty vehicles equipped with 6.OL engines (RPO LSO) and Fuller Manual transmissions (RPOs MSA and MSC) were shipped with incorrect clutch forks installed. The incorrect clutch fork is approximately 3/4 of an inch too short. This can cause increased clutch pedal effort, clutch free play, premature clutch cable failure, and over travel causing release bearing, clutch disc, and/or clutch cover failures. To correct this condition, dealers will install an extension to the clutch fork. VEHICLES INVOLVED Involved are certain 1992 C6/7H TopKick/Kodiak vehicles built within the following Build period:
MODEL YEAR MODEL FROM THROUGH ----- ----- ---- ------- 1992 TopKick/Kodiak August 26, 1991 September 9, 1991
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 cor- rection according to instructions contained in this bulletin.
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
1. Block the rear wheels and disconnect the negative battery cable from the battery.
2. Disconnect the clutch cable and spring from the clutch fork.
3. Install the clutch fork extension (P/N 3895390) (Figure 1, "30"), bolt (P/N 11 513606) (Figure 1, "29"), washer (P/N 15614758) (Figure 1, "18"), and nut (P/N 11501033) (Figure 1, "17"). Torque nut to 25 N-m. (18 lbs. ft.).
4. Connect the clutch cable.
5. Adjust the clutch pedal free travel to 38 mm (1.5-2.0 in.).
6. Tighten the jam nut (Figure 1, "19") to 35-45 N-m. (26-33 lbs. ft.) and install the return spring (Figure 1, "20").
7. Reconnect the negative battery cable and remove the wheel blocks.
8. Install "Campaign Identification Label".
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 ----------- ----------- -------- 3895390 Extension, Clutch 1 Fork
11513606 Bolt, Hex 1 (M lOxl.5x35)
11501033 Nut, Hex 1 (M 10xl.5)
156l4758 Washer, Flat M 10.8xl8.54xl.95)
WARRANTY INFORMATION
Dealers should submit a warranty claim on each vehicle completed under this campaign.
LABOR OPER. *TIME TROUBLE NUMBER DESCRIPTION ALLOWANCE CODE ------ ----------- --------- ------- V7320 Install Clutch 0.4 hrs. 96 Fork Extension
*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 GM Truck Owner:
Our records show that you own one of our new 1992 model General Motors TopKick/Kodiak medium trucks. The rate at which these trucks have been accepted into the stream of commerce has been very gratifying to us. In addition, feedback from customers, dealers and our own tracking systems indicate a very high degree of product reliability thus far.
We have recently become aware of a situation on certain early built 1992 TopKick/Kodiaks equipped with 6.OL engines (RPO LSO) and Fuller Manual transmissions (RPOs MSA and MSC) that may eventually reduce your truck's reliability. Your truck was shipped with an incorrect clutch fork installed. The incorrect clutch fork is approximately 3/4 of an inch too short. This can cause increased clutch pedal effort, clutch free play, premature clutch cable failure, and over travel causing release bearing, clutch disc, and/or clutch cover failures.
In the interest of maintaining you truck's reliability, we would like to correct this condition by installing an extension to the clutch fork. This service will be completed for you at no charge.
Instructions for performing this service have been sent to your GM TopKick/Kodiak dealer. Please contact your GM TopKick/Kodiak dealer to arrange a service date. Refer to your GM TopKick/Kodiak Servicing Dealers booklet for the dealer nearest you. The labor time necessary to perform this correction is approximately 30 minutes. Please ask your dealer how much additional time will be needed to process your vehicle.
The enclosed postage paid owner reply card identifies your vehicle. Presentation of this card to your GM TopKick/Kodiak 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 the 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 continued safisfaction.
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.