CAMPAIGN: PARKING BREAK SOLEOID VALVE MALFUNCTION
PRODUCT SAFETY CAMPAIGN
SUBJECT: 96-C-39 - PARKING BRAKE SOLENOID VALVE MALFUNCTION --------------------------------------------------
MODELS: 1996 TOPKICK/KODIAK WITH AUTO-APPLY PARK BRAKE SYSTEMS (J71) -------------------------------------------------------
The Highway 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 customer has tendered it for repair. A failure to repair within sixty (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 customer 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 remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the divisional letter that is being sent to customers, the customers are being instructed to contact the appropriate Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.
DEFECT INVOLVED
General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1996 TopKick and Kodiak model medium duty conventional vehicles equipped with auto-apply park brakes. These vehicles may exhibit an intermittent inoperative park brake apply under certain conditions. If the park brake does not apply (manual or auto application), the "Service Park Brake" warning light will illuminate. However, if the warning light goes unnoticed and the operator exits the vehicle, the vehicle could roll away and a vehicle crash could occur.
To correct this condition, dealers are to replace the parking brake solenoid valve with one having a 12 volt coil and the original valve spring.
VEHICLES INVOLVED
Involved are certain 1996 GMC TopKick and Chevrolet Kodiak model vehicles (465 in total) that are equipped with optional auto-apply park brakes (RPO J71) and built within the following VIN breakpoints:
PLANT YEAR DIVISION MODEL PLANT CODE FROM THROUGH ---- --------- ----- ----- ----- ---- -------
1996 GMC TopKick Janesville "J" TJ512588 TJ850395 1996 Chevrolet Kodiak Janesville "J" TJ108601 TJ111252
NOTICE: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) or ServiceNet (GMC only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved]
Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The Customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.
These dealer listings may contain customer 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 the follow-up necessary to complete this campaign.
PARTS INFORMATION
Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order.
Part Quantity/ Number Description Vehicle ----- ----------- ---------
15687353 Parking Brake Solenoid Valve Assembly 1
DEALER CAMPAIGN RESPONSIBILITY
All unsold new vehicles in dealers' possession and subject to this campaign must be held and repaired per the service procedure of this campaign bulletin before customers take possession of these vehicles.
Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the appropriate divisional customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.
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.
SERVICE PROCEDURE
REFER TO FIGURE 1.
1. Chock the wheels and follow all safety related precautions.
2. Disconnect the negative battery cable.
3. Remove the cover from the compartment box on the driver's side of the truck.
4. Locate the parking brake solenoid valve assembly in the compartment box near the left rear corner of the box.
CAUTION:
The solenoid may be extremely hot. Use caution when handling the solenoid and/or solenoid valve assembly.
5. Disconnect the parking brake solenoid coil electrical connector.
6. Position a drain pan under the work area to catch any droplets of fluid that may leak out.
7. Disconnect the two hydraulic pipe assembly fittings attached to the parking brake valve assembly.
8. Remove two parking brake solenoid valve mounting nuts, (Item 6) four washers (Items 2 and 7) and two bolts (item 1) located near the bottom of the valve assembly.
9. Remove the solenoid valve assembly (item 4).
10. Remove the nut (item A) and metal label and solenoid coil (item B) from the top of the valve assembly (Item C). Retain the 12-volt black solenoid coil. Remove and retain the fittings from the valve assembly. Note orientation of the fittings. Discard valve.
11. PENSKE VEHICLES ONLY: Remove the nut from the replacement valve. Proceed to Step 13.
12. ALL OTHER VEHICLES: It is necessary to remove and discard the 1 0-volt solenoid coil on the replacement assembly. 12-volt solenoid coils must be used on all vehicles.
Remove the nut (item A) and metal label and solenoid coil (Item B) from the top of the replacement valve assembly (Item C). Discard the 10-volt black solenoid coil. Proceed to Step 13.
13. Install the removed 12-volt solenoid coil on the replacement valve. Install the metal label and nut. Torque the nut (Item A) to 5-8 N.m maximum (4-6 lb ft).
