CAMPAIGN:RIGHT-HAND FRAME & BODY MOUNT CRACKS

CAMPAIGN NUMBER: 93-C-53 GROUP: 3C FRONT SUSPENSION DATE: OCTOBER 1994

SUBJECT: RIGHT-HAND FRAME AND BODY MOUNT CRACKS

MODELS: 1992-1993 P3 COMMERCIAL MODELS WITH 9L6 LOW PROFILE CHASSIS

CERTAIN 1992 THROUGH 1993 P3 COMMERCIAL LOW PROFILE CHASSIS VEHICLES MAY EXHIBIT A CRACKING CONDITION OF THE RIGHT-HAND FRONT BODY MOUNTING BRACKET AND/OR OF THE RIGHT-HAND FRAME RAIL IN THE AREA OF THE BODY MOUNTING BRACKET. IF A CRACK DEVELOPS IN THE BRACKET OR FRAME, AND IS NOT REPAIRED, IT MAY PROPAGATE AND CAUSE ADDITIONAL CRACKS TO OTHER FRAME ATTACHMENTS. THIS CONDITION IS CAUSED BY A "BOTTOMING OUT" OF THE FRONT SUSPENSION THAT CAUSES HIGH IMPACT LOADS TO BE TRANSMITTED TO THE RIGHT-HAND FRAME AND BODY MOUNT BRACKET.

TO CORRECT THIS CONDITION, A FRONT AIR BAG SUSPENSION KIT WILL BE INSTALLED ON ALL INVOLVED VEHICLES. ON VEHICLES EXHIBITING A CRACK IN THE RIGHT-HAND BODY MOUNT OR FRAME, IT WILL BE NECESSARY TO INSTALL A RIGHT-HAND BODY MOUNT KIT AND REPAIR THE CRACKS.

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1991-1993 P3 WITH 9L6 (LOW-PROFILE CHASSIS) VEHICLES BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS:

YEAR MODEL FROM THROUGH 1992 P30842 W/9L6 SOP EOP 1993 P30842 W/9L6 SOP P3501776 (AND P3321558 WHICH WAS BUILT OUT OF SEQUENCE)

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. DEALERS SHOULD CONFIRM VEHICLE ELIGIBILITY THROUGH VISS (VEHICLE INFORMATION SERVICE SYSTEM) OR SERVICENET PRIOR TO BEGINNING CAMPAIGN REPAIRS.

ALL UNSOLD VEHICLES IN DEALERS' 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 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 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.

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 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 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.

SERVICE PROCEDURE

STEPS 1 THROUGH 4 INSPECT FOR RIGHT-HAND FRONT BODY MOUNT ASSEMBLY OR FRAME CRACKS.

STEPS 5 THROUGH 9 PROVIDE INSTALLATION FOR NEW RIGHT-HAND FRONT BODY MOUNT KIT.

RIGHT-HAND FRONT BODY MOUNT KIT WILL BE INSTALLED ONLY ON VEHICLES EXHIBITING FRONT BODY MOUNT OR FRAME CRACKS.

STEPS 10 THROUGH 14 INSTALL THE SUSPENSION KIT.

INSPECTION FRAME CRACKING

1. RAISE THE FRONT OF THE VEHICLE. REFER TO THE 1994 P3 AND P/G CHASSIS SERVICE MANUAL NAPT-9432 GENERAL INFORMATION SECTION OA-8 ENTITLED GENERAL VEHICLE LIFTING AND JACKING.

2. REMOVE THE RIGHT AND LEFT-HAND FRONT WHEEL ASSEMBLIES.

3. REFER TO FIGURE 1. ACCESS THE RIGHT-HAND FRONT WHEEL HOUSE AREA AND LOCATE THE RIGHT-HAND BODY MOUNT BRACKET ASSEMBLY (ITEM 1) ATTACHED TO THE FRAME RAIL. INSPECT THE FRAME RAIL AND THE RIGHT-HAND FRONT BODY MOUNT BRACKET ASSEMBLY FOR LOOSENESS OR CRACKING.

4. IF NO CRACKS ARE DETECTED IN EITHER THE RIGHT FRONT BODY MOUNT BRACKET OR THE FRAME RAIL, PROCEED TO STEP 10.

NOTICE: DUE TO A LIMITED AMOUNT OF RIGHT-HAND FRONT BODY MOUNT KITS, D O NOT ORDER THE MOUNT KIT UNLESS THE INSPECTION INDICATES A NEED FOR THE KIT.

FRONT BODY MOUNT KIT INSTALLATION

5. IF A CRACKING CONDITION EXISTS IN THE RIGHT-HAND FRONT BODY MOUNT BRACKET OR THE FRAME RAIL, IT WILL BE NECESSARY TO REMOVE THE BODY MOUNT BRACKET.

