For 1990-2009 cars

# CAMPAIGN: INCORRECTLY MACHINED REAR BRAKE DRUM

#### SUBJECT: INCORRECTLY MACHINED REAR BRAKE DRUM

#### Models: 1995 Chevrolet/Geo Metro and Pontiac Firefly (3-Door & Non-ABS Brake)

#### TO: ALL GENERAL MOTORS DEALERS

General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1995 Chevrolet/Geo Metro and Pontiac Firefly 3-Door Non-ABS vehicles. Certain of these vehicles may have been built with incorrectly machined rear brake drums. As the vehicle is driven, loss of wheel clamp load could result from this condition. Once clamp load is lost, all tire loads are taken by the wheel studs, this loading could result in fatigue failure of the wheel studs. If this occurs, a wheel could separate from the vehicle. and a crash could occur without prior warning.

To prevent the possibility of this condition occurring, dealers are to replace both rear brake drums on all involved vehicles.

#### VEHICLES INVOLVED:

Involved are certain 1995 Chevrolet/Geo Metro and Pontiac Firefly 3-Door & Non-ABS vehicles built within the following VIN breakpoints:

#### Year Model Plant Plant Code From Through

1995 Chevrolet "M" Car Cami - Ingersoll 6 S6705905 S6708879 1995 Pontiac "M" Car Cami - Ingersoll 6 S6707622 S6708030

#### NOTE: PLEASE CHECK DCS SCREEN 45 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

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:

All unsold new vehicles in dealer's 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 perform this campaign on all involved vehicles at no charge to owners, regardless of kilometers traveled, 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 instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner 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 is taken into your new or used 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.

#### 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 (see copy of owner letter included with this bulletin). 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 ----------- ----------- ---------------- 91172152 Rear Brake Drum Kit 2

#### Kit contains:

Brake Drum Wheel Studs Inner & Outer Wheel Bearings Spacer Dust Cover Spindle Nut Spindle Nut Washer

#### 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 Replace Both Rear Brake Drums & Spindle Nuts .7

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 40% to cover parts handling.

#### SERVICE PROCEDURE:

1. Raise vehicle and suitably support.

2. Remove wheel cover (if equipped)

3. Remove tire/wheel.

4. Remove dust cover (not to be reused).

5. Unstack spindle nut.

6. Remove spindle nut (not to be reused) and washer (not to be reused).

7. Remove brake drum (not to be reused).

8. Install NEW brake drum.

9. Install NEW washer and NEW spindle nut and torque to 120 N.m (86.5 lb. ft.).

10. Stake spindle nut.

11. Install NEW dust cover.

12. Repeat procedure for rear brake drum on other side of vehicle.

13. Lower vehicle.

14. 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:

General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1995 Chevrolet/Geo Metro and Pontiac Firefly 3-Door Non-ABS vehicles. Certain of these vehicles may have been built with incorrectly machined rear brake drums. As the vehicle is driven, loss of wheel clamp load could result from this condition. Once clamp load is lost, all tire loads are taken by the wheel studs, this loading could result in fatigue failure of the wheel studs. If this occurs, a wheel could separate from the vehicle, and a crash could occur without prior warning.

To prevent the possibility of this condition occurring, your dealer will replace both rear brake drums on all involved vehicles.

This service will be provided for you at no charge.

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

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered fore scheduling your 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.

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

Customer Support Department General Motors of Canada Limited

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.