Special Policy Adjustment - Upper Ball Joint Replacement

General Motors has received reports that some owners of certain 1996 and 1997 4-wheel drive Blazer/Jimmy/Bravada vehicles have had to pay for replacement of the upper ball joints that have separated. Vehicle owners of these 1996 and 1997 4-wheel drive Blazer, Jimmy and Bravada vehicles are being sent a letter making a special policy available to them. This special policy will cover upper ball joint replacement if the customer followed the recommended maintenance schedule for the chassis lubrication and the vehicle still requires the replacement of the upper ball joints due to separation. Involved vehicles are certain vehicles within a 14 month-build frame.

For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after November 27, 2001 are covered by this special policy and must be submitted using the labor operation codes provided with this bulletin. Claims with repair order prior to November 27, 2001 must be submitted to the Service Contract provider.

This special policy covers the condition described above for a period of 8 years or 100,000 miles (161,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The upper ball joint replacement, due to separation, will be made at no charge to the customer during this period.

Involved are certain 1996-1997 Chevrolet Blazers, GMC Jimmys and Oldsmobile Bravadas built within the following VIN breakpoints:

Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO).

Important: All parts are to be returned to the Warranty Parts Center (WPC). Submission of the warranty claim will generate the request from the WPC authorizing the part return.

Customers will be notified of the special policy on their vehicles by General Motors (see copy of typical customer letter included with this bulletin -- actual divisional letter may vary slightly).

Important: All parts are to be returned to the Warranty Parts Center (WPC). Submission of the warranty claim will generate the request from the WPC authorizing the part return.

Important: Perform the following procedures on both upper ball joints.

Removal Procedure

1. Raise and suitably support the vehicle with safety stands.
2. Remove the tire and wheel.
3. Remove the wheel speed sensor electrical connector from the upper control arm.
4. Disconnect the wheel speed sensor electrical connector.
5. Remove the cotter pin from the upper ball joint stud.
6. Remove the upper ball joint stud nut.
7. Using a pry bar, placed under the upper control arm and on top of the frame, pry upward.
8. With the aid of a helper, carefully hammer on the steering knuckle in the area of the upper ball joint stud in order to release the stud from the steering knuckle.



9. Remove the upper ball joint from the steering knuckle.

9.1.	Place a block under the upper control arm to keep the control arm and the steering knuckle out of the way.

9.2.	Suspend the steering knuckle to prevent straining the brake line.

10. Using an air chisel, carefully remove the heads of the rivets that are retaining the ball joint to the upper control arm.
11. Remove the rivets using a pin punch and hammer.
12. Remove the upper ball joint.
13. Using a 6 mm (1/4 in) drill bit, deburr the upper control arm ball joint attaching holes, if required.

Installation Procedure

1. Install the new upper ball joint to the upper control arm.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fasteners joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the upper ball joint retaining bolts and the nuts.

Tighten
Tighten the upper ball joint retaining nuts to 18 N·m (13 lb ft).




3. Install the upper ball joint to the steering knuckle.
4. Install the upper ball joint to steering knuckle nut.

Tighten

•	Tighten the upper ball joint to steering knuckle nut to 83 N·m (61 lb ft).

•	Tighten the upper ball joint to steering knuckle nut in order to align for the cotter pin. Do not tighten the nut more than 1/6 turn.

5. Install the new cotter pin to the upper ball joint stud. Bend the pin ends against the nut.
6. Connect the wheel speed sensor electrical connector.
7. Install the wheel speed sensor electrical connector to the upper control arm.
8. Lubricate both upper ball joints.
9. Install the tire and wheel.
10. Lower the vehicle.
11. Check the front wheel alignment. Align if necessary. Refer to Wheel Alignment Specifications in the appropriate Service Manual.

For vehicles repaired under the terms of this special policy, submit a claim with the information indicated below:

Customer requests for reimbursement of previously paid repairs to replace the upper ball joints due to separation are to be submitted prior to or by November 30, 2002, (this time limitation may be longer depending upon the law in your state). Repairs must have occurred within the eight (8) years of the date the vehicle was originally placed in service, or 100,000 miles (161,000 km), whichever occurs first.

When a customer requests reimbursement, they must provide the following:

Customers from the States of California, Connecticut, Virginia, and Wisconsin must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter.

If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership.

Dear General Motors Customer:

As the owner of a 1996 or 1997 4-wheel drive Blazer, Jimmy or Bravada, your satisfaction with our product is very important to us. Your vehicle was provided with a new vehicle warranty, which covers certain parts of your vehicle for a specified period. These warranties are of considerable value to you if you should experience problems with your vehicle.

General Motors has received reports that some owners of certain 1996 and 1997 4-wheel drive Blazers, Jimmys and Bravadas have had to pay for replacement of their upper ball joints. Even though upper ball joints are subject to wear under normal driving conditions, with proper maintenance these parts should perform satisfactorily well beyond the warranty period. After receiving these reports from owners and observing warranty regarding ball joints, General Motors has determined that upper ball joints on certain 1996 and 1997 4-wheel drive Blazers, Jimmys and Bravadas are wearing out earlier than customer expectations.

We are contacting you to remind you of the importance of following the maintenance schedule for chassis lubrication listed in your owner's manual. Chassis lubrication consists of lubricating the front suspension, ball joints, steering linkage, transfer case shift linkage, parking brake cable guides, propshaft splines, universal joints and the brake pedal springs.

This letter is intended to make you aware that if you followed the recommended maintenance schedule for the chassis lubrication, and, in the unlikely event that your vehicle still requires the replacement of your upper ball joints due to separation within eight (8) years of the date your vehicle was originally placed in service or 100,000 miles (161,000 km), whichever occurs first, General Motors will replace them at no charge to you.

This is not a recall campaign. Do not take your vehicle to your General Motors dealer as a result of this letter. In the event that you have followed the recommended maintenance schedule for chassis lubrication and if your vehicle were to require an upper ball joint replacement due to separation within the time mentioned above, this letter would authorize your dealer to replace your upper ball joints at no charge to you.

To address the above mentioned condition, General Motors is providing owners with special warranty coverage. If this condition occurs on your 4-wheel drive Blazer/Jimmy/Bravada within eight (8) years of the date your vehicle was originally placed in service or 100,000 miles (161,000 km), whichever occurs first, the condition will be repaired for you at no charge .

Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. Keep this letter with your other important glovebox literature for future reference.

If you have followed the maintenance schedule for chassis lubrication and have already paid for some or all of the cost to have your upper ball joints replaced due to separation and you have not received reimbursement under a Vehicle Service Contract, and the in-service time and mileage was less than eight (8) years and 100,000 miles (161,000 km), you should contact your dealer to seek reimbursement consideration. Please provide your dealer with your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair. Your request for reimbursement, including the information and documents mentioned above, must be received by your dealer by November 30, 2002.

If you have followed the maintenance schedule for chassis lubrication and have already paid for some or all of the cost to have the upper ball joints replaced due to separation, and you have not received reimbursement under a Vehicle Service Contract, and the in-service time and mileage was less than eight (8) years and 100,000 miles (161,000 km), you should write to your division to seek reimbursement. Please provide your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair. This information must be provided within two (2) years after the date on which you paid for the repair.

If you have any questions or need any assistance, must contact your dealer or the appropriate Customer Assistance Center at the number listed below:

We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products.

General Motors Corporation