6. REFER TO FIGURE 1 ITEMS 5, 6 7 AND 8. REMOVE THE BOLT AND NUT ASSEMBLY FROM THE RIGHT-HAND FRONT BODY MOUNT BRACKET AND RETURN. WHEN REMOVING THE BOLT ASSEMBLY, THE BODY MAY MOVE RELIEVING MOST OF THE PRESSURE ON THE BODY MOUNT BRACKET. THIS WILL ALLOW EASIER REMOVAL OF THE RIVETS AND BODY MOUNT BRACKET. DEPENDING ON THE BODY BUILDER THERE MAY ALSO BE A RADIATOR SUPPORT BRACKET ATTACHED TO THE RIGHT-HAND BODY MOUNT.

7. REMOVE THE RIGHT-HAND FRONT BODY MOUNT BRACKET. USE A #5 CENTER DRILL TO AID IN REMOVAL OF THE SIX BODY MOUNT ATTACHING RIVETS. AFTER THE RIVETS HAVE BEEN CENTER DRILLED, USE A CHISEL AND REMOVE THE HEAD OF THE RIVET AND DRIVE THE SHAFT OF THE RIVET THROUGH THE FRAME RAIL WITH A DRIFT PIN. DISCARD THE RIVETS AND THE OLD BRACKET ASSEMBLY.

8. INSPECT THE RIGHT-HAND FRONT FRAME RAIL FOR ANY CRACKS THAT MIGHT HAVE BEEN HIDDEN BY THE BRACKET ASSEMBLY. REPAIR ALL CRACKS IN THE FRAME RAIL AS NECESSARY. REFER TO THE SERVICE MANUAL, SECTION 2A-5 FOR WELDING INSTRUCTIONS.

9. REFER TO FIGURE 1. INSTALL THE NEW RIGHT-HAND FRONT BODY BRACKET ASSEMBLY (ITEM 1) AND THE INSIDE FRAME REINFORCEMENT (ITEM 2). LOOSELY INSTALL BOLTS(ITEM 3) AND NUTS (ITEM 4). DO NOT TIGHTEN THE ASSEMBLY AT THIS TIME. RE-INSTALL AND PARTIALLY TIGHTEN THE BODY BOLT AND NUT ASSEMBLY (ITEMS 5, 6, 7 AND 8). THIS WILL ASSIST THE TECHNICIAN WITH ALIGNING THE TOTAL ASSEMBLY. TIGHTEN THE BODY-MOUNTING BRACKET BOLTS (ITEM 3) TO 38 N.M (28 LBS. FT.) IN AN ALTERNATING PATTERN. TIGHTEN THE UPPER BODY MOUNT NUT (ITEM 8). THE UPPER BODY MOUNT BOLT WAS ORIGINALLY INSTALLED BY A BODY BUILDER. CHECK BOLT HEAD FOR IDENTIFICATION AND REFER TO SERVICE MANUAL SECTION OA-12 GENERAL INFORMATION FOR FASTENER IDENTIFICATION AND TORQUE INFORMATION.

SUSPENSION KIT INSTALLATION

10. REFER TO SECTION 3C-8 OF THE SERVICE MANUAL NATP-9432. ON THE RIGHT AND LEFT-HAND FRONT SUSPENSION, REMOVE STABILIZER SHAFT CLAMPS (FIGURE 6, ITEM 42) ATTACHED TO THE LOWER CONTROL ARMS AND REMOVE THE FASTENERS (FIGURE 5, ITEMS 21, 22, AND 23) FROM THE LOWER PORTION OF THE SHOCK ABSORBER ASSEMBLY.

11. REFER TO SECTION 3C-13 FIGURE 15. DISCONNECT THE LOWER BALL JOINTS FROM THE STEERING KNUCKLES. THIS WILL ALLOW ACCESS TO THE COIL SPRING FOR REMOVAL.

12. REFER TO SECTION 3C-15 FIGURE 18. CAREFULLY REMOVE THE COIL SPRING ASSEMBLY.

13. AFTER THE COIL SPRINGS HAVE BEEN REMOVED, INSPECT THE AIR BAG ASSEMBLIES FROM SUSPENSION KIT P/N 15988948. THE END PADS SHOULD BE SECURED TO BOTH ENDS OF THE AIR BAG. IF PADS ARE LOOSE, REINSTALL BY SNAPPING PADS ONTO AIR BAG. REFER TO 3C-15 AND 3C-16 OF THE SERVICE MANUAL FOR AIR BAG INSTALLATION TO COIL SPRING.

