CAMPAIGN: LOWER CONTROL ARM BALL JOINT. Buick Roadmaster 1996

SUBJECT: PRODUCT SAFETY CAMPAIGN - LOWER CONTROL ARM BALL JOINT ------------------------------------------------------

MODELS AFFECTED: CERTAIN 1995-96 BUICK ROADMASTERS ---------------------------------

The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to repair within sixty (60) days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time.

If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation.

To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter that is being sent to customers, the customers are being instructed to contact the Buick Customer Relations Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.

DEFECT INVOLVED

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1995-96 Buick Roadmaster model vehicles. The lower control arm ball joint attachment nut may be loose. This condition can cause the lower control arm ball joint to loosen, fatigue and separate from the front suspension knuckle. If separation were to occur with the vehicle in motion, loss of vehicle control may occur which could result in a vehicle crash without prior warning.

To correct this condition, all involved vehicles will have both front lower control arm ball joint attachment nuts inspected for proper torque. If the ball joint has loosened from the knuckle, both the ball joint and knuckle will be replaced.

VEHICLES INVOLVED

Involved are certain 1995-96 Buick Roadmaster model vehicles built within the following VIN breakpoints: PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ------- ---- -------

1995 Roadmaster Arlington "R" SR418849 SR430508 1996 Roadmaster Arlington "R" TR400001 TR402787

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, customer name and address data, and are furnished to involved dealers with the campaign bulletin. Customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign.

These listings may contain customer 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 to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

PARTS INFORAIATION

IT IS ANTICIPATED THAT APPROXIMATELY IS OF THE KNUCKLE/BALL JOINT ASSEMBLIES WILL REQUIRE REPLACEMENT FOR THIS CONDITION DURING THE LIFE OF THE VEHICLE. DUE TO THE SMALL NUMBER OF VEHICLES REQUIRING KNUCKLE/BALL JOINT REPLACEMENT, DEALERS ARE ENCOURAGED NOT TO