CAMPAIGN: REAR SIDE RAIL TIE DOWN

GENERAL MOTORS HAS DETERMINED THAT A DEFECT WHICH RELATES TO MOTOR VEHICLE SAFETY EXISTS ON SOME 1980 PHOENIX MODELS.

THE REAR AXLE CONTROL ARM TO REAR SIDE RAIL ATTACHMENT ON THE SUBJECT VEHICLES MAY HAVE BEEN INADEQUATELY WELDED UDING THE VEHICLE ASSEMBLY PROCESS. THIS CONDITION MAY RESULT IN DAMAGE TO THE BRAKE OR FUEL LINES, IN THE VICINITY OF THE ATTACHMENT, DURING SHIPMENT OF THE VEHICLE. IN ADDITION, THE INADEQUATE WELDS COULD ALLOW THE ATTACHMENT TO CRACK AND/OR SEPARATE FROM THE BODY SILL DUE TO REAR AXLE LOADS. SHOULD ANY OF THESE CONDITIONS EXIST, THEY COULD EVENTUALLY RESULT IN FUEL OR BRAKE LINE RUPTURE, OR A CHANGE IN VEHICLE HANDLING CHARACTERISTICS. THE VEHICLE DRIVER MAY OR MAY NOT SENSE WARNING OF SYSTEM FAILURE, AND THE CONDITION COULD RESULT IN A VEHICLE CRASH WITHOUT PRIOR WARNING.

VEHICLES INVOLVED

ALL 1980 PHOENIX MODELS ASSEMBLY AT GMAD TARRYTOWN WITHIN THE FOLLOWING PARAMETERS:

PLANT BEGINNING VIN UP TO AND INCLUDING

1980 TARRYTOWN SOP 2Z687AT105640

OWNER NOTIFICATION

NO OWNER NOTIFICATION WILL BE REQUIRED SINCE ALL INVOLVED VEHICLES ARE IN DEALER STOCK.

DEALER CAMPAIGN RESPONSIBILITY

ALL INVOLVED VEHICLES ARE NOT TO BE SOLD BY THE DEALER UNTIL CAMPAIGN HAS BEEN COMPLETED.

DEALER ACTION

DEALERS ARE INSTALL THE REAR SIDE RAIL TIE DOWN PLATE(S) AS DIRECTED IN THE SERVICE PROCEDURE.

SERVICE PROCEDURE

1. RAISE VEHICLE ON HOIST AND INSPECT LEFT AND RIGHT REAR SIDE RAILS IN AREA OF SHIPPING TIE DOWN ATTACHING HOLES (FIGURE 1). IF ANY CRACKS LONGER THAN 10 MM (3/8") OR ANY UNUSUAL METAL DISTORTION OR MOVEMENT ARE NOTED, LOWER VEHICLE AND REQUEST ZONE INSPECTION BEFORE PROCEEDING WITH THIS REWORK. IF ABOVE CONDITION DOES NOT EXIST, PROCEED TO STEP 2.

NOTICE: EACH STEP OF PROCEDURE SHOULD BE PERFORMED ALTERNATELY ON LEFT, THEN RIGHT HAND SIDE OF VEHICLE.

2. ON RIGHT SIDE, REMOVE PARKING BRAKE BRACKET BOLTS AND CABLE LINKAGE ASSEMBLY.

3. REMOVE BOLTS SECURING FUEL AND BRAKE LINES (3) PLACES RIGHT SIDE; 2 PLACES LEFT SIDE). PULL LINES DOWN AND INBOARD TO CLEAR AREA OF SIDE RAIL TO BE REWORKED.

4. PROTECT LINES FROM HEAT IN AREA OF GAS WELDING OPERATIONS BY WRAPPING WITH WET RAGS.

5. USING VICE GRIPS, WELDING PLIERS, OR EQUIVALENT, CLAMP REAR SIDE RAIL TO ROCKER INNER TO PULL METAL TOGETHER AS SHOWN IN FIGURE 2. HAMMER DOWN OUTER ENDS OF FLANGE AS REQUIRED.

6. USING A NO. 2 WELDING TIP, GAS WELD RELIEF NOTCHES AT FRONT AND REAR LOWER ENDS OF SIDE RAIL FLANGE TO SECURE RAIL TO ROCKER INNER AS SHOWN IN FIGURE 2. WELD ANY CRACKS 3/8" OR LESS THAT ARE PRESENT AT THESE CORNERS.

