FMVSS Non-Compliance - Front Brake Pipe Union Leak

ON AUGUST 2, 1999, ALL MODEL YEAR 2000 CHEVROLET AND GMC 2WD S-TRUCKS BUILT AT LINDEN AND SHREVEPORT WERE PLACED ON STOP DELIVERY VIA DCS392. VEHICLES OUTSIDE THE VIN BREAKPOINTS ARE RELEASED FOR DELIVERY. THIS CAMPAIGN BULLETIN WILL RELEASE VEHICLES FROM STOP DELIVERY ONCE THE SERVICE PROCEDURE HAS BEEN COMPLETED.

The Highway Safety Act, as amended, provides that each vehicle which is subject to a recall campaign 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 (60) 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. As you will see in reading the attached copy of the divisional letter that is being sent to customers, the customers are being instructed to contact the appropriate Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.

General Motors has decided that certain 2000 model year Chevrolet and GMC 2WD S-Trucks built at Linden and Shreveport Assembly Plants may fail to conform to Federal Motor Vehicle Safety Standard (FMVSS) 105, "Hydraulic Service Brake-Normal, Emergency, and Park Braking Performance." These vehicles may have had the right-hand ABS (Antilock Brake System) module feed pipe and/or brake crossover pipe tube nuts tightened without seating the pipe-flared-ends enough to withstand normal assembly and vehicle inputs without partially unseating. If this occurred, the seating seal could be broken during vehicle assembly, or from early road inputs or brake fluid cycling, and a leak could occur. If this occurred when minimum stopping distance was required, it could result in a vehicle crash.

To correct this condition, dealers are to inspect the union for signs of brake fluid, and if necessary, install a new union.

Involved are certain 2000 model year Chevrolet and GMC 2WD S-Trucks built at Linden and Shreveport Assembly Plants, and built within the following VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be 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 campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer 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 the follow-up necessary to complete this campaign.

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. 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.

*Important: Only 2% of the vehicles are expected to require brake fitting replacement, dealer are encouraged NOT to order campaign parts for use as shelf stock. Parts should only be ordered when inspection determines that it is necessary to replace the brake fitting.

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

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

Dealers are to service all vehicles subject to this campaign 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. Campaign 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 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.

This bulletin is notice to you that the new motor vehicles included in this campaign may not comply with the standard identified above. Under 41 U.S.C. section 30112 of the Highway Safety Act as amended, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the campaign correction, your dealership may be subject to a civil penalty up to $1,100 for each such sale.

Inspection Procedure

1. With the engine running and the automatic transmission in PARK or manual transmission in neutral with the parking brake set, pump the brake pedal 5 times and hold the pedal fully depressed.
2. Continue to hold the brake pedal down. Turn the wheels to the right and turn the ignition to OFF.

Important: A second technician is required for visual inspection

3. With the brake pedal still applied, wait 30 seconds and have the second technician lift the left rubber inner fender well flap and inspect for brake fluid leakage at the right-hand ABS feed pipe and brake crossover pipe union.

-	If no leakage is present, no further action is required. Install the GM Campaign Identification Label.

-	If a leak is present, proceed to the Repair Procedure below.

Important: If a leak if found, DO NOT attempt to re-torque the tube nuts. The union must be replaced.

Repair Procedure

1. Raise the vehicle.
2. Remove the left-hand tire and wheel assembly.
3. Tape the rubber inner fender well flap to the inner fender well for access to the union.
4. Place shop rags under the union and pipe to prevent contact of brake fluid on the frame and other components.
5. Remove the union.
6. Install the new union by finger starting the tube nuts to the union.

Tighten

•	Tighten the upper tube nut to 24 N·m (18 lb ft) while holding the position of the union.

•	Tighten the lower tube nut to 24 N·m (18 lb ft) while holding the position of the union.

7. Clean the union and the affected area.
8. Verify that the brake lines are securely engaged in the clip located above the union.
9. Bleed the right front brake circuit.

-	Fill the master cylinder reservoir with DOT 3 motor vehicle brake fluid.

-	Place a clear tube over the caliper bleeder valve.

-	Immerse the opposite end of the hose into a clear container partially filled with clean brake fluid.

-	Slowly apply the brake pedal one time and hold.

-	Loosen the bleeder valve using J 21472 in order to purge the air from the brake line.

-	Tighten the bleeder valve and slowly release the brake pedal.

-	Wait 15 seconds.

-	Repeat the above sequence, including the 15 second wait, until all air is purged from the system.

Tighten
Tighten the bleeder valve to 7 N·m (62 lb in).

10. Clean any brake fluid off of the vehicle.
11. Fill the master cylinder reservoir to the proper level.
12. Remove the tape from the rubber inner fender well flap and return it back to the proper position to avoid contact with the brake pipes.
13. Install the left-hand tire and wheel assembly.

Tighten
Tighten the wheel nuts to 140 N·m (100 lb ft).

14. Lower the vehicle.
15. Perform the inspection procedure above.
16. Install the GM 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 the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a 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 by the customer for periodic servicing. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels can be obtained from Dealer Support Materials by calling 1-888-414-6322 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Apply the "Campaign Identification Label" only on a clean, dry surface.

Submit a Product Campaign Claim with the information indicated below.

Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission.

Dear Chevrolet/GMC 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 certain 2000 model year Chevrolet and GMC 2WD S-Trucks built at Linden and Shreveport Assembly Plants may fail to conform to Federal Motor Vehicle Safety Standard (FMVSS) 105, "Hydraulic Service Brake-Normal, Emergency, and Park Braking Performance." These vehicles may have had the right-hand ABS (Antilock Brake System) module feed pipe and/or brake crossover pipe tube nuts tightened without seating the pipe-flared-ends enough to withstand normal assembly and vehicle inputs without partially unseating. If this occurred, the seating seal could be broken during vehicle assembly, or from early road inputs or brake fluid cycling, and a leak could occur. If this occurred when minimum stopping distance was required, it could result in a vehicle crash.

To correct this condition, your dealer will inspect the brake pipe union for signs of brake fluid, and if necessary, install a new brake pipe union. This service will be performed for you at no charge .

The length of time required to perform this inspection is approximately 15 minutes, and another 40 minutes will be required if replacement of the brake pipe union is necessary. 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 schedule, process, and repair your vehicle.

Please contact your Chevrolet/GMC 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 Chevrolet/GMC 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 1-800-424-9393 (Washington, DC residents use 202-366-0123).

The enclosed 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 postage paid reply card and returning it to us.

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.

Chevrolet/Pontiac-GMC Division

General Motors Corporation

Enclosure