CAMPAIGN:STARTER MOTOR PINION STOP

SUBJECT: STARTER MOTOR PINION STOP

MODELS: 1994 S/T, C/K, M/L, AND G TRUCKS EQUIPPED WITH DELCO REMY STARTERS

IMPORTANT!

THIS BULLETIN SUPPLEMENTS INFORMATION IN DCS 93SV0210, DATED DECEMBER 23,1993.

GENERAL MOTORS HAS DETERMINED THAT CERTAIN 1994 S/T, C/K, M/L, AND G TRUCKS MAY HAVE IMPROPERLY HEAT TREATED PINION STOP COLLARS. THIS CONDITION MAY RESULT IN PART FAILURE CAUSING SLOW ENGINE CRANK SPEEDS OR AN ENGINE NO START CONDITION.

TO PREVENT THIS CONDITION FROM OCCURRING, DEALERS ARE TO INSPECT AND REPAIR CERTAIN STARTER MOTORS FROM THE VEHICLES IDENTIFIED BELOW. STARTER MOTORS WITH DATE CODES OF N093, N103, N113, N123, N133, N153, AND N163 ARE TO BE REPAIRED BY REPLACING THE PINION STOP COLLAR AND RETAINING RING. NO REPAIRS ARE NECESSARY ON MOTORS THAT FALL OUTSIDE OF THESE DATE CODES.

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1994 S/T, C/K, M/L, AND G TRUCKS BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS:

MODEL ENGINE VIN PLANT VIN FROM THROUGH CODE CODE ------------------------------------------------------------------- S 4 8 R8507797 R8509393 S 4 K RK506380 RK507661 S/T Z, W 8 R8508230 R8509399 S/T Z, W 2 R2514199 R2517619 S/T Z, W K RK503421 RK507660 M/L Z, W B RB517576 RB520091 C/K H, Z E RE516902 RE519059 C/K H, Z I R1521885 R1524036 C/K H, Z Z RZ518755 RZ519965 G H, Z F RF510382 RF511588

DEALER CAMPAIGN RESPONSIBILITY

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.

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.

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

INSPECTION PROCEDURE

1. ALL VEHICLES WITHIN THE BREAKPOINTS SHOULD BE INSPECTED TO DETERMINE THE STARTER MOTOR DATE CODES. THE DATE CODES ARE IMPRINTED ON THE UPPER HALF OF A TAG LOCATED ON THE MOTOR END OF THE STARTER. THE TAG INFORMATION IS READ UPSIDE DOWN AS VIEWED FROM THE BOTTOM.

2. A) MOST VEHICLES MAY BE INSPECTED BY UTILIZING A MIRROR, FLASHLIGHT AND/OR USE OF A PLIABLE MATERIAL SUCH AS MODELING CLAY TO MAKE AN IMPRESSION OF THE DATE CODE. AFTER MAKING AN IMPRESSION, READ THE CODE IN A MIRROR.

B) SOME VEHICLES EQUIPPED WITH OIL COOLERS (T TRUCKS) WILL REQUIRE STARTER MOTOR REMOVAL TO READ THE DATE CODES PER SECTION 6D2 OF THE SERVICE MANUAL.

3. REMOVE ALL STARTERS PER INSTRUCTIONS IN THE SERVICE MANUAL SECTION 6D2 WITH DATE CODES OF N093, N103, N113, N123, N133, N153, & N163 AND PERFORM SERVICE PROCEDURE. (NOTE: REMOVE NEGATIVE CABLE FROM BATTERY).

4. REINSTALL STARTER MOTORS PER INSTRUCTIONS IN SERVICE MANUAL, SECTION 6D2.

5. INSTALL CAMPAIGN IDENTIFICATION LABEL ON ALL VEHICLES INSPECTED AND/OR SERVICED.

SERVICE PROCEDURE TO REPLACE PINION STOP COLLAR

1. DISCONNECT NEGATIVE BATTERY CABLE.

2. REMOVE FIELD LEAD ATTACHING SCREW FROM SOLENOID TERMINAL.

3. LOOSEN BUT DO NOT REMOVE THROUGH BOLTS IN THE STARTER MOTOR ASSEMBLY. DO NOT SEPARATE THE COMMUTATOR END AND FRAME.

4. SEPARATE THE FRAME WITH THE ARMATURE INSIDE FROM THE HOUSING.

5. REMOVE THE THRUST COLLAR FROM THE END OF THE SHAFT IF IT IS NOT STUCK TO THE HOUSING.

6. USE CARE IN REMOVING AND INSTALLING THE RETAINING RING TO PREVENT SCRATCHING OR DAMAGING THE ARMATURE SHAFT.

7. REMOVE THE PINION STOP RETAINING RING FIRST PRYING THE PINION STOP COLLAR OFF THE RING. PRY THE PINION STOP RING OFF OF THE ARMATURE WITH A SMALL SCREW DRIVER. DISCARD RING.

