CAMPAIGN:BRACKET INTERFERENCE RUBBING THROUGH BRAKE LINE. Pontiac LeMans 1983

For 1990-2009 cars

# CAMPAIGN:BRACKET INTERFERENCE RUBBING THROUGH BRAKE LINE

GENERAL MOTORS HAS DETERMINED THAT A DEFECT WHICH RELATES TO MOTOR VEHICLE SAFETY EXISTS IN SOME 1983 (G) CARS EQUIPPED WITH 5.7 LITER V-8 DIESEL ENGINES. THE FRONT BRAKE MASTER CYLINDER BRAKE PIPE MAY RUB ON THE AIR CLEANER RESONATOR BRACKET. OVER AN EXTENDED PERIOD OF OPERATION, THE BRAKE PIPE COULD WARE THROUGH, RESULTING IN A BRAKE FLUID LEAK AND LOSS OF THE FRONT BRAKES. THESE VEHICLES ARE EQUIPPED WITH DUAL BRAKING SYSTEM; PART OF THE SYSTEM WILL STILL WORK AND ALLOW THE VEHICLE TO BE STOPPED, BUT OVER A GREATER DISTANCE. LOSS OF FRONT BRAKING AT A TIME WHEN MINIMUM STOPPING DISTANCE IS REQUIRED COULD RESULT IN A VEHICLE CRASH WITHOUT PRIOR WARNING.

DEALER ACTION

TO PREVENT THE POSSIBILITY OF THIS CONDITION OCCURRING ON VEHICLES INVOLVED, DEALERS ARE TO MAKE SURE THERE IS A MINIMUM OF 19MM (3/4 INCH) CLEARANCE BETWEEN THE BRAKE PIPE AND RESONATOR BRACKET. IF THERE IS NOT, THEY MUST REPOSITION PIPE TO PROVIDE THIS CLEARANCE. ALSO, IF THE PIPE IS WORN DUE TO CONTACTING THE BRACKET, THE PIPE IS TO BE REPLACED.

DEALER CAMPAIGN RESPONSIBILITY

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.

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

VEHICLES INVOLVED

1983 "G" SERIES EQUIPPED WITH 5.7L (VIN CODE N) V-8 DIESEL ENGINES WITHIN THE FOLLOWING SERIAL NUMBERS:

ASSEMBLY PLANT BEGINNING UP TO AND INCLUDING

FLINT DH800001 DH970721 ARLINGTON DR400001 DR421521

DEALER MATERIAL

IF YOUR DEALERSHIP HAS VEHICLES INVOLVED IN THIS CAMPAIGN, YOU WILL RECEIVE THE FOLLOWING ITEMS:

A. LIST OF ALL VEHICLES INVOLVED IN THEIR CAMPAIGN SHIPPED TO YOUR DEALERSHIP.

B. ONE (1) CAMPAIGN IDENTIFICATION LABEL PER VEHICLE INVOLVED.

INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER COMPUTER LISTINGS. COMPUTER LISTINGS CONTAIN THE COMPLETE VEHICLE IDENTIFICATION NUMBER, OWNER NAMES AND ADDRESS DATA, AND ARE FURNISHED TO THE 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 FOR THE FOLLOW UP NECESSARY TO COMPLETE THIS CAMPAIGN.

PARTS INFORMATION

BRAKE PIPE, PART NUMBER 25519243, IF REQUIRED FOR THIS CAMPAIGN IS TO BE OBTAINED FROM WDDGM. VERY FEW PIPES WILL REQUIRE REPLACEMENT ON VEHICLES INSPECTED.

TO ENSURE THIS PART WILL BE OBTAINED AS SOON AS POSSIBLE, IT SHOULD BE ORDERED FROM GM PART (WDDGM) ON A C.I.O. ORDER WITH NO SPECIAL INSTRUCTION CODE, BUT ORDER ON AN ADVISE CODE (2).

