PARK BRAKE LEVER RATTLE OR INCORRECT LEVER TRAVEL. Saturn Saturn 1991

For 1990-2009 cars

# PARK BRAKE LEVER RATTLE OR INCORRECT LEVER TRAVEL

#### SUBJECT: Park Brake Lever Rattle and/or Incorrect Lever Travel (New Design Lever Assembly and Revised Adjustment Procedure)

#### MODELS AFFECTED: All 1991 and 1992 Saturns

#### CONDITION:

Some owners may comment about a rattle noise that may be heard from the center console/park brake lever area or the amount of park brake lever travel.

#### CAUSE:

A rattle noise may be caused by a first design park brake lever assembly that does not have an adjuster nut spring. A rattle may also occur on the second design park brake lever due to a weak adjuster nut spring or a field adjustment not in accordance with the correct adjustment procedure. Comments about the park brake lever travel may also result from a field adjustment not in accordance with the correct adjustment procedure.

CORRECTIVE ACTION: A second design park brake lever was incorporated into production during March, 1991 along with its own adjustment procedure.

First Design: All 1991 vehicles built before, and including VIN MZ115964

Second Design: 1991 vehicles built after, and including VIN MZ115965 and all 1992 vehicles

The second design lever assembly consisted of a change in the length of the threaded rod, and the addition of a spring between the equalizer and adjuster nut. The change in the length of the threaded rod allows for increased adjustment travel. The spring prevents a possible rattle noise when the park brake is in the released position.

To correct vehicles that have a rattle coming from the console/park brake area or have a misadjusted park brake lever, refer to one of the following bulleted items:

#### NOTE: If you are not certain of the park brake lever design, refer to "Park Brake Lever Design Determination" on page 3 of this bulletin.

o First design--Install adjuster nut with spring, adjust the park brake lever according to Step 5 under "Service and Adjustment" in this bulletin.

o Second design--Replace adjuster nut spring if necessary and adjust the park brake lever according to Step 6 under "Service and Adjustment" in this bulletin.

#### IMPORTANT: Use the correct adjustment check and service adjustment procedures dependent on park brake lever design (i.e., first design park brake adjustment procedures must be used in conjunction with the first design park brake lever, etc.).

PARK BRAKE LEVER DESIGN DETERMINATION Measure the length of the threaded rod from the center of the pivot pin attachment to the end of the rod (A).

#### IMPORTANT: You must remove the center console to measure the threaded rod. Refer to "Park Brake Adjustment" in the "Brakes Service Manual" and follow the console removal and installation procedures.

o First Design: The length of the threaded rod from center of the pivot pin attachment to the end of the rod (A) is less than, or equal to 147mm (5.78 in.). The first design equalizer is larger than the second design.

o Second Design: The length of the threaded rod from center of the pivot pin attachment to the end of the rod (A) is greater than 158mm (6.22 in.). The second design equalizer is smaller than the first design.

#### IMPORTANT: All leather park brake lever assemblies are of the second design.

PARK BRAKE ADJUSTMENT CHECK CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY PROVIDE ADDITIONAL SUPPORT TO THE OPPOSITE END OF THE VEHICLE FROM WHICH COMPONENTS WILL BE REMOVED.

FIRST DESIGN 1. Raise vehicle on hoist.

2. Pull park brake lever up to first click. There should be no brake drag at either rear wheel.

3. Pull park brake lever up to second click. There should be light drag at rear wheels when turned by hand.

4. Adjust if necessary. Refer to Step 5 under "Service and Adjustment" in this bulletin.

#### IMPORTANT: If both rear wheels do not exhibit similar drag in Steps 2 and 3, check for damaged or incorrect installation of drum brake assembly components, park brake cables and/or park brake lever assembly. The park brake is adjusted correctly if it meets the specifications explained in Steps 2 and 3.

SECOND DESIGN 1. Raise vehicle on hoist.

2. Pull the park brake lever up and to the second click. There should be no brake drag at either rear wheel.

3. Pull the park brake lever up to the third click. There should be no brake drag to light brake drag at both rear wheels when turned by hand.

4. Pull the park brake lever up to the fourth click. There should be a light brake drag to no rotation at both rear wheels when turned by hand.

5. Pull the park brake lever up to the fifth click. There should be heavy brake drag to no rotation at both rear wheels when turned by hand.

