Product Safety Recall-Clutch Master-Cylinder Pushrod Wearout

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999 and 2000 Chevrolet and GMC T-Series; and Isuzu FSR, FTR and FVR vehicles equipped with manual transmissions. Some of these vehicles have a condition in which the clutch master-cylinder pushrod end that attaches to the clutch pedal pin may wear to the point of not performing as intended. The first noticeable effect of this wear may be the clutch pedal not returning completely to the full-up position. If this occurs, the fast-idle engine speed control may not function. If the clutch master-cylinder pushrod end wear sufficiently to allow the attaching end to bend open or break off, the pedal pin would detach from the clutch rod link and the clutch would engage. If clutch engagement occurred while the vehicle was stopped, with the engine running and the transmission in gear, and if the brakes were not applied, the vehicle could move forward if the transmission were in a forward gear, or rearward if the transmission were in a reverse gear. Vehicle motion could be immediately stopped by applying the service or park brake.

Dealers are to install a new clutch master-cylinder assembly and clutch pedal assembly.

Involved are certain 1999 and 2000 Chevrolet and GMC T-Series vehicles, and Isuzu FSR, FTR and FVR vehicles equipped with manual transmissions. Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada Only) before beginning recall repairs. Not all vehicles are 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 recall bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall.

For GM Dealers

Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

For Isuzu Dealers

Parts required to complete this recall are to be obtained from American Isuzu Parts Distribution Network (AIPDN). Please refer to your "involved vehicles listing" prior to ordering requirements.

The following procedure describes how to replace the clutch master-cylinder assembly and the clutch pedal. Both parts must be replaced to complete this recall.

Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information.

Important: Have shop towels and a suitable container inside the vehicle for draining the clutch fluid when disconnecting the hose in the next step.

1. From underneath the instrument panel (I/P), reposition the clamp and remove the rubber hose that connects to the plastic pipe that comes through the sheet metal from the rear of the clutch fluid reservoir.
2. Remove the retaining clip that attaches the clutch master-cylinder rod to the clutch pedal and disconnect the rod. Do not reuse the clip.
3. Remove the three bolts that attach the clutch master-cylinder mounting bracket to the I/P support. Lower the assembly to the floor.
4. Open the hood and locate the clutch master-cylinder inline connector on the braided hose behind the grille. Remove all dirt from connector.
5. Using a flat-bladed screwdriver, slide and push the white nylon ring located on the male side of the connector into the female half of the connector. When the nylon ring is almost completely (all the way around) inside the connector, the male half of the connector will disengage.
6. From inside the vehicle, remove the rubber grommet from the floor pan and remove the complete clutch master-cylinder assembly from the vehicle.
7. Remove the clutch master-cylinder from the mounting bracket by twisting the cylinder clockwise.
8. Install the new clutch master-cylinder in the mounting bracket and twist the cylinder counterclockwise to lock in place.
9. Install rubber grommet on the braided hose and set the assembly aside.

Important: Loosen but do NOT remove the bolt in the next step. The bolt will be used for pushing the pivot shaft to the right in the following step.

10. From inside the vehicle, loosen the bolt attaching the clutch pedal assembly to the I/P support until about ten threads are visible. The bolt is located on the left side of the pedal pivot shaft.
11. Push the head of the bolt back into the I/P support or towards the center (to the right) of the vehicle. As you push the bolt back in, the pivot shaft on the other side of the BRAKE pedal will begin to come out of the I/P support. This pivot shaft supports both the clutch and brake pedals.
12. Continue loosening and remove the attaching bolt.

Important: To obtain the necessary clearance for the pivot shaft in the next step, it may be necessary to remove the plastic tie strap and reposition the wiring harness located just to the left of the raised section in the sheet metal.

13. From the right side of the brake pedal, grasp the square metal plate on the end of the pivot shaft and continue to pull it out of the I/P support until it contacts the raised (bump) section in the sheet metal. Rotate or turn the square metal plate as necessary to allow for more of the shaft to be pulled out of the support before the plate contacts the raised section in the sheet metal.

