CAMPAIGN:NEUTRAL START SWITCH DAMAGE. Pontiac Grand Am 1993

Subject: PRODUCT SAFETY CAMPAIGN 93-C-06 NEUTRAL START SWITCH DAMAGED

Models Affected: 1993 PONTIAC GRAND AM

TO: ALL PONTIAC DEALERS

The National Traffic and Motor Vehicle 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 owner 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 owner 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 solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter that is being sent to owners, the owners are being instructed to contact the Pontiac 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.

DEFECT INVOLVED

General Motors has determined that certain 1993 Pontiac Grand Am model vehicles contain a neutral start switch that was fractured at installation. Over time, this fracture could result in a no-start condition. A vehicle with this condition may also be started in gear which could cause a vehicle crash without prior warning.

To prevent these conditions from occurring, dealers are to replace the neutral start switch on all involved vehicles and inspect/replace the manual shaft assembly as required per the Service Procedure Section of this bulletin.

VEHICLES INVOLVED

Involved are certain 1993 Grand Am model vehicles built within the following VIN breakpoints: Up To And Year Plant Beginning Including ---- ----- --------- --------- 1993 Lansing PC790679 PC799576 1993 Lansing A PM603391 PM613233

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings 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 the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Pontiac Division (see copy of Owner Letter included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

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 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.

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 the instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owners 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 it 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.

PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operation (GMSPO). To ensure that these parts are obtained as soon as possible, they should be ordered from GMSPO on a C.I.O. order with no special instruction code, but on an advise code (2).

Quantity Description Part Number Per Vehicle ----------- ----------- ----------- Neutral Start Switch *1994333 1

Shaft, Manual with Detent Lever and Hub 8682973 1 as required Arm, Pin, and Rod and Retainer Assembly

Package, Gasket, Case to Case Cover 8631979 1 as required

Gasket, Valve Body Cover 8678169 1 as required

* GMSPO will preship Neutral Start Switches to each dealer with involved vehicles equal to 100% of the number of vehicles to be repaired. These switches will be charged to the dealer's open account.

NOTE: Service package 8682973 (containing shaft, manual with lever and hub, and pin) must be serviced as a set. Do not replace one part without replacing the others.

SERVICE PROCEDURE

1. With gear selector in neutral, disconnect the negative battery cable.

2. Remove shift control cable lever assembly at transaxle and neutral start switch (see Figure 1).

3. Remove neutral start switch connector.

4. On 3.3L engine application only:

a. Raise vehicle.

b. Loosen lower coolant tube bracket bolt and unclip vacuum hose retainer and move vacuum hose aside.

IMPORTANT: Lower coolant tube bracket bolt needs to be loosened on 3.3L (RPO LG7) engine applications (only). This allows the coolant tube to be temporarily moved so sufficient clearance is available to vertically remove the neutral start switch. Failure to remove the switch vertically may cause internal alignment concerns in the switch and cause difficulty in adjusting the switch during reassembly.

c. Lower vehicle.

5. Remove neutral start switch mounting bolts.

6. Remove neutral start switch (move coolant tube aside for clearance on 3.3L application).

7. Place new neutral start switch over manual shaft.

a. If neutral start switch fits on manual shaft assembly without force, manual shaft assembly does not require replacement. Proceed to step 8.

b. If neutral start switch requires force to install on manual shaft assembly, then manual shaft assembly requires replacing. Follow procedure in 1993 Grand Am Service Manual Section 7A-1B-32 for manual shaft (704); lever and hub assembly (703) pin detent lever to shaft (702); and rod and retainer assembly (701) replacement, Figure 94.

Install kit part number 8682973. All parts in package are to be installed.

8. Install new neutral start switch reversing steps 1 to 6. Mounting bolts should be torqued to 24 N.m (18 lb.ft.). See 1993 Grand Am Service Manual, page 7A-12, Figure 10 for tightening sequence.

a. If bolt holes do not align with mountings boss on transaxle, verify shift shaft is in "Neutral" position, do not rotate neutral start switch. New switch is pinned in "Neutral" position.

b. If switch has been rotated and pin broken, neutral start switch can be adjusted by using the "Replacement - Using Old Switch" procedure. (Refer to Service Manual Section 7A "Automatic Transaxle On-Vehicle Service" for "Replacement - Using Old Switch" procedure.)

IMPORTANT: After switch adjustment, verify that engine will only start in "Park" or "Neutral." If engine will start in any other position re-adjust switch.

9. Switch Adjustment:

a. Place transaxle control shifter assembly in the "Neutral" notch in detent plate.

b. Loosen neutral start switch attaching bolts.

c. Rotate switch on shifter assembly to align service adjustment hole with carrier tang hole.

d. Insert 2.34 mm (3/32") max. diameter gage pin to a depth of 9.0 mm (9/64").

e. Tighten mounting bolts to 24 N.m (18 lbs.ft.). Follow tighten procedure in 1993 Grand Am Service Manual, Page 7A-12, Figure 10.

f. Remove gage pin.

10. Install Campaign Identification Label.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified 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, the five digit dealer code of the dealer performing the campaign service, and the date the vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. Install the label only on a clean, dry surface of the radiator baffle where it is readily visible. (Additional campaign labels are available on stationery order as Form 7201-709.)

CLAIM INFORMATION

A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.

DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:

*Other Failure Labor Labor Labor Operation Code Operation Hours Hour ---------------------------------------------------------------------------- Install New Neutral Start Switch 96 V8201 2.3L SOHC (RPO L40) 0.5 0.1 3.3L (RPO LG7) 0.8 0.1

Install New Neutral Start Switch and Manual Shaft Kit 96 V8202 2.3L SOHC (RPO L4O) 6.9 0.1 3.3L (RPO LG7) 6.6 0.1

* In addition, dealerships will receive 0.1 hours credit for dealer administrative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed for credit. This entry will not require authorization.

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

Parts required are to be listed in your warranty claim in the normal manner. Parts will be credited at dealer net plus 30% dealer handling allowance.

Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the labor operation as outlined.

RECORDING COMPLETION

Repairs submitted for vehicles not involved in the campaign will not be paid.

Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS. " Owners are being asked to present the owner reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.

Dear Pontiac Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

REASON FOR THIS RECALL

WHAT WE WILL DO

To correct this condition, your dealer will inspect the manual shaft and replace the neutral start switch. The manual shaft will be replaced if an oversized condition exists.

This service will be performed for you at no charge.

WHAT YOU SHOULD DO

Please contact your Pontiac dealer as soon as possible to arrange an appointment and so the dealer may order the necessary parts for the repair.

Instructions for making this correction have been sent to your Pontiac Dealer and parts are currently available. The time needed to inspect the manual shaft and replace the neutral start switch is approximately one (1) hour. If the manual shaft requires replacement, the time needed is approximately seven (7) hours. However, due to scheduling times, your dealer may need your car more than one full work day. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

Your Pontiac dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date, or within five (5) days, we recommend you contact the Pontiac Customer Assistance Center by calling: 1-800-762-2737.

After contacting your dealer and the Pontiac Customer Assistance Center, if 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, S. W., Washington, DC 20590 or call 1-800-424-9393 (Washington, DC residents use 366-0123).

The enclosed Campaign Owner Reply Card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary inspection/correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage-paid Owner 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.

PONTIAC DIVISION General Motors Corporation

Object Number: 84111 Size: FS

Object Number: 89476 Size: FS

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.