#### IMPORTANT: If both rear wheels do not exhibit similar drag in Steps 2 through 5, check for damaged or incorrect installation of drum brake assembly components, park brake cables and/or park brake lever assembly. The park brake is adjusted correctly if it meets the specifications explained in Steps 2, 3, 4 and 5.

SERVICE AND ADJUSTMENT 1. Remove center console. Refer to "Park Brake Adjustment" in the "Brakes Service Manual" and follow the console removal procedure.

#### NOTE: After removing the console make sure to follow the correct adjustment procedures in this bulletin.

2. If complaint is noise (rattle), inspect park brake adjuster nut for presence of spring:

a. If spring is not present, remove adjuster nut and install new adjuster nut and spring (P/N 21011611).

b. If spring is present, remove adjuster nut and spring and measure free standing height of spring. If spring height is less than 18mm (0.71 in.), install a new equalizer nut and spring (P/N 21011611) then proceed to Step 3. If spring height is equal to, or greater than 18mm (0.71 in.), install adjuster nut and spring and proceed to Step 3.

3. Check orientation of equalizer:

a. First design equalizer should be installed with cable entry holes facing down.

b. Second design equalizer may be installed with cable entry holes facing up or down.

#### CAUTION:

MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE ADDITIONAL SUPPORT TO THE OPPOSITE END OF THE VEHICLE FROM WHICH COMPONENTS WILL BE REMOVED.

#### NOTICE: On vehicles equipped with rear drum brakes that have been serviced, before performing park brake adjustment procedures, apply and release the pedal 20 times. This allows the adjuster to position the brake shoes, and prevents premature wear of the brake linings due to improper park brake adjustment.

4. Raise vehicle on hoist.

5. For first design park brake adjustment:

a. Pull park brake lever to second click from released position.

b. Tighten adjuster nut until light brake drag is felt at the rear wheel.

c. Apply and release park brake several times.

d. Pull lever up to first click.

e. There should be no drag at rear wheels.

f. Pull brake lever to second click.

g. There should be light drag at rear wheels.

h. Repeat Steps 5a through 5g, if necessary.

i. Inspect the adjuster nut and rod. If the end of the rod is not past the face of the nut at least 2mm (0.08 in.) or there is at least one thread of the rod visible, check for damaged or incor- rect installation of rear disc or drum brake assembly components, park brake cables and/or park brake lever assembly. Correct as necessary according to information in the "Brakes Service Manual." If no damage or incorrect installation is found, install new park brake lever assembly (P/N 21011610). Refer to "Lever Assembly" in the "Brakes Service Manual" for removal and installation procedures. After installation of the new park brake lever assembly go to Step 6 under "Service and Adjustment" in this bulletin.

6. For second design park brake adjustment:

a. Pull park brake lever up to the third click.

b. Tighten adjuster nut until light brake drag is felt at both rear wheels when turned by hand.

c. Apply and release park brake several times.

d. Pull park brake lever up to the second click. There should be no drag at either rear wheel when turned by hand.

e. Pull park brake lever to the third click. There should be light drag at both rear wheels when turned by hand.

f. Pull park brake lever to the fourth click. There should be heavy drag or n rotation at both rear wheels when turned by hand.

g. Repeat Steps 6a through 6f, if necessary, until adjustment is correct.

#### IMPORTANT: If both rear wheels do not exhibit similar drag in Steps 5a through 5g or Steps 6a through 6f, check for damage or incorrect installation of rear disc or drum brake assembly components, park brake cables and/or park brake lever assembly. Correct as necessary, according to information in the "Brakes Service Manual," then retum to Step 5a or 6a of the this procedure, depending on parking brake design.

#### IMPORTANT: Park brake lever assembly must be properly centered in the console. If not properly centered, the lever cover may contact the console and cause the button and rod to stick or be inoperative. If this condition occurs, center the lever in the console by loosening the lever fasteners and positioning the lever, then tightening.

7. Lower vehicle from hoist.

8. Install center console. Refer to "Park Brake Adjustment" in the "Brakes Service Manual" and follow the console installation procedure.

PARTS REQUIREMENTS: 21011610 Lever Assembly- Park Brake 21011584 Lever Assembly- Park Brake (Leather) 21011611 Nut and Spring Kit-Equalizer

CLAIM INFORMATION: To receive credit for one of the labor operations, submit a claim through the Saturn Dealer System as follows:

Labor Case Operation Type Description Code Time ---- ----------- --------- ---- VW Parking Brake -Adjust H2800 0.6 hrs

VW Lever Assembly, Parking H2840 1.0 hrs Brake - Replace

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.