CAMPAIGN: COMPOSITE BRAKE ROTOR CORROSION. GMC Truck Safari

SUBJECT: COMPOSITE BRAKE ROTOR CORROSION (ONTARIO & QUEBEC)

Models: 1988-1992 K1 & K2 Trucks with GVW up to 7200 and 1990-1992 'L' Vans (Ontario & Quebec Provinces Only)

TO: ALL GENERAL MOTORS DEALERS

General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1988-1992 K1 & K2 Trucks and 1990-1992 All-Wheel Drive 'L' Van model vehicles. These vehicles have composite front brake rotors. If severe corrosion were present, die stamped-steel center section of the composite front brake rotor could separate from the cast outer rotor resulting in a total loss of braking capability of the affected wheel. Partial loss of front braking at a time when stopping distance is at a minimum could result in a vehicle crash without prior warning.

Severe corrosion of this type is time related not mileage related, therefore, 1988 owners involved in this campaign will be notified first, then additional model year vehicle owners will be notified sequentially as parts become available.

Since this potential failure is time related, there will be no requirement for visual inspection prior to the owner receiving his owner notification nor any reason to reimburse for previous repairs related to normal maintenance.

To prevent this condition from occurring, dealers are to replace both front brake rotors with rotors having a corrosion protective coating. Replacement of the brake linings is considered a normal maintenance item. Due to normal wear, it is possible that the brake linings will need to be replaced. Replacement of the brake linings, if necessary, should be done at the owner's expense.

VEHICLES INVOLVED:

Involved are all 1988-1992 K1 models, 1988-92 K2 models with 7200 GVW (RPO C5Z) and 1990-1992 'L' Vans which operate in Ontario and Quebec Provinces and were built within the following VIN breakpoints:

Year Model Plant Plant Code From Through ---- ----- ----- ---------- ---- ------- 1988-91 Chev/GMC K1 Pontiac East "E" SOP EOP Chev/GMC K2 W/C5Z 1988-91 Chev/GMC K1 Fort Wayne "Z" SOP EOP Chev/GMC K2 W/C5Z

1988-91 Chev/GMC K1 Oshawa "1" SOP EOP Chev/GMC K2 W/C5Z

1992 Chev K1 Pontiac East "E" SOP NE159588 Chev K2 W/C5Z " GMC K1 NE523264 GMC K2 W/C5Z " 1992 Chev K1 Fort Wayne "Z" SOP NZ128562 Chev K2 W/C5Z " GMC K1 NZ507749 GMC K2 W/C5Z "

1992 Chev K1 Oshawa "1" SOP N1166649 Chev K2 W/C5Z " GMC K1 N1523434 GMC K2 W/C5Z "

1992 Chev K1 Janesville "J" SOP NJ302199 Chev K2 W/C5Z " GMC K1 NJ700900 GMC K2 W/C5Z "

1990 Chev/GMC L Van Baltimore "B" SOP EOP

1991 Chev/GMC L Van Baltimore "B" SOP EOP

1992 Chev L Van Baltimore "B" SOP NB128944 GMC L Van NB509434

NOTE: PLEASE CHECK DCS SCREEN 45 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

ALL affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

DEALER CAMPAIGN RESPONSIBILITY:

All unsold new vehicles in dealer's 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 perform this campaign on all involved vehicles at no charge to owners, regardless of kilometers traveled, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner letter accompanying this bulletin. Campaign follow- up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign is taken into your new or used 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.

CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors (see copy of owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose. Owner mailings will be phased starting with 1988 model year vehicles beginning November 15, 1993 (tentative).

PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 15984034 Front Brake Rotor Kit (Contains 2 Rotors) 1 - All 1992 K1 - 1988-91 K1 Without C5G GVW Rating - 1988-92 K2 With C5Z GVW Rating 15984033 Front Brake Rotor Kit (Contains 2 Rotors) 1 - 1988-91 K1 With C5G GVW Rating 15984036 Front Brake Rotor Kit (Contains 2 Rotors) 1 - 1990-92 'L' Vans

992667 GM Supreme II Brake Fluid 2

PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ----------- -------------- 2A Replace Both Front Brake Rotors (Part #15984034) .7 - K1-2 models with GVW up to and including 7200 3A Replace Both Front Brake Rotors (Part #15984033) .7 - K1 models with 5600 GVW (RPO C5G)

4A Replace Both Front Brake Rotors (Part #15984036) .7 - 'L' Van

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 30% to cover parts handling.

SERVICE PROCEDURE:

1. Drain 2/3 of the brake fluid from the master cylinder.

2. Raise the vehicle.

3. Remove both front wheel assemblies.

4. Remove and support both front brake calipers.

5. Remove both front brake rotors.

6. Install new front brake rotors.

7. Reinstall both front calipers torquing the bolts to 51 N.m (35 lbs. ft.).

8. Reinstall the front wheels torquing the nuts to 160 N.m (120 lbs. ft.) for 'K' Models or to 140 N.m (100 lbs. ft.) for 'L' Vans.

9. Lower the vehicle.

10. Refill the master cylinder with new brake fluid.

11. Install "Campaign Identification Label."

NOTE: Due to normal wear, it is possible that the brake linings will need to be replaced. Replacement of die brake linings, if necessary, should be done at the owner's expense.

INSTALLATION OF CAMPAIGN INFORMATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label This will indicate that the campaign has been completed.

Dear General Motors Customer.

General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1988 Chevrolet and GMC 'K1 & K2' Four-Wheel Drive Trucks, and 1990-1992 All-Wheel Drive Vans registered in Ontario and Quebec.

These vehicles may have composite front brake rotors. If severe corrosion were present, the stamped-steel center section of the composite front brake rotor could separate from the cast outer rotor resulting in a total loss of braking capability of the affected wheel. Partial loss of front braking at a time when stopping distance is at a minimum could result in a vehicle crash without prior warning.

To prevent this condition from occurring, your dealer will replace both front brake rotors with rotors having a corrosion protective coating. This service will be provided for you at no charge.

During brake rotor replacement, it may be determined that due to normal wear your vehicle's brake linings require replacement. However, replacement of brake linings is considered a normal item. Replacement of the brake linings, if necessary, will be performed at your expense.

Please contact your GM dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department General Motors of Canada Limited

Dear General Motors Customer.

General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1989 Chevrolet and GMC 'K1 & K2' Four-Wheel Drive Trucks, and 1990-1992 All-Wheel Drive, Vans registered in Ontario and Quebec.

To prevent this condition from occurring, your dealer will replace both front brake rotors with rotors having a corrosion protective coating. This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department General Motors of Canada Limited

Dear General Motors Customer.

General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1990, 1991, 1992 Chevrolet and GMC 'K1 & K2' Four-Wheel Drive Trucks, and 1990-1992 All-Wheel Drive, Vans registered in Ontario and Quebec.

To prevent this condition from occurring, your dealer will replace both front brake rotors with rotors having a corrosion protective coating. This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department General Motors of Canada Limited

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.