CAMPAIGN: CLUTCH CABLE TO B BRAKE MASTER CYL. INTERFERENCE. Pontiac Phoenix 1982

For 1990-2009 cars

# CAMPAIGN: CLUTCH CABLE TO B BRAKE MASTER CYL. INTERFERENCE

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 ADEQUATELY REPAIR WITHIN 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.

IN ORDER TO AVOID HAVING TO PROVIDE THESE BURDENSOME SOLUTIONS, EVERY EFFORT MUST BE MADE TO PROMPTLY SCHEDULE AN APPOINTMENT WITH EACH OWNER AND TO REPAIR HIS VEHICLE AS SOON AS POSSIBLE. AS YOU WILL SEE IN READING THE ATTACHED COPY OF THE LETTER WHICH IS BEING SENT TO OWNERS, THE OWNER IS BEING INSTRUCTED TO CONTACT THE NEAREST PONTIAC ZONE OFFICE IF HIS DEALER DOES NOT REMEDY THE CONDITION WITHIN FIVE DAYS OF THE MUTUALLY AGREED UPON SERVICE DATE. IF THE CONDITION IS NOT REMEDIED WITHIN A REASONABLE TIME, HE IS INSTRUCTED ON HOW TO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION.

DEFECT INVOLVED

GENERAL MOTORS HAS DETERMINED THAT A DEFECT WHICH RELATES TO MOTOR VEHICLE SAFETY EXISTS IN SOME 1982 PHOENIX MODELS EQUIPPED WITH A FOUR-SPEED MANUAL TRANSMISSION AND A POWER BRAKE SYSTEM. THE CLUTCH CABLE ON THESE VEHICLES MAY RUB AGAINST THE MASTER CYLINDER BRAKE PIPE WHEN THE CLUTCH PEDAL IS OPERATED. OVER AN EXTENDED PERIOD OF OPERATION, THE INSULATION ON THE CLUTCH CABLE COULD WEAR THROUGH RESULTING IN A METAL-TO METAL CONTACT. SHOULD THIS CONDITION EXIST, IT WOULD EVENTUALLY RESULT IN THE FAILURE OF THE BRAKE PIPE CAUSING LOSS OF BRAKE FLUID AND A PARTIAL LOSS OF BRAKING ACTION.

BECAUSE THESE VEHICLES ARE EQUIPPED WITH A DUAL BRAKING SYSTEM, PART OF THE SYSTEM WILL REMAIN FUNCTIONAL ALLOWING THE VEHICLE TO BE STOPPED BUT OVER A GREATER DISTANCE. SHOULD PARTIAL LOSS OF BRAKING ACTION OCCUR WHILE THE VEHICLE IS IN MOTION AT A TIME WHEN MINIMUM STOPPING DISTANCES ARE REQUIRED, A VEHICLE CRASH COULD OCCUR WITHOUT PRIOR WARNING.

VEHICLES INVOLVED

CERTAIN 1982 PHOENIX MODELS EQUIPPED WITH A MANUAL FOUR-SPEED TRANSMISSION AND POWER BRAKE SYSTEMS BUILT WITHIN THE FOLLOWING BREAKPOINTS:

PLANT FROM TO AND INCLUDING

OKLAHOMA CITY SOP C6107432 TARRYTOWN SOP CT102801

SOME VIN'S WITHIN THE ABOVE LISTING RANGE OF NUMBERS WERE CORRECTED BY THE ASSEMBLY PLANT(S) AND WILL NOT APPEAR ON THE PRINTOUT.

DEALER CAMPAIGN RESPONSIBILITY

DEALERS ARE TO CHECK FOR 13 MM (1/2")CLEARANCE BETWEEN THE CLUTCH CABLE AND THE LEFT FRONT BRAKE PIPE AT THE MASTER CYLINDER.

DEALERS ARE TO PERFORM THIS RECALL CAMPAIGN AT NO CHARGE TO THE OWNER ON INVOLVED VEHICLES, REGARDLESS OF TIME, MILEAGE OR OWNERSHIP, AND ARE TO CORRECT ALL AFFECTED VEHICLES IN DEALER NEW AND USED CAR INVENTORY PRIOR TO THEIR SALE.

WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN IS TAKEN INTO YOUR NEW OR USED CAR INVENTORY IN THE FUTURE, YOU SHOULD TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE RESELLING THE VEHICLE.

DEALERS ARE TO PERFORM THE CAMPAIGN SERVICES ON ALL AFFECTED VEHICLES AS THEY ARE BROUGHT IN FOR ANY KIND OF SERVICE UNTIL ALL AFFECTED VEHICLES HAVE BEEN CORRECTED.

OWNER NOTIFICATION

OWNERS OF VEHICLES INVOLVED IN THIS CAMPAIGN,WHOSE NAMES ARE ON RECORD AT THE TIME THE CAMPAIGN LISTS WERE PREPARED, WILL BE NOTIFIED BY PONTIAC MOTOR DIVISION (SEE COPY OF OWNER LETTER INCLUDED WITH THIS BULLETIN).

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 THE INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. OWNER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOWUP WITH OWNERS INVOLVED IN THIS CAMPAIGN.

THESE COMPUTER LISTING 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 FOR THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN.

#### NOTICE: OWNERS OF VEHICLES RECENTLY SOLD FROM YOUR NEW VEHICLE INVENTORY ARE TO BE CONTACTED BY THE DEALER, AND ARRANGEMENTS MADE TO MAKE THE REQUIRED MODIFICATION ACCORDING TO INSTRUCTIONS CONTAINED IN THIS BULLETIN.

SERVICE PROCEDURE

1. MAKE SURE CLUTCH CABLE IS LOCATED IN THE CLIP ON THE INSIDE OF THE LEFT FRONT SHOCK TOWER (SEE FIGURE 1.)

2. IF THE CABLE IS NOT TIGHT IN THE CLIP THEN REMOVE THE CABLE FROM THE CLIP AND BEND THE CLIP CLOSED AND SNAP THE CABLE BACK INTO THE CLIP. CHECK FOR MINIMUM CLEARANCE OF 13MM (1/2") (SEE FIGURE 1.)

3. IF CLEARANCE IS LESS THAN SPECIFIED, REFORM BRAKE PIPE AS NECESSARY TO PROVIDE A MINIMUM 13 MM (1/2") CLEARANCE BETWEEN THE CLUTCH CABLE AND BRAKE PIPE.

4. SHOULD THE CLIP BE BROKEN, MISSING OR MISPOSITIONED, A NEW CLIP MAY BE INSTALLED USING THE FOLLOWING PROCEDURE:

A. REMOVE THE TWO NUTS ATTACHING THE MASTER CYLINDER TO THE BRAKE BOOSTER. SLIDE THE MASTER CYLINDER OFF THE STUDS AND LET IT HANG ON THE BRAKE PIPES.

B. LOCATE THE WELD FLANGE ON THE LEFT SHOCK TOWER. CENTER PUNCH AND DRILL A 3/16" HOLE IN THE WELD FLANGE AT THE LOCATION SHOWN IN FIGURE 2. ALSO DRILL A 3/16" HOLE IN A NEW FURNISHED CLIP.

C. USING A 3/16" POP RIVET, ATTACH THE NEW CLIP ON THE LEFT SHOCK TOWER IN THE LOCATION SHOWN IN FIGURE 2 ON FOLLOWING PAGE. D. SQUEEZE THE CLIP CLOSED AND SNAP THE CABLE INTO THE CLIP. FOLLOW THE ABOVE PROCEDURE TO OBTAIN MINIMUM CLEARANCE. E. REINSTALL THE MASTER CYLINDER AND TORQUE THE ATTACHEING NUTS TO 30-40 NM (25-30 FT.LBS.) NOTE: ACCORDING TO ASSEMBLY PLANT DATA, A VERY LOW PERCENTAGE OF INVOLVED VEHICLES WILL HAVE THE CLIP ACTUALLY MISSING.

5. EACH VEHICLE MODIFIED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS SERVICE PROCEDURE 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 VEHICLE WAS CAMPAIGNED. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR BALLPOINT PEN. INSTALL THE LABEL ON THE RADIATOR BAFFLE WHERE IT IS READILY VISIBLE.

PARTS INFORMATION

SHOULD IT BE NECESSARY TO INSTALL A CLIP, PLEASE CONTACT YOUR PONTIAC ZONE OFFICE AND THEY WILL MAKE ARRANGEMENTS TO HAVE THE CLIP SHIPPED "NO CHARGE" TO THE DEALERSHIP. POP RIVETS MAY BE OBTAINED FROM A LOCAL SOURCE.

ENCLOSED WITH THE COPY OF THIS BULLETIN

A LIST OF THOSE VEHICLES INVOLVED, WHICH OUR RECORDS INDICATE ARE IN YOUR GEOGRAPHICAL AREA, IS ATTACHED FOR YOUR FOLLOW-UP. ADVISE THE ZONE IF VEHICLES APPEARING ON THE ATTACHED LIST ARE NOT IN YOUR AREA. (IF A LIST OF VEHICLES IS NOT ATTACHED, OUR RECORDS INDICATE NO AFFECTED VEHICLE(S) IN YOUR AREA.)

IF A VEHICLE HAS BEEN TRANSFERRED OR SOLD TO ANOTHER LOCATION, PLEASE FORWARD THE NEW NAME AND ADDRESS OF THE VEHICLE TO YOUR PONTIAC ZONE OFFIEC.

RECORDING COMPLETION

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.

ADDITIONAL CAMPAIGN LABELS ARE AVAILABLE ON STATIONERY ORDER AS FORM 7201-709.

DEALERS SHOULD STILL SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS: NOTICE: A COMPLETE WARRANTY CLAIM IS TO BE KEPT AS A PERMANENT RECORD OF COMPLETION.

WARRANTY CREDIT

A SEPARATE REPAIR ORDER MUST BE USED FOR EACH VIN.

FAILURE LABOR LABOR OTHER* DESCRIPTION CODE OPERATION HOURS HOURS

INSPECTION & CORRECTION 96 V1120 0.2 HR. 0.1 HR. INSPECTION,CORRECTION& 96 V1121 0.2 HR. 0.1 HR. INSTALL CLIP

*"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 ZONE AUTHORIZATION."

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

(CREDITING)

DEALERS WILL BE CREDITED VIA WARRANTY DOCUMENT OR TERMINAL TRANSMISSION, WHICHEVER IS THEIR NORMAL METHOD OF SUBMISSION FOR PAYMENT. CLAIMS MUST CONTAIN ALL INFORMATION REQUIRED AND SHOULD LIST THE LABOR OPERATION AS OUTLINED.

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.