14. REMOVE BOTH THE LEFT AND RIGHT-HAND UPPER REBOUND BUMPERS. DRIVE THE EXISTING REBOUND BUMPERS OUT OF THE UPPER CONTROL ARM ASSEMBLIES USING A DRIFT PIN. DISCARD THE EXISTING BUMPERS AND INSTALL NEW BUMPER ASSEMBLIES FROM THE SUSPENSION KIT (REFER TO FIGURE 2, ITEMS 1, 2 AND 3). TORQUE THE BUMPER NUT (ITEM 1) TO 155 N.M (114 LBS. FT.).

15. REFER TO 3C-14 IN THE SERVICE MANUAL (FIGURE 16) AND REMOVE THE JOUNCE BUMPER NUTS (ITEM 58) AND JOUNCE BUMPERS (ITEM 33) OF BOTH THE RIGHT AND LEFT-HAND LOWER CONTROL ARM ASSEMBLIES. RETAIN THE NUT (ITEM 58)AND INSTALL NEW JOUNCE BUMPERS (FIGURE 2, ITEM 4) FROM THE SUSPENSION KIT. TORQUE THE JOUNCE BUMPER NUT TO 35 N.M (26 LBS. FT.) (FIGURE 2, ITEM 5).

16. REFER TO SECTION 3C-14. REINSTALLATION OF COIL SPRINGS WITH NEW AIR BAGS.

REATTACH THE LOWER CONTROL ARM BALL JOINTS (3C-14 FIGURE 16 ITEM 35) TO THE STEERING KNUCKLES. TORQUE BALL JOINT NUTS TO 122 N.M (90 LBS. FT.) AND INSTALL COTTER PIN (ITEM 34).

17. REFER TO SECTION 3C-8. REINSTALL THE SHOCK ABSORBERS LOWER FASTENERS (FIGURE 5, ITEMS 21, 22 AND 23). TORQUE NUT (ITEM 23) TO 101 N.M (74 LBS. FT.).

18. REFER TO SECTION 3C-8. REINSTALL THE STABILIZER SHAFT CLAMPS (ITEM 42) AND ATTACHING FASTENERS (ITEMS 38, 39, 41 AND 43). TORQUE NUTS (ITEM 38) TO 33 N.M (24 LBS. FT.).

NOTICE: REFER TO SERVICE MANUAL PAGE 3C-32 FOR FASTENER TIGHTENING SPECIFICATIONS - INDEPENDENT FRONT SUSPENSION.

19. REFER TO SERVICE MANUAL SECTION 3E-9, FIGURE 10. REINSTALL THE WHEEL ASSEMBLIES.

20. LOWER THE VEHICLE.

21. INFLATE THE AIR BAGS TO 70 PSI.

22. ALIGN THE FRONT END. ALIGNMENT SPECIFICATIONS ARE PROVIDED IN SECTION 3A OF THE SERVICE MANUAL..

NOTICE: ALIGNMENT PROCEDURES SHOULD BE PERFORMED WITH VEHICLE LOADED ( UNDER NORMAL OPERATING CONDITIONS).

23. INSTALL CAMPAIGN IDENTIFICATION LABEL.

PARTS INFORMATION

PARTS ARE TO BE OBTAINED FROM GENERAL MOTORS SERVICE PARTS OPERATION (GMSPO). TO ENSURE PARTS ARE OBTAINED AS SOON AS POSSIBLE, ORDER THEM FROM GMSPO ON A C.I.O. ORDER WITH NO SPECIAL INSTRUCTION CODE BUT ORDER UNDER AN ADVISE CODE (2).

PART NUMBER DESCRIPTION QUANTITY 15988948 FRONT AIR BAG SUSPENSION KIT 1(ALL VEHICLES) 15999333 RIGHT-HAND FRONT BODY MOUNT KIT 1 (AS REQUIRED)

WARRANTY INFORMATION

DEALERS SHOULD SUBMIT A WARRANTY CLAIM ON EACH VEHICLE COMPLETED UNDER THIS CAMPAIGN.

LABOR OPERATION NUMBER DESCRIPTION *TIME ALLOWANCE TROUBLE CODE

V9190 INSTALL FRONT AIR BAG SUSPENSION KIT 2.4 96

V9191 INSTALL FRONT AIR BAG SUSPENSION KIT AND RIGHT-HAND FRONT BODY MOUNT KIT 3.6 96

V9192 INSTALL FRONT AIR BAG SUSPENSION KIT, RIGHT-HAND FRONT BODY MOUNT KIT AND REPAIR FRONT FRAME RAIL CRACKS 4.3 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 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

FIGURES: 2

PROCEDURES COVERING THIS CAMPAIGN ARE OUTLINED IN SECTION V OF YOUR DEALERSHIP'S "GMC TRUCK WARRANTY CLAIMS PROCESSING MANUAL" #P9119 REVISED 2/94.

GMC TRUCK BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A " DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THESE 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 YOUR GMC TRUCK DEALER FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.