NOTICE: Voltage identification is stamped on the bottom of the solenoid coil. The replacement part from GMSPO will include a 10-volt solenoid coil. The 10-volt solenoid coil MUST be removed and discarded. The 12-volt coil MUST be installed on the replacement valve assembly.
CAUTION:
Over-tightening the nut may cause valve failure.
14. Install fittings on replacement valve assembly in the correct position. Reinstall the valve assembly on the vehicle. Torque the mounting nuts (item 6) to 13 Nm (115 lb. in).
15. Reconnect the hydraulic pipe assemblies. Torque the pipe fittings to 16 Nm (12 1b. ft).
16. Reconnect the parking brake solenoid coil electrical connector.
17. Reconnect the negative battery cable.
18. Cycle the parking brake system several times. Check for leaks.
19. Clear any Diagnostic Trouble Codes that may have been set in the Module Assembly. For displaying and clearing diagnostic trouble codes refer to the 1996 Medium Duty Truck Service Manual, Book 1 of 2, Section Electric/Hydraulic Parking Brake, Page 5Fl-5.
20. Check for proper operation of the parking brake. To apply the parking brake, start the vehicle and pull the "Park Brake" knob toward you, then shift the transmission to Neutral (N) or Park (P). To release the parking brake, press the knob in. In order to release the parking brake, the ignition must be in the Run position and the shift lever out of Park (P). The parking brake will apply if the ignition is turned off or if it is in Park (P). It will also apply if the vehicle's battery is dead or disconnected. The "Park Brake" light may flash while the parking brake is being released and should be on when the parking brake is applied.
CAUTION:
It may take a few seconds for the parking brake to fully apply, and even longer when it is cold outside. If you turn the ignition off before the parking brake is applied, an alarm will sound until the parking brake applies fully.
21. Reinstall the compartment box cover.
22. Remove the wheel blocks.
23. Install the GM Campaign Identification Label.
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 the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a 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 by the customer for periodic servicing. When installing the Campaign Identification Label, be sure to install the clear protective covering. Additional Campaign Identification Labels can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday-Friday, 8:00 a.m. to 4:30 p.m. EST). Ask for Item Number S-1015 when ordering.
Apply the "Campaign Identification Label" only on a clean, dry surface.
CLAIM INFORMATION
Submit a Product Campaign Claim with the information indicated below:
REPAIR PART FAILED PARTS LABOR LABOR PERFORMED COUNT PART NO. ALLOW CC-FC 0P HOURS --------- ----- -------- ----- ----- ----- -----
Remove And Install 1 15740953 ** MA-96 V9952 0.6 Parking Brake Valve Assembly
* For Campaign Administrative Allowance, add 0.1 hours to the "Labor Hours".
** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 40% for parts needed to complete the repair.
Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission.
Dear GM Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1996 TopKick and Kodiak model medium duty conventional vehicles equipped with RPO J71 auto-apply brakes.. These vehicles may exhibit an intermittent inoperative park brake apply under certain conditions. If the park brake does not apply (manual or auto application), the "Service Park Brake" warning light will illuminate. However, if the warning light goes unnoticed and the operator exits the vehicle, the vehicle could roll away and a vehicle crash could occur.
To correct this condition, dealers are to replace the parking brake solenoid valve assembly with one having a 12 volt solenoid original valve spring. This service will be performed for you at no charge.
Instructions for performing this service have been sent to your GMC/Chevrolet dealer. Please contact your dealer to arrange a service date. The labor time necessary to perform this correction will be approximately 40 minutes and parts are available. Please ask your dealer how much additional time will be needed to process your vehicle.
Your GMC/Chevrolet 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 GMC Consumer Relations by telephone. Consumer Relations will assist you and your dealer in getting your vehicle corrected. The telephone number of the Consumer Relations office is listed in your Warranty and Owner Assistance Information Manual.
After contacting your GMC/Chevrolet dealer and GMC Consumer Relations, 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 202-366-0123).
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 product.
Pontiac-GMC Division GENERAL MOTORS CORPORATION
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.
