For 1990-2009 cars

# CAMPAIGN: REAR DISC BRAKE CONE CLUTCH PARK BRAKE ADJUST.

#### Models: 1982-86 Chevrolet and Pontiac "F" Cars and 1984-86 Pontiac "P" Cars With Rear Disc Brakes And Manual Transmissions

General Motors of Canada has determined that a defect which relates to motor vehicle safety exists in certain 1982-86 Chevrolet and Pontiac "F" cars and 1984-86 Pontiac "P" cars equipped with rear disc brakes and manual transmissions. These vehicles may exhibit a lack of park brake automatic adjustment leading to reduced parking brake effectiveness.

To correct this condition, all involved vehicles will have an improved design rear brake caliper actuator installed. Other repairs to restore park brake functions to proper operation may also be made in conjunction with this campaign.

#### VEHICLES INVOLVED:

Involved are certain 1982-86 Chevrolet and Pontiac "F" cars and 1984-86 Pontiac "P" cars equipped with rear disc brakes and manual transmissions, and built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH "F" CARS---- ------- ------- ----- -------- ---------- 1982 Camaro Norwood N SOP CN168020 1982 Camaro Van Nuys L CL123326 CL221394 1982 Firebird Norwood N CN500009 CN525838 1982 Firebird Van Nuys L CL512143 CL547717 1983 Camaro Norwood N DN103234 DN165071 1983 Camaro Van Nuys L DL100280 DL168650 1983 Firebird Norwood N DN200005 DN237321 1983 Firebird Van Nuys L DL204059 DL237537 1984 Camaro Norwood N SOP EN200276 1984 Camaro Van Nuys L SOP EL260754 1984 Firebird Norwood N SOP EN250762 1984 Firebird Van Nuys L EL200052 EL277535 1985 Camaro Norwood N SOP FN176201 1985 Camaro Van Nuys L FL100079 FL503417 1985 Firebird Norwood N SOP FN241006 1985 Firebird Van Nuys L FL200453 FL654814 1986 Camaro Norwood N SOP GN188639 1986 Camaro Van Nuys L SOP GL203370 1986 Firebird Norwood N SOP GN251089 1986 Firebird Van Nuys L SOP GL25905C

PLANT YEAR MODEL PLANT CODE FROM THROUGH "P" CARS---- ----- ------- ---- ----- ---------- 1984 Fiero Pontiac P SOP EP336842 1985 Fiero Pontiac P SOP FP276369 1986 Fiero Pontiac P SOP GP283974

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

#### DEALER CAMPAIGN RESPONSIBILITY

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, age of vehicle, or ownership, from this time forward.

Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service, you are to ensure the campaign correction has been made before selling or releasing the vehicle.

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.

#### CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

#### OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors. The listings provided are for campaign activity only and should not be used for any other purpose.

#### PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ------------- ---------------------------- ------------------- F-CAR PARTS 18019028 Rear Brake Caliper Actuator Kit 1 Each Kit Contains - 2 Actuator Assemblies - All Necessary Gaskets & Seals - 2 Brake Pad Dampening Springs

18009815 Brake Pads As Required 18010361 Levers As Required 10200446 Parking Brake Cable As Required - Front 10200443 Left Rear Cable As Required 10200444 Right Rear Cable As Required 10046472 Parking Brake Apply Handle As Required 992669 Brake Fluid 1 Litre 10139097 Banjo Washer As Required

Part Number Description Quantity/Vehicle ----------- ----------------------- ----------------- P-CAR PARTS 18019027 Rear Brake Caliper Actuator Kit 1 Each Kit Contains: - 2 Actuator Assemblies - All Necessary Gaskets & Seals - 2 Brake Pad Dampening Springs

18011292 Brake Pads As Required 18011072 Levers (Left Hand) As Required 18011073 Levers (Right Hand) As Required 10200445 Parking Brake Cable As Required - Front 10200441 Left Rear Cable As Required 10200442 Right Rear Cable As Required 10046473 Parking Brake Apply Handle As Required 992669 Brake Fluid 1 Litre 10139097 Banjo Washer As Required

DEALERS ARE TO RETURN ALL SERVICE INVENTORY OF SEAL KITS 18010453 AND 18011329, ACTUATOR KITS 18016369 AND 18016368, AND REAR CALIPER PART NUMBERS 18016374, 18014436 AND 18014437. PLEASE IDENTIFY THESE PARTS AS SPECIAL RETURNS ON YOUR GMP83 DOCUMENT.

#### PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ----------------------- --------------- **2A Install New Actuator Kit Camaro/Firebird 2.1 Fiero 3.0

***T1749 - Supplemental Repairs For Campaign ID08

FIERO CAMARO/FIREBIRD Description Labour Hours Labour Hours ---------------------------- ----------- ------------- Replace Front Park Brake Cables 0.7 0.7 Replace Both Rear Park Brake Cables 0.3 0.2 Replace All Park Brake Cables 0.8 0.9 Replace Park Brake Handle 0.7 0.5

Remove And Reinstall Wheel Lock Nuts 0.1 0.1

Replace Tapered Brake Pads (The labour hours to perform this repair are included in 2A. Use T1749 only to claim the applicable parts allowance.)

Replace Actuator Levers (The labour hours to perform this repair are included in 2A. Use T1749 only to claim the applicable parts allowance.)

Dealers will automatically receive the correct labour and material allowances for Repair Code 2A.

** An amount of $6.35 has been added to Repair Code 2A for fluid allowance.

** Labour Hours required to replace tapered pads, install actuator levers, and adjust park brake cables are included in Repair Code 2A. No additional time is needed as procedures to perform these repairs are part of the campaign actuator installation procedure.

*** The Labour Hours required for supplemental repairs to complete this campaign are listed above. If multiple repairs were required, add appropriate times together.

T1750 Reimburse Owner For Previous Repair

#### REIMBURSEMENTS

Claims for customer reimbursements on previously paid repairs to correct a previous parking adjuster condition will be considered. Owners should present documentation which reasonably confirms the amount of unreimbursed repair expense, a description of the repair, the date of the repair, and the person or entity performing the repair.

Review the owner's documentation, and process under T1750 (authorization is required).

#### SERVICE PROCEDURE:

A. Raise vehicle and remove both rear tire/wheel assemblies. B. Inspect park brake apply system for proper function, corrosion, kinks, etc. Remove nonfunctional cables. C. Spray equalizer and both bleeder screws with Liquid Wrench (or equivalent product). Do not remove screws at this time. D. Remove both rear calipers following the procedures in the appropriate Service Manual. E. Remove brake pads. F. Inspect brake pads for taper wear or excessive wear. Taper wear can be determined by taking measurements at the four points shown in the diagram below.

Calculate pad taper by subtracting the thinnest point measured from the thickest point measured. The brake pads should be replaced if taper is greater than 0.20 cm. (.080 inches). G. Overhaul calipers as follows:

#### Tools Required:

* J-22269-01 Piston Installer * J-38898 Boot Seal Installer

1. Remove shoe damping spring from end of piston. 2. Remove park brake lever. 3. Remove lever seal and anti-friction washer. 4. Remove piston by turning actuator screw with lever or wrench.

#### NOTICE: DO NOT REUSE OLD PISTON OR OLD BALANCE SPRING.

5. Remove actuator screw by pressing on threaded end. 6. Remove shaft seal and thrust washer from actuator screw. 7 Remove old boot while being careful not to scratch the housing bore. 8. Remove piston seal, using a wood or plastic tool that will not damage the caliper bore. 9. Remove caliper mounting bolts, bushings and sleeves. 10. Remove bleeder screw.

#### NOTICE: If excessive resistance is encountered, use the following procedure to prevent breakage.

(A) First put a 10mm socket over bleeder screw and tap lightly on it.

(B) If step (A) does not help, use a propane torch to heat the caliper around bleeder screw after assuring that any excess Liquid Wrench has been removed from surface. Apply heat to caliper for approximately 30 seconds to 1 minute (maximum). DO NOT USE AN ACETYLENE TORCH. Overheating of the aluminum caliper could cause the bleeder screw to strip its threads.

