CAMPAIGN: REAR AXLE HOUSING FRACTURE. Geo Tracker - 4WD 1993

For 1990-2009 cars

# CAMPAIGN: REAR AXLE HOUSING FRACTURE

#### Subject: PRODUCT SAFETY CAMPAIGN 94C22 (a) - REAR AXLE HOUSING FRACTURE

--- REISSUE ---

#### Model and Year: 1993-94 GEO TRACKER

#### To: All Chevrolet/Geo Dealers

THIS BULLETIN REPLACES PRODUCT SAFETY CAMPAIGN BULLETIN 94C22 ISSUED MAY, 1994. THE VEHICLES INVOLVED, OWNER NOTIFICATION, SERVICE PROCEDURE AND CLAIMS INFORMATION SECTIONS HAVE BEEN REVISED. SPECIFICALLY, CHANGES HAVE BEEN MADE TO REFLECT ADDITIONAL VEHICLES INVOLVED, SERVICE PROCEDURE ADDITIONS TO REINSPECT AXLES ALREADY REPLACED SINCE THE INITIAL RECALL, CLARIFICATION OF AXLE RETURN PROCEDURE, AND ADDITIONAL LABOR OPERATIONS TO COVER INSPECTION AND REPAIR OF PREVIOUSLY REPLACED AXLES. REVISED INFORMATION IS SHOWN IN BOLD TYPE.

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 Chevrolet 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 a defect which relates to motor vehicle safety exists in certain 1993-94 Geo Tracker model vehicles. Some of these vehicles have a rear axle shaft housing tube that was incorrectly welded and could fracture. Fracture of the rear axle shaft housing tube could result in a loss of rear braking and affect vehicle control.

To prevent the possibility of this condition occurring, dealers are to inspect the rear axle assemblies on involved vehicles and, if necessary, replace the complete rear axle assembly

#### VEHICLES INVOLVED (Revised 1994 ending VIN Breakpoint)

Involved are certain 1993-94 Geo Tracker model vehicles built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---------------------------------------------------------------- 1993 E10 & J10 Ingersoll "6" P6900179 P6938624 1994 E10 & J10 Ingersoll "6" R6900001 R6947897

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.

#### 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 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.

#### OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin). Owners of vehicles which have already been repaired under the initial recall must be recontacted and arrangements must be made to reinspect the replacement axle at the owner's home or location of choice.

#### SPECIAL INSPECTION GAUGE

Each Dealer was shipped an inspection gauge for use in this campaign. Tools were sent to dealers at no charge during the week of April 18, 1994.

#### PARTS INFORMATION

While the rear axle shaft housing tube is the cause of this condition, dealers are to replace the complete rear axle assembly.

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO as a SPAC CASE (vehicle VIN will be required) and GMSPO will arrange for an exchange axle assembly to be shipped NEXT DAY AIR directly to your dealership. THE EXCHANGE AXLE WILL BE SHIPPED PREPAID.

Quantity/ Part Number Description Vehicle ----------- ----------- --------- 91171637 Rear Axle Assembly - Manual Transmission 1 91171638 Rear Axle Assembly - Automatic Transmission 1 - 8 Valve Engine 91171639 Rear Axle Assembly - Automatic Transmission 1 - 16 Valve Engine 12346190 Synthetic Gear Lubricant 2.2 Liters (Or Equivalent) (4.6 Pints) 01052542 Brake Fluid 1 Quart

#### NOTICE:

REAR AXLE ASSEMBLY PART NUMBERS 91171637, 91171638 AND 91171639 WILL NOT BE RETURNABLE TO GMSPO UNDER THE RETURN PARTS PROGRAM.

#### SERVICE PROCEDURE

#### REINSPECTION OF PREVIOUSLY REPAIRED VEHICLES

Vehicles which had axles replaced prior to the issuing of this supplement are to be reinspected using the service procedure in the initial bulletin and also following the revisions below. Some axles which may have been used when 94C31 was originally issued may have the same suspect welds as the axles which were replaced. Vehicles which were inspected and did not have the axle replaced do not need to be reinspected.

#### AXLE INSPECTION PROCEDURE

#### NOTICE:

(PERFORM THIS OPERATION PRIOR TO STEP 2 OF SERVICE PROCEDURE)

FOR VEHICLES PRODUCED BETWEEN VIN's R6908149 & R6947897 A HOUSING PREINSPECTION PRIOR TO WELD INSPECTION IS NECESSARY ONCE VEHICLE HAS BEEN RAISED ON HOIST. CLEAN REAR FACE OF AXLE HOUSING AND INSPECT FOR MANUFACTURE'S IDENTIFICATION CODES.

0 IF AXLE HOUSING DOES NOT HAVE ANY MANUFACTURER'S IDENTIFICATION CODES ON THE BACK OF THE HOUSING (AS INDICATED ON LEFT BELOW), IT IS NOT NECESSARY TO INSPECT FOR PROPER WELD LOCATION. DO NOT REPLACE THE AXLE. INSTALL CAMPAIGN IDENTIFICATION LABEL AND RETURN VEHICLE TO CUSTOMER.

0 IF AXLE HOUSING DOES HAVE MANUFACTURE'S CODES (AS INDICATED ON RIGHT BELOW), CONTINUE TO SERVICE PROCEDURE STEP 2 AND FOLLOWING PROCEDURE REVISIONS WHICH FOLLOW.

Figures referenced are located on pages 6 and 7.

#### AXLE INSPECTION PROCEDURE

1. Raise vehicle on hoist.

2. Clean dirt/undercoat from front of axle tube near bottom of weld area (See Figure 1, shaded area).

3. Visually inspect welds for any oil leaks. If leaks are found, the axle assembly will require replacement (skip to "AXLE REPLACEMENT PROCEDURE").

4. Place gauge tool over nuts "A" and "B" (Figure 2) ensuring that the gauge tool is resting on the axle (also see label on tool for proper positioning).

5. Position your line of sight with gauge slot (Figure 3) and inspect location of weld #1 (Figure 2). The part is acceptable if the weld is located within the slot. See Figure 5 for acceptable criteria of weld location.

6. Place gauge tool over nuts "C" and "D" and inspect location of weld #2 (Figures 2 & 4) . The part is acceptable if weld bead is located within the slot. See Figure 5 for acceptable criteria of weld location.

7. If weld areas do not pass inspection procedure, it will be necessary to replace the rear axle following the repair procedure which follows. If the weld area does pass inspection, do not make any further repair but install Campaign Identification Label.

#### AXLE REPLACEMENT PROCEDURE

1. Remove two (2) screws, two (2) clips and parking brake lever cover from inside of vehicle.

2. Remove park brake cable locknut and spacer.

3. Remove park brake cable from equalizer.

4. Raise and suitably support vehicle. Refer to section OA of service manual.

5. Remove both rear wheels.

6. Remove bolts (8 total) from left and right park brake cable protectors on trailing rod, frame and crossmember.

7. Remove park brake cables from openings in floor.

8. Remove rear axle drain plug and drain fluid from rear axle into drain pan or other suitable container.

9. Disconnect propeller shaft from rear axle. Secure shaft under vehicle.

10. Loosen rear axle trailing rod through bolts.

11. Position hydraulic jack under the vehicle and support rear axle housing.

12. Remove four (4) bolts at rear control arm ball joint boss and separate ball joint boss from differential carrier.

13. Remove wheel speed sensor cover bolts.

14. Disconnect wheel speed sensor connector.

15. Disconnect brake fluid hose and remove E clip from brake hose bracket.

16. Disconnect rear axle breather hose.

17. Remove both lower shock mounting bolts and nuts.

18. Remove trailing rod through bolts.

19. Remove wheel speed sensor harness connector at axle.

20. Slowly lower rear axle and coil springs from vehicle.

#### NOTICE: Rear coil springs are under pressure. Lower hydraulic jack under rear axle slowly until coil springs become relieved. If rear coil springs become unseated while under pressure, serious bodily injury may result.

21. Remove old axle and hydraulic jack from under vehicle.

22. Install new axle on hydraulic jack and position axle under vehicle.

23. Raise axle assembly and install coil springs in their proper position.

#### NOTICE: When installing rear coil springs in their spring seats, make sure that the spring end with the stepped portion is aligned with the stepped portion of the rear axle housing.

24. Install speed sensor wiring harness to rear axle.

25. Install trailing rod through bolts and torque to 90 Nm (66 lb. ft.).

26. Install both lower shock through bolts and nuts. Torque nuts to 90 Nm (66 lb. ft.).

27. Connect rear axle breather hose to rear axle housing; secure with one clamp.

28. Connect brake fluid hose and install E clip to brake hose bracket.

29. Connect wheel speed sensor connector.

30. Install wheel speed sensor cover; secure with two bolts. Torque bolts 15 Nm (11 lb. ft.). (Through hole bolt must have GM 12346004 or equivalent sealant.)

31. Install rear control arm ball joint boss to differential carrier; secure with four bolts. Torque bolts to 50 Nm (37 lb. ft.).

32. Remove hydraulic jack from under the rear axle.

33. Install propeller shaft; secure with four (4) bolts and nuts. Torque to 50 Nm (36 lb. ft.).

34. Refill rear axle with approximately 2.2 liters (4.6 pts.) of synthetic gear lubricant. Oil level should be level with the bottom of the rear axle housing oil level/filler plug.

35. Install axle housing oil level/filler plug and torque to 50 Nm (36 lb. ft.).

36. Install park brake cables through floor openings.

37. Install left and right park brake cable protectors on trailing rod, frame and crossmember. Secure with four (4) bolts per side.

38. Bleed rear brakes. Refer to Section 5 of service manual.

39. Install both rear wheels.

40. Lower vehicle.

41. Install park brake cables to equalizer and connect equalizer to connecting rod. Secure with spacer and locknut.

42. Adjust park brake lever by loosening or tightening the locknut until parking brake is applied with between 7 and 9 clicks on parking brake lever with about 20 Kg (44 lb.) force.

43. Install park brake lever cover to vehicle; secure with two (2) screws and two (2) clips.

44. Install Campaign Identification Label.

45. Return removed rear axle assembly as follows:

ALL AXLE ASSEMBLIES REMOVED FROM VEHICLES IN CONJUNCTION WITH PERFORMING THIS CAMPAIGN SHOULD BE PROMPTLY RETURNED WITHIN 24 HOURS OF COMPLETING THE REPLACEMENT SERVICE PROCEDURE.

A. Drain all fluid from removed axle assembly.

B. Secure removed axle assembly on original shipping container.

C. Fill in information on shipping tag.

D. Contact freight carrier appropriate for your state:

Michigan: Central Transport (Use local phone listings)

All Other States: Yellow Freight 1-800-458-3323

E. Complete the bill of lading to indicate that freight charges will be billed to:

CAMI Automotive 300 Ingersol St. Ingersol, Ontario, Canada N5C4A6 ATTN.: R. McCulligh

F. A "Rear Axle Return Document" was included with the new axle housing assembly. Complete this card and return it along with the defective axle assembly

G. Return removed rear axle assembly by shipping collect to:

PARTS PACKAGING CO. ATTN.: DENNIS ONEILL 391 EAST WILSON ST. PONTIAC, MI 48053

H. A GSD40 Parts Return Tag should be completed and attached securely to the returned axle.

#### 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 la or core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner. Additional campaign Identification Labels" can be obtained from DAC.

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

#### CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below: * FAILED PARTS LABOR LABOR OTHER NET REPAIR PERFORMED PC PART NO. ALLOW CC-FC OP HOURS HOURS AMOUNT

Inspect - Axle Welded Correctly Or No - - - - - SK-00 V8870 0.2 0.1 - - Manufacturing Codes On Axle Housing

Inspect - Axle Requires - - - - - SK-00 V8871 2.2 0.3 * * Replacement 1993 Tracker

Inspect - Axle Requires - - - - - SK-00 V8872 2.2 0.3 * * Replacement 1994 Tracker

Inspect & Replace Axle Previously - - - - - SK-00 V8873 2.2 0.3 * * Installed - 1993 Tracker

Inspect & Replace Axle Previously - - - - - SK-00 V8874 2.2 0.3 * * Installed - 1994 Tracker

Inspect Previously Replaced Axle - - - - - SK-00 T2520 0.2 0.1 * * No Additional Replacement Needed

* 0.1 hours for Campaign Administrative Allowance. For operations V8871, V8872, V8873 & V8874 dealerships will also receive an additional 0.2 hours credit for packaging of the axle assembly for return. The 0.3 hours total allowance is to be entered in the "Others Hours- field. This entry will not require authorization.

* * Replacement of the complete axle assembly is due to the incorrect rear axle shaft housing tube weld. Therefore, the 30% (1993 - V8871 & V8873) or 40% (1994 - V8872 & V8874) dealer net will be applied only to the cost of the rear axle shaft housing. This 30% or 40% allowance plus the full cost of the rear axle assembly and the cost of necessary fluids will appear in the net amount. Cost of the technician's travel time to and from owner's location to reinspect previously replaced axle assemblies, alternate transportation or towing should be added to the NET AMOUNT.

Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim Submission.

Dear Geo Tracker 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

General Motors has determined that a defect which relates to motor vehicle safety exists in certain 1993-94 Geo Tracker model vehicles. Some of these vehicles have a rear axle shaft housing tube that was incorrectly welded and could fracture. Fracture of the rear axle shaft housing tube could result in a lose of rear braking and affect vehicle control.

#### WHAT WE WILL DO

To prevent the possibility of this condition occurring, your dealer will inspect the rear axle assembly on your vehicle and, if necessary, replace the complete rear axle assembly. This service will be performed for you at no charge.

#### WHAT YOU SHOULD DO

Please contact your Chevrolet/Geo dealer as soon as possible to arrange a service date and so the dealer may order the necessary parts for the repair. Instructions for making this inspection/correction have been sent to your dealer and parts are available. The labor time necessary to perform this inspection is approximately ten minutes. If rear axle replacement is required, replacement will require approximately two hours. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

Your Chevrolet/Geo 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 Chevrolet Customer Assistance Center by calling 1-800-222-1020.

After contacting your dealer and the 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, D.C. 20590 or call 1-800-424-9393 (Washington D.C. residents use 366-0123).

The enclosed 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 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 Motor Division GENERAL MOTORS CORPORATION

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.