TECHNICAL PROCEDURE

1. OPEN VEHICLE HOOD AND CHECK TO DETERMINE IF THE FRONT BRAKE SYSTEM PIPE FROM MASTER CYLINDER TO PROPORTIONER VALVE HAS A MINIMUM CLEARANCE OF 3/4" TO THE AIR CLEANER RESONATOR BRACKET. REFER TO FIGURE 1 AND 2 - VIEW A.

2. IF THE BRAKE PIPE HAS BEEN CONTACTING THE BRACKET AND HAS A SHINY OR WORN SPOT DUE TO THIS CONTACT, REPLACE PIPE WITH PART NUMBER 25519243 REFER TO SECTION 5 OF THE 1983 CHASSIS SERVICE MANUAL FOR BRAKE BLEEDING INFORMATION AND FIGURE 2 - FOR REQUIRED PIPE CLEARANCES.

3. IF CLEARANCE IS LESS THAN SPECIFIED, REFORM THE PIPE TO PROVIDE 3/4 INCH CLEARANCE IF THE PIPE IS REPLACED DUE TO WEAR, BE SURE TO PROVIDE 3/4 CLEARANCE BETWEEN IT AND THE RESONATOR BRACKET, AND PROPERLY REFILL THE SYSTEM WITH BRAKE FLUID, AND BLEED TO ENSURE PERFORMANCE.

4. INSTALL CAMPAIGN IDENTIFICATION LABEL.

EACH VEHICLE MODIFIED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED HEREIN WILL REQUIRE A CAMPAIGN IDENTIFICATION LABEL. EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER, THE FIVE (5) DIGIT DEALER CODE OF THER DEALER PERFORMING THE CAMPAIGN SERVICE, AND THE DATE VEHICLE WAS CAMPAIGNED. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR BALLPOINT PEN. WHEN IN- STALLING LABEL, CLEAN THE SURFACE OF THE FAN SHROUD AND APPLY THE CAMPAIGN LABEL.

A. LIST CAMPAIGN NUMBER B. LIST DEALER CODE AND, C. DATE ON LABEL AS SHOWN AFTER CAMPAIGN COMPLETED.

WARRANTY INFORMATION

DEALERS ARE TO SUBMIT EACH CAMPAIGNED VEHICLE AS A SEPARATE CASE ON THE ONE-LINE WARRANTY DOCUMENT FORM S-764. DEALERS SUBMITTING WARRANTY CLAIMS BY TELETYPE TERMINAL ARE TO TRANSMIT CAMPAIGN COMPLETIONS AS A SEPARATE CASE ALSO.

LIST THE ONE APPLICABLE LABOR OPERATION

SUBLET PART FAILED PARTS FAILURE LABOR LABOR OTHER DEALER OPER COUNT PART NO. ALLOW. CODE OP. NO. HRS. HRS. MTL.TWG

INSPECT AND REPOSITION * BRAKE PIPE 96 V1830 .2 .1 INSPECT AND REP. BRAKE PIPE ** * 1 25513371 $3.77 96 V1831 .5 .1 - * .1 HOUR FOR ADMINISTRATION ** PART CREDIT IS FOR DEALER PRICE OF BRAKE PIPE NUMBER 25513371 ($2.28) PLUS 30% ($.68) AND 1/2 PINT OF BRAKE FLUID ($.62) PLUS 30% ($.19)

TO ASSURE ACCURATE RECORDS OF ALL TRANSACTIONS ON THIS CAMPAIGN, IT IS RECOMMENDED THAT CAMPAIGN REPAIRS FOR EACH VEHICLE BE LISTED ON A SEPARATE REPAIR ORDER. OTHER REPAIRS PERFORMED TO THE VEHICLE MAY BE LISTED ON THE SAME REPAIR ORDER, AND WARRANTY CASES OTHER THAN CAMPAIGNS MAY BE LISTED ON THE SAME WARRANTY DOCUMENT.

ZONE AUTHORIZATION IS NOT REQUIRED.

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.