Important: Depending on the amount of clearance, it may be necessary to slightly pry or rotate (twist) the clutch pedal assembly to remove it from the I/P support in the next step.

14. Remove the clutch pedal assembly.

Important: Some vehicles were manufactured with a clutch pedal assembly that has a rubber bumper on the welded metal bracket for the starter interlock switch. The new clutch pedal assembly does NOT require the rubber bumper and therefore the hole for it has been removed from the bracket. Also, the bracket on the new pedal assembly has been relocated to compensate for the rubber bumper, which is no longer used. As a result, it should not be necessary to adjust the starter interlock switch when installing the new pedal assembly.

15. Transfer the clutch pad, two plastic bushings, and the switch bracket (including the nut, bolt and rubber bumper) to the new pedal assembly.

Tighten
Tighten the nut and bolt to 16 N·m (12 lb ft).

16. Install the new clutch pedal assembly into the I/P support.
17. From the right side of the brake pedal, push the pivot shaft completely back into the I/P support.
18. Install the bolt attaching the left side of the clutch pedal assembly to the I/P support.

Tighten
Tighten to 45 N·m (33 lb ft).

Important: To ease the routing of the braided hose and to keep the connector clean, do not remove the plastic protective cover from the connector until after the hose has been installed.

19. From inside the vehicle, route the braided hose assembly through the hole in the floor pan and install the rubber grommet.
20. From outside the vehicle, remove the plastic protective cover and connect the braided hose to the in-line connector located behind the grille.
21. From inside the vehicle, position the master-cylinder mounting bracket to the I/P support and install the three bolts.

Tighten
Tighten to 45 N·m (33 lb ft).

22. Connect the clutch master-cylinder rod to the clutch pedal and install a new retaining clip, P/N 03817880.
23. Connect the rubber hose on the clutch master-cylinder to the plastic pipe on the rear of the clutch fluid reservoir and install the clamp.
24. Fill the clutch fluid reservoir with clean DOT 3 brake fluid.
25. Start the engine and verify proper clutch system operation.
26. Install the GM Recall Identification Label.

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP91 when ordering.

Using a ballpoint pen, fill out the following information on a recall label (Part Number 2-90028-700-0).

Affix the recall label adjacent to the manufacturer's identification label located on the driver's side B-pillar.

Submit a Product Recall Claim with the information indicated below:

Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission.

Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter included with this bulletin).

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall 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 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. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall 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 customer letter accompanying this bulletin. Recall 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 recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear General Motors 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 1999 and 2000 Chevrolet and GMC T-Series; and Isuzu FSR, FTR and FVR vehicles equipped with manual transmissions. Some of these vehicles have a condition in which the clutch master-cylinder pushrod end that attaches to the clutch pedal pin may wear to the point of not performing as intended. The first noticeable effect of this wear may be the clutch pedal not returning completely to the full-up position. If this occurs, the fast-idle engine speed control may not function. If the clutch master-cylinder pushrod end wear sufficiently to allow the attaching end to bend open or break off, the pedal pin would detach from the clutch rod link and the clutch would engage. If clutch engagement occurred while the vehicle was stopped, with the engine running and the transmission in gear, and if the brakes were not applied, the vehicle could move forward if the transmission were in a forward gear, or rearward if the transmission were in a reverse gear. Vehicle motion could be immediately stopped by applying the service or park brake.

Your dealer will install a new clutch master-cylinder assembly and clutch pedal assembly. This service will be performed for you at no charge .

The length of time required to perform this service correction is approximately 50 minutes. Additional time may be required to schedule and process your vehicle. If you 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 to schedule, process and repair your vehicle.

Please contact your 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.

Your 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 appropriate Customer Assistance Center at the number listed below:

If, after contacting the appropriate 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 SW, Washington, DC 20590 or call 1-888-327-4236.

The attached 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 attached and mailing it in the postage paid envelope.

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.

General Motors Corporation/General Motors Isuzu Commercial Truck LLC

Enclosure