CAMPAIGN: FRONT DISC BRAKE FLEXIBLE HOSE DAMAGE
PRODUCT SAFETY CAMPAIGN
SUBJECT: 97027 - FRONT DISC BRAKE FLEXIBLE HOSE DAMAGE
MODELS: 1997 W4 (GAS) MEDIUM DUTY TRUCKS
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 1997 W4 Medium Duty Trucks. Some of these vehicles have damage to the left and/or right front disc brake flexible hoses which could result in a brake fluid leak. Brake fluid leakage could reduce brake effectiveness and increase stopping distances. Partial loss of braking at a time when minimum stopping distance is required could result in a vehicle crash without prior warning.
To prevent the possibility of this condition occurring, dealers e existing left and right front disc brake flexible hoses for evidence of chafing and/or damage, and replace any flexible hoses that are found chafed and/or damaged with new ones.
VEHICLES INVOLVED
Involved are certain 1997 W4 Medium Duty Trucks built within the following VIN breakpoints: PLANT YEAR DIVISION MODEL PLANT CODE FROM THROUGH
1997 Chevrolet W4 Janesville "J" VJOOOO79 VJOO1106
1997 GMC W4 Janesville "J" VJOOOO85 VJOO1228
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.
Notice: It is estimated that only 14% of involved vehicles will require replacement of one hose and only 1% of involved vehicles will require replacement of both hoses. Please order parts accordingly.
Part Quantity/ Number Description Vehicle
97039542 Flex Hose 1 or 2, As Req'd 94027190 Eye Bolt 1 or 2, As Req'd 94000373 Flex Gasket 2 or 4, As Req'd 12377967 Brake Fluid As Req'd
CUSTOMER NOTIFICATION
Customers will be notified of this campaign on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly).
DEALER CAMPAIGN RESPONSIBILITY
All unsold new vehicles in dealers' possession and subject to this campaign must be held and inspected/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
1. Tilt the vehicle cab and lock it in place.
2. Inspect both the left and right front disc brake flexible hoses for evidence of chafing and/or damage.
* If either of the flexible hoses is chafed and/or damaged, the affected flexible hose(s) must be replaced. Stop here, lower the cab and go to "REPLACING THE FRONT DISC FLEXIBLE HOSE (LEFT/RIGHT)" listed below.
* If neither of the flexible hoses is chafed and/or damaged, no further action is required. Lower the cab and install the GM Identification Label.
REPLACING THE FRONT DISC BRAKE FLEXIBLE HOSE (LEFT/RIGHT)
1. Raise the vehicle front and support it using suitable jack stands.
2. Remove the front wheel and tire.
3. Disconnect the brake line union nut and the frame clip from the frame bracket.
4. Pull the flexible hose end from the frame bracket.
5 .Remove the special eye bolt (Figure 1, Item 2) and two copper gaskets (Figure 1 , Item 3) at the banjo end (Figure 1 , Item 1 ) of the flexible hose (Figure 1 , Item 4). Remove the flexible hose from the front wheel cylinder.
6. Install a new flexible hose (Figure 1, Item 4) and secure the banjo end (Figure 1, Item 1) to the front wheel caliper using a new special eye bolt (Figure 1, Item 2) and two new copper gaskets (Figure 1, Item 3).
7. Attach the flexible hose end to the frame bracket and secure it with the frame clip. Connect the brake line union nut.
8. When all affected flexible hose have been replaced, bleed the brake system in accordance with the bleeding procedure in Section 5, of the Service Manual.
9. Reinstall the front wheel with tire, remove the jack stands, and lower the vehicle.
10. Check front disc brakes for proper operation.
11. Install the GM Campaign Identification Label.
CLAIM INFORMATION
Submit a Product Campaign Claim with the information indicated below:
REPAIR PERFORMED PART FAILED PARTS LABOR LABOR NET COUNT PARTNO. ALLOW CC-FC 0P HOURS ITEM
Inspect Only - No --- --- --- MA-96 V0042 0.2 --- Further Action Required
Inspect and Replace 4 --- MA-96 V0043 0.7 *** One Front Disc Brake Flexible Hose (Includes Brake Bleed and Check For Proper Operation)
Inspect and Replace 8 --- MA-96 V0044 0.9 *** Both Front Disc Brake Flexible Hoses (Includes Brake Bleed and Check For Proper Operation) I
* 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.
*** The amount identifed in the "Net Item" column should represent the sum total of the Current GMSPO Dealer Net Price plus 40% for actual brake fluid used to perform the required repairs, not to exceed $2.40.
Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission.
June,1997
Dear General Motors Truck Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Reason For This Recall: General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1997 W4 Medium Duty Trucks. Some of these vehicles have damage to the left and/or right front disc brake flexible hoses which could result in a brake fluid leak. Brake fluid leakage could reduce brake effectiveness and increase stopping distances. Partial loss of braking at a time when minimum stopping distance is required could result in a vehicle crash without prior warning.
What Will Be Done: To prevent the possibility of this condition occurring, your GMC dealer will inspect the existing left and right front disc brake flexible hoses for evidence of chafing and/or damage, and replace any flexible hoses that are found chafed and/or damaged with new ones. This service will be performed for you at no charge.
How Long Will The Repair Take? The length of time required to perform this service correction is approximately 15 minutes for the inspection and an additional 35-45 minutes for replacement of the front disc brake flexible hose(s), if required. Additional time may be required to schedule and process your vehicle. If your dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed.
Contacting Your Dealer: Please contact your GMC dealer as soon as possible to arrange a service date. Parts are available and instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Your GMC dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the Pontiac-GMC Customer Assistance Center at 1-800-462-8782. Deaf, hearing impaired or speech impaired should call 1-800-462-8583 (utilizes Telecommunication Devices for the Deaf/Text Telephones, TDD/TTY).
If, after contacting the Pontiac-GMC Customer Assistance Center, you are still not satisfied that we have done our best to remedy this condition without charge and 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 1-800-424-9393 (Washington D.C. residents use 202-366-0123).
Customer Reply Card: The enclosed customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the postage paid 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.
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.