7. FROM INSIDE, NEST DRILLING TEMPLATE (FIGURE 3) AGAINST SIDE RAIL AS SHOWN IN FIGURE 4. TEMPLATE MUST FIT AGAINST RAIL AND COVER BOTH FRONT VERTICAL AND LOWER HORIZONTAL FLANGES OF SIDE RAIL. MARK LOCATION OF FRONT AND REAR EDGE OF TEMPLATE ON LOWER EDGE OF ROCKER. REMOVE TEMPLATE. FROM OUTSIDE, POSITION DRILLING TEMPLATE (USING MARKS PREVIOUSLY MADE ON ROCKER) AND MARK LOCATION OF SLOT TO BE CUT IN ROCKER PANEL (FIGURE 4).

8. USING A CHISEL, PUNCH HOLE IN LOWER SURFACE OF OUTER ROCKER. CUT HOLE TO SIZE (APPROXIMATELY 1/4" X 1"). KEEPING CHISEL AND HOLE IN LINE WITH VERTICAL WALL OF SIDE RAIL (FIGURE 4).

9. INSERT VERTICAL LEG OF DRILL TEMPLATE THROUGH HOLE IN ROCKER. HOLDING TEMPLATE AGAINST ROCKER OUTER, AS SHOWN IN FIGURE 5, ALIGN REAR EDGE WITH PREVIOUSLY MARKED LINES ON ROCKER. CLAMP TEMPLATE IN POSITION. USING TEMPLATE AS A GUIDE, DRILL FOUR 1/8" DIAMETER PILOT HOLES FROM OUTBOARD SIDE OF ROCKER. REMOVE TEMPLATE AND DRILL FOUR 9/32" HOLES AT PILOT LOCATIONS.

NOTICE: IF AFTER FOUR (4) LOWER 9/32" HOLES HAVE BEEN DRILLED, IT IS NOTED THAT MORE THAN ONE HALF OF ANY HOLE DOES NOT PASS THROUGH THE SIDE RAIL LOWER FLANGE (HOLES ARE TOO LOW), STOP REWORK AT THIS POINT AND CONTACT ZONE OFFICE BEFORE PROCEEDING.

10. HOLD DRILLING TEMPLATE AGAINST INSIDE SURFACE OF ROCKER AND ALIGN HOLES IN TEMPLATE WITH HOLES IN ROCKER. INSTALL FRONT AND REAR ATTACHING BOLTS. DRILL 1/8" PILOT HOLE IN FRONT UPPER ATTACHING HOLE LOCATION OF TEMPLATE (FIGURE 6). BOLT HOLE LOCATION SHOULD FALL APPROXIMATELY IN CENTER OF VERTICAL FLANGE OF RAIL.

11. REMOVE TEMPLATE AND DRILL 9/32" HOLE THROUGH VERTICAL FLANGE OF SIDE RAIL AND ROCKER INNER PANEL.

12. REMOVE ANY LOOSE SCALE FROM REWORKED AREA WITH STEEL WOOL OR A WIRE BRUSH.

NOTICE: DO NOT USE POWER OPERATED WIRE BRUSH OR GRINDER, AS DAMAGE COULD OCCUR TO FUEL AND BRAKE LINES.

13. APPLY CHROMATE PRIMER (DUPONT-ACRYLIC CHROMATE PRIMER (GREEN) 215-S), OR EQUIVALENT TO PROTECT METAL SURFACES WHERE GALVANIZED SURFACE AND PRIME COATING MAY HAVE BEEN BURNED BY GAS WWLDING OPERATION. FOLLOW LABEL DIRECTIONS OF PAINT MANUFACTURER. BE CERTAIN TO COAT RAW EDGES OF HOLES DRILLED IN RAIL FLANGES AND ROCKER PANEL WITH PRIMER.

14. USING GM GUARD-MOR ANTI-CORROSION MATERIAL, INSERT SPRAY EXTENSION NOZZLE THROUGH PUNCHED HOLE IN ROCKER OUTER AND APPLY COMPOUND TO INSIDE SURFACE OF ROCKER INNER AND SIDE RAIL (FIGURE 7). CLEAN ANY EXCESS MATERIAL FROM ROCKER OUTER, USING A WAX AND GREASE REMOVER SUCH AS PREP-SOL, ACRILI CLEAN, OR EQUIVALENT.