11. Inspect caliper bore and seal groove. If necessary, use crocus cloth to polish out any light corrosion. 12. Clean all parts with GM brake parts cleaner P/N 12345754 (or equivalent). 13. Dry parts with unlubricated compressed air. 14. Blow out all passages in housing and bleeder screw. 15. Clean internal passage in bleeder screw, reinstall bleeder screw and torque to 6-9 N.m (80-140 lb. in.). 16. Install new piston seal. Lubricate seal and bore with brake fluid.

#### NOTICE: Make sure seal is not twisted.

17. Install new lubricated boot onto new piston with inside lip of boot in piston groove and boot fold toward end of piston which contacts inboard brake pad. 18. Install thrust washer on actuator screw with copper side of washer toward the piston assembly and gray surface toward the caliper housing. 19. Install lubricated shaft seal on actuator screw. 20. Install actuator screw into piston. 21. Install new balance spring into piston recess. 22. Guide lubricated piston assembly into lubricated bore of caliper.

#### NOTICE: Excessive force is not required to install the piston assembly into the caliper bore.

DO NOT ALLOW PISTON TO COCK IN BORE AS SEAL WILL BE DAMAGED.

23. When resistance (seal engagement) is met, rotate piston assembly back and forth to insure it is square to seal. 24. Use #J-22269-01 to install piston through piston seal. Shake tool to align piston to the seal while gently turning the jack screw to push piston through the seal to the bottom of the caliper bore. See illustration below. 25. Install lubricated and anti-friction washer and lever seal over end of actuator screw.

#### NOTICE: The sealing bead on the lever seal should be against the housing.

26. Install lever on actuator screw. Rotate lever away from stop slightly and hold while installing nut to 48 N.m (35 lb. ft.). Then, rotate lever back to contact stop. 27. Seat boot into caliper housing counter bore using new Kent-Moore tool #J-38898. 28. Install new brake pad dampening spring (included in kit) into groove on end of piston. 29. Clean, lubricate and reinstall sleeves, bushings and caliper mounting bolts. 30. Install brake shoes. H. Reinstall calipers, per the appropriate shop manual. I. Install hydraulic fitting and bolt, using 2 new brass washers, and torque to 33 N.m (24 lb. ft.). J. Bleed brake system (power or manual) as required, per shop manual. K. Apply approximately 778 N (175 lb.) force 3 times to the brake pedal to seat the linings. L. Clinch outboard shoe to caliper, per shop Manual. M. Readjust park brake cable, per shop manual. N. Reinstall wheels and tire assemblies. 0. Install Campaign Identification Label.

#### INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

Dear General Motors Customer:

As we informed you in our previous letter, General Motors of Canada has determined that a defect which relates to motor vehicle safety exists in 1982-86 Chevrolet Camaro, Pontiac Firebird and 1984-86 Pontiac Fiero model vehicles equipped with rear disc brakes and manual transmissions. As we explained in that letter, the parking brake system of these vehicles may contain a nonfunctional parking brake adjuster in the rear disc brake assemblies. This condition may result in a gradual loss of parking brake effectiveness as the rear disc brake pads wear during normal brake usage. As a result, the parking brake system may not be able to hold the vehicle on a steep incline. If the vehicle is parked or left unattended with the transmission in neutral or a gear other than "reverse", the vehicle may roll away and result in personal injury or property damage.

In our previous letter, we informed you that a new parking brake adjuster was in the process of being developed. Development of that new parking brake adjuster is now complete, and parts to repair the affected vehicles are now available.

To improve parking brake performance in your Camaro, Firebird or Fiero your General Motors Dealer will install the new design parking brake adjusters in your vehicle. This service will be performed for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time. Subsequent to contacting your dealer, further assistance, if required, may be obtained from our Customer Assistance Centre, toll free, by calling 1-800-263-3777 (English), or 1-800-263-7854 (French).

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

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.