8. REMOVE PINION STOP COLLAR FROM ARMATURE SHAFT. DISCARD COLLAR.

9. INSTALL NEW PINION STOP COLLAR ON ARMATURE SHAFT. FLAT SIDE GOES TOWARDS PINION.

10. INSTALL NEW RETAINING RING ONTO ARMATURE SHAFT AND SEAT IT IN THE SHAFT GROOVE. USE DUE CARE NOT TO DAMAGE THE ARMATURE SHAFT.

11. INSTALL THRUST COLLAR ONTO ARMATURE SHAFT WITH SMALL FLANGE TOWARD RETAINING RING. USE TWO PLIERS TO SQUEEZE PINION STOP COLLAR AND THE THRUST COLLAR TO SEAT THE STOP COLLAR ON THE RETAINING RING.

12. ASSEMBLE THE FRAME, ARMATURE, AND DRIVE ASSEMBLY INTO THE HOUSING. ENSURE THE SHIFT LEVER IS ENGAGED WITH THE DRIVE ASSEMBLY. ENSURE THE ARMATURE SHAFT IS ENGAGED WITH THE HOUSING BEARING. TIGHTEN THE THROUGH BOLTS.

13. INSTALL STARTER FIELD LEAD TO SOLENOID.

PARTS INFORMATION

GENERAL MOTORS SERVICE PARTS OPERATION (GMSPO) HAS LIMITED QUANTITIES OF PARTS WHICH ARE IN MERCHANDISED PACKAGES OF 10 PIECES EACH. PLEASE USE VIP CIO ORDER FORM AND DO NOT OVER ORDER TO INSURE AVAILABILIIY TO ALL VEHICLES INVOLVED.

INSURE THAT REMOVED PARTS ARE DISPOSED OF TO PREVENT POTENTIAL REUSE.

PART NUMBER DESCRIPTION QUANTITY ----------- ----------- -------- 01927849 PINION STOP COLLAR 1 01927848 RETAINING RING 1

WARRANTY INFORMATION

LIST ONE APPLICABLE LABOR OPERATION. A SEPARATE REPAIR ORDER MUST BE USED FOR EACH VEHICLE. A COMPLETE WARRANTY CLAIM IS TO BE KEPT AS A PERMANENT RECORD OF COMPLETION.

LABOR OPERATION *TIME PARTS TROUBLE NUMBER DESCRIPTION ALLOWANCE ALLOWANCE CODE ------------------------------------------------------------------------- V8530 STARTER INSPECTION 0.2 HR. ** 96 WITHOUT REMOVAL

V8531 STARTER INSPECTION 0.7 HR. ** 96 WITH REMOVAL

V8532 STARTER INSPECT AND 1.2 HR. ** 96 REPAIR

* FOR DEALER TO RECEIVE ADMINISTRATIVE TIME ALLOWANCE ASSOCIATED WITH THIS CAMPAIGN, ADD 0.1 HOUR TO THE LABOR OPERATION TIME ALLOWANCE.

** THE AMOUNT IDENTIFIED IN THE "PARTS ALLOWANCE" COLUMN ABOVE REPRESENTS 40% OF DEALER NET FOR PARTS THAT ARE FURNISHED IN THIS CAMPAIGN. THIS AMOUNT IS TO BE PLACED IN THE NET ITEM AMOUNT COLUMN OF THE CLAIM AND TYPE CODE "M."

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

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

Dear GMC Truck Owner:

As a valued customer, your complete satisfaction with your GMC truck is our goal. In keeping with this goal, we want to let you know that we have discovered a problem that could affect your vehicle and we want to take care of it at no charge to you.

A number of 1994 Sonomas, Jimmies, Sierra Pickups, All Safaris, and Vandura and Rally Vans, such as yours, may have improperly heat treated starter motor pinion stop collars. This condition may result in part failure causing slow engine crank speeds or an engine no start condition.

To be absolutely sure that your vehicle is to specifications, we will inspect and repair your starter motor. Instructions for performing this service have been sent to your GMC Truck dealer, and parts are available. Please contact your GMC Truck dealer to arrange a service date as soon as possible. This procedure will take about one hour to complete, but you should ask how much additional time your dealer will need to schedule and process your vehicle.

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 the 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 continued satisfaction with our product.

GMC TRUCK 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.