15. POSITION TAPPED PLATE ON OUTBOARD SURFACE OF ROCKER AND INSTALL BOLTS AS FOLLOWS: FIRST LOOSELY INSTALL FRONT UPPER ATTACHING BOLT (1 1/4" LONG BLUNT END BOLT). THEN INSTALL FOUR LOWER ATTACHING BOLTS, ALONG ROCKER FLANG (5/8" LONG POINTED BOLTS). REFER TO FIGURE 8.

16. HAND TORQUE ALL 5 BOLTS IN TAPPED PLATE TO 14-17 NEWTON METERS (125-150 INCH LBS.)

17. LOCATE AND DRILL ONE 9/32" DIAMETER HOLE IN WHEELHOUSE FLANGE FROM OUTSIDE. WHEEL WILL NOT HAVE TO BE REMOVED IF AN EXTRA LONG BIT, MINIMUM OF 8" LONG, IS USED. INSTALL BOLT (3/4" LONG BLUNT END) AND NUT ASSEMBLY, FIGURE 9. HOAND TORQUE BOLT TO 14-17 NEWTON METERS (125-150 INCH LBS.) APPLY ANTI-CORROSION MATERIAL TO INSIDE OF DRILLED HOLE.

18. MASK ROCKER OUTER AND APPLY 3M UNDERSEAL BRAND RUBERIZED UNDERCOATING (NO. 08883 OR EQUIVALENT) ALONG LOWER SURFACE FULL LENGTH OF ROCKER. IN ADDITION, APPLY SAME MATERIAL TO ALL EXPOSED BOLT HEADS, NUTS, AND AREAS THAT WERE PREVIOUSLY PRIMED WITH CHROMATE. REFER TO FIGURE 9.

19. REMOVE ALL MASTING TAPE AND INSPECT ALL FUEL AND BRAKE LINES.

20. REINSTALL PARKING BRAKE LINKAGE ASSEMBLY, FURL AND BRAKE LINE BRACKETS.

21. LOWER VEHICLE.

22. OPEN HOOD.

23. CLEAN THE SURFACE OF THE UPPER RADIATOR SUPPORT TIE BAR WHERE IT IS READILY VISIBLE WHEN THE VEHICLE IS BROUGHT IN FOR PERIODIC SERVICING BY THE OWNER. WHEN SURFACE IS CLEAN AND DRY, APPLY CAMAPIGN "IDENTIFI- CATION LABEL 80-C-6."

NOTICE: YOUR 6 DIGIT DEALER CODE IS TO BE TYPED OR WRITTEN IN WITH BALL-POINT PEN ON THE CAMPAIGN IDENTIFICATION LABEL.

24. CLOSE HOOD.

ENCLOSED WITH YOUR CERTIFIED MAIL COPY OF THIS LETTER ARE THE FOLLOWING:

A LIST OF THOSE VEHICLES INVOLVED WHICH OUR RECORDS INDICATE HAVE BEEN SHIPPED TO YOUR DEALERSHIP IS ATTACHED. ADVISE THE ZONE IF ANY OF THE VEHICLES APPEARING ON THE ATTACHED LIST ARE NOT IN YOUR AREA. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN WAS NOT SHIPPED ANY INVOLVED VEHICLES.

CAMPAIGN IDENTIFICATION LABELS 80-C-6 ARE FURNISHED FOR INSTALLATION TO IDENTIFY CARS COMPLETED. IF A VEHICLE HAS BEEN TRANSFERRED TO ANOTHER LOCATION, PLEASE FORWARD DETAILS OF THE TRANSFER TO YOUR PONTIAC ZONE OFFICE.

PARTS AND MATERIAL INFORMATION

EACH DEALER WILL RECEIVE NO-CHARGE THE FOLLOWING PARTS FOR EACH VEHICLE ON YOUR VIN LIST:

A. PROVIDED BY PONTIAC MOTOR DIVISION

8 - 1/4 X 5/8 RATCHET HEAD HOLT AND WASHER ASSEMBLIES - INSTALLED THROUGH LOWER LANGE OF ROCKER INTO TAPPED PLATE.

2 - 1/4 X 1 1/4 RATCHET HEAD BOLT AND WASHER ASSEMBLIES - INSTALLED THROUGH ROCKER INNER INTO TAPPED PLATE.

2 - 1/4 X 3/4 RATCHET HEAD BOLT FLAT WAHSERS AND NUTS - INSTALLED THROUGH WHEELHOUSE AND REAR FLANGE OF SIDE RAIL.

2 - "L" SHAPED TAPPED PLATES- INSTALLED ALONG LOWER FLANGE OF ROCKER OUTER PANEL

1 - "L" SHPAED TAP PLATE (ONE PER DEALER) TO BE USED AS A DRILLING TEMPLATE. THIS PLATE WILL INCUR THREAD DAMAGE DURING DRILLING OPERATION AND SHOULD NOT BE INSTALLED ON A VEHICLE. PAINT OR OTHERWISE IDENTIFY THIS PIECE AND RETAIN FOR FUTURE REWORKS.

NOTICE: BOLTS AND NUTS SUPPLIED ARE SPECIFIC FOR THIS REWORK AND NO SUBSTITIOUTIONS SHOULD BE MADE.

B. PROVIDED BY DEALER

DUPONT 215-S ACRYLIC CHROMATE PRIMER - TO COAT ANY BARE METAL IN REWORK AREA. AVAILABLE FROM LOCAL DUPONT JOBBER.

GM PART NO. 1052290 ANTI CORROSION COMPOUND OR BULK GUARD MOR (FIGURE 7) TO RESORE CORROSION PROTECTION TO INTERIOR SURFACES OF ROCKER PANEL. AVAILABLE FROM GMPD

3 M UNDERSEAL RUBBERIZED UNDERCOATING NO. 08883. AVAILABLE FROM LOCAL 3 M JOBBER

RECORDING COMPLETION

CAMPAIGN COMPLETION WILL BE RECORDED FROM PROPERLY COMPLETED AND PAID WARRANTY CLAIMS.

ADDITIONAL LABELS ARE AVAILABLE FROM YOUR ZONE OFFICE SERVICE DEPARTMENT.

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

NOTICE A COMPLETED WARRANTY CLAIM IS TO BE KEPT AS A PERMANENT RECORD OF COMPLETION.

WARRANTY CREDIT

A SEPARATE REPAIR ORDER MUST BE USED FOR EACH VIN.

(LABOR)

THE NEW LABOR OPERATIONS ARE ASSIGNED SPECIFICALLY FOR THIS CAMPAIGN.

LABOR TROUBLE DESCRIPTION OPERATION CODE TIME

INSPECT VEHICLE E000495 96 0.2 HOURS STEP 1 - SERVICE PROCEDURE

INSTALL R & L REAR E000496 96 2.0 HOURS SIDE RAIL PLATES (TIME INCLUDES INSPECTION)

USE ONLY ONE OF THE LABOR OPERATIONS PER VEHICLE.

TROUBLE CODE 96 MUST BE USED WITH THIS LABOR OPERATION.

DEALERS WILL AUTOMATICALLY RECEIVE 0.1 HOURS CREDIT FOR DEALER ADMINISTRATION DETAIL ASSOCIATED WITH THIS CAMPAIGN.

(PARTS)

THE NECESSARY PARTS WILL BE FORWARDED TO DEALERS NO-CHARGE; THEREFORE, PART NUMBERS ARE NOT TO BE LISTED ON THE WARRANTY CLAIM. LIST ONLY THE APPLICABLE AMOUNT SHOWN UNDER THE NET ITEM COLUMN.

MATERIAL -$3.00 NET AMOUNT CODE - M

THIS REPRESENTS 30% OF THE DEALER PRICE OF THE FURNISHED SERVICE PARTS. ALSO AN ADDITIONAL $2.00 MAY BE LISTED AS PAINT ALLOWANCE.

(CREDITING)

DEALERS WILL BE CREDITED VIA WARRANTY DOCUMENT OR TERMINAL TRANSMISSION, WHICHEVER IS THEIR NORMAL METHOD OF SUBMISSION FOR PAYMENT. CLAIMS SHOULD BE CLAIM TYPE 01, CONTAINING ALL INFORMATION REQUIRED FOR A REGULAR CLAIM, AND SHOULD LIST THE APPROPRIATE LABOR OPERATION AS OUTLINED ABOVE.

REPAIRS SUBMITTED FOR VEHICLES NOT INVOLVED IN THE CAMPAIGN WILL NOT BE PAID.

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.