CAMPAIGN: REAR AXLE CONTROL ARM INADEQUATELY WELDED. Chevrolet Citation 1980

For 1990-2009 cars

# CAMPAIGN: REAR AXLE CONTROL ARM INADEQUATELY WELDED

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

THE REAR AXLE CONTROL ARM TO REAR SIDE RAIL ATTACHMENT ON THE SUBJECT VEHICLES MAY HAVE BEEN INADEQUATELY WELDED DURING 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 WITHOU PRIOR WARNING.

VEHICLES INVOLVED

ALL 1980 CHEVROLET CITATION MODELS ASSEMBLED AT TARRYTOWN, FROM THE START OF PRODUCTION UP TO AND INCLUDING VEHICLE IDENTIFICATION NUMBER 1X115AT106899. THESE ARE THE ONLY VEHICLES INVOLVED.

VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER COMPUTER LISTINGS. THE LISTINGS HAVE BEEN FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN WAS NOT SHIPPED ANY INVOLVED VEHICLES.

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 MODIFICATION HAS BEEN COMPLETED.

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 10MM (3/8") OR ANY UNUSUAL METAL DISTORTION OR MOVEMENT IS NOTED, LOWER VEHICLE AND REQUEST ZONE INSPECTION BEFORE PROCEEDING WITH THIS REWORK. IF ABOVE CONDITION DOES NOT EXIST, PROCEED TO STEP 2.

#### NOTE: 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. CAULK 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.

#### NOTE: 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 TOOL 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 ATTACH- ING 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 BRUCH.

#### NOTICE: DO NOT USE POWER OPERATED WIRE BRUCH 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 WELDING 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 PART NO. 1052290 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) AND NUT ASSEMBLY, FIGURE 9. HAND TORQUE BOLT TO 14-17 NEWTON METERS (125-150 INCH LBS.).

L8. MASK ROCKER OUTER AND APPLY 3 M UNDERSEAL BRAND RUBBERIZED 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 MASKING TAPE AND INSPECT ALL FUEL AND BRAKE LINES.

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

21. LOWER VEHICLE.

PARTS AND MATERIAL INFORMATION

A. PROVIDED BY ZONE OFFICE

8 - 1/4 X 5/8 RATCHET HEAD BOLT AND WASHER ASSEMBLIES - INSTALLED THROUGH LOWER FLANGE 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 WASHERS 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" SHAPED TAP PLATE - 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.

#### NOTE: BOLTS AND NUTS SUPPLIED ARE SPECIFIC FOR THIS REWORK AND NO SUBSTITUTIONS 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 EQUIVALENT - TO RESTORE CORROSION PROTECTION TO INTERIOR SURFACES OF ROCKER PANEL. AVAILABLE FROM G.M.P.D.

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

WARRANTY INFORMATION, FAILURE CODE, LABOR TIME ALLOWANCE, FAILED LABOR OPERATION AND CONDITION CODE

DEALERS ARE TO SUBMIT EACH CAMPAIGNED VEHICLE AS A SEPARATE CASE ON THE ONE-LINE WARRANTY CLAIM FORM, GSD-970.

THE CAMPAIGN FAILURE CODE, LABOR OPERATION NUMBER AND OCNDITION CODE ARE TO BE SUMITTED EXACTLY AS SHOWN ON THE EXAMPLE GSD-970 ONE-LINE CLAIM FORM INCLUDED IN THIS CAMPAIGN BULLETIN.

DEALERS SUBMITTING WARRANTY CLAIM APPLICATIONS ON THE CHEVROLET DEALER COMMUNICATION SYSTEM ARE TO SUBMIT CAMPAIGN CLAIMS VIA THE DEALER COMMUNICATION TERMINAL ACCORDING TO THE CAMPAIGN CLAIM PROCEDURE DOCUMENTED IN THE CHEVROLET "DEALER COMMUNICATION SYSTEM-OPERATION GUIDE.

FAILED FAILURE LABOR TIME LABOR CONDITION CODE ALLOWANCE OPERATION CODE

1A .2 HOURS 80C09 89

DESCRIPTION: INSPECT VEHICLE - REFER TO STEP 1, IN THE SERVICE PROCEDURE OF THIS BULLETIN.

1B 2.0 HOURS 80C09 89

DESCRIPTION: REPLACE BOTH RIGHT AND LEFT REAR SIDE RAIL PLATES ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THE ABOVE LABOR TIME INCLUDES INSPECTION.

DEALERS WILL AUTOMATICALLY RECEIVE .1 HOURS DEALER ADMINISTRATIVE DETAIL ASSOCIATED WITH THIS CAMPAIGN.

IN ADDITION, DEALERS WILL AUTOMATICALLY RECEIVE 30% OF DEALER NET WHEN PARTS ARE FURNISHED AT NO-CHARGE, BY CHEVROLET ($3.00) AND AN ADDITIONAL ($2.00) PAINT ALLOWANCE.

CAMPAIGN IDENTIFICATION LABEL

EACH VEHICLE MODIFIED IN ACCORDANCE WITH THE INSTRUCITONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL". EACH LABEL PROVIDES A SPACE TO INCLUDE THE FIVE DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR BALLPOINT PEN.

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.