PARK BRAKE CABLES HANG DOWN BELOW CAR (SECURE W/TIE STRAPS. Saturn Saturn 1991

For 1990-2009 cars

# PARK BRAKE CABLES HANG DOWN BELOW CAR (SECURE W/TIE STRAPS

#### SUBJECT: Park Brake Cables Hang Down Under Vehicle Body (Secure with Tie Straps)

This bulletin is being revised to change the procedure and add a template. There was also a misprint in the labor operation code of the previously published bulletin. Please discard Technical Information Bulletin 92-T-56 which this bulletin supercedes. MODELS AFFECTED: All 1991 and some 1992 Saturns

CONDITION: Some owners may comment that the park brake cables hang down under the vehicle body.

CAUSE: The park brake cables sag due to reduced support.

CORRECTIVE ACTION: All production vehicles built after, and including VIN NZ157775 have tie straps installed to secure the cables to the underbody. If necessary, vehicles built before this breakpoint can be retrofitted using procedures and parts listed in this bulletin.

After this breakpoint, either brake pipe clips, or sections of brake pipe armor (or both) were installed to separate the left park brake cable from the brakes pipes. All rear brake pipes used in production during and after May, 1992 had brake pipe armor installed.

PROCEDURE

Perform the following procedure to prevent the park brake cable from hanging down under the vehicle body (See Figure 1).

#### CAUTION:

MAKE SURE THE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED PRIOR TO LIFTING. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE TO BE REMOVED.

1. Raise vehicle on a hoist.

2. Visually inspect the right and left under side of the vehicle for presence of 6.1 mm (1/4in.) holes in the underbody. Refer to Figure 2 (left side shown in Figure 2, right side similar).

3. If holes are not present: a. Make a copy of the attached templates and cut on dashed lines. b. Using templates, mark location of holes to be drilled. (See disclaimer at bottom of this bulletin)

#### CAUTION:

DO NOT ALLOW SMOKING OR THE USE OF OPEN FIAMES IN THE AREA WHERE WORK NEAR THE FUEL SYSTEM IS TAKING PLACE.

#### NOTICE: When drilling holes, be careful not to drill into or damage fuel lines.

#### IMPORTANT: Early 1991 vehicles do not have a tab on the rocker flange as shown in the illustration. To correctly locate holes to be drilled, align template with straight flange and large underbody hole.

#### NOTICE: To prevent damage to the vehicle, attach a drill stop to the drill bit and set it for 12.7 mm (1/2 in.).

c. Using a drill motor and 6.1 mm (1/4in.) drill bit, drill holes at the two locations marked in Step 3b (one hole is required on each side to secure each cable.) d. Protect holes against rust by applying underbody primer.

#### NOTICE: If brake pipe clip or armor is not installed or is not correctly positioned, the park brake cable could contact the brake pipes. The protective coating on the brake pipe could be worn off allowing excessive corrosion. Eventually, pipe perforation and a loss of brake fluid may occur resulting in reduced brake system performance.

4. If brake pipe armor or clips are not present on the left side (the right side does not require armor or clips): (See Figure 1)

a. Hold the left park brake cable against brake pipes and note the location of contact between the cable and the brake pipes.

b. Install two brake pipe clips (P/N 21010764) at the locations determined in Step 4a to separate the cable and the pipes.

5. Push one tie strap base (P/N 25518466) into each underbody hole as shown in illustration (left side shown in illustration, right side similar).

6. Fasten each tie strap around the appropriate park brake cable, and pull end of tie strap until cable is secure.

7. Use side cutters or end cutters to remove excess tie strap.

8. Lower vehicle from hoist.

Park Brake Cable Tie Strap Installation

1. If tie strap is damaged, remove tie strap from underbody hole using pliers.

2. Inspect position of protective pipe clips or brake pipe armor. Reposition if necessary to fully separate brake pipes and left park brake cable as shown in illustration.

3. Push base of new tie strap (P/N 25518466) into underbody hole.

4. Fasten tie strap around the park brake cable, and pull end of tie strap until cable is secure.

5. Use side cutters or end cutters to remove excess tie strap.

PARTS REQUIREMENTS: 21010764 - Clips (2) 25518466 - Straps Parking Brake Cable (2)

CLAIM INFORMATION: To receive credit for this repair, submit a claim through the Saturn Dealer System as follows:

Labor Case Operation Type Description Code Time

VW Park Brake Cable Tie Strap T9626 0.3 hrs Installation and Replacement

***************************************************************************** *STG DISCLAIMER*

"THE TEMPLATE DISPLAYED IN THIS SERVICE PUBLICATION IS NOT INTENDED FOR USE" (Please refer to the actual publication for an accurate "TEMPLATE" to use in this service procedure.) *****************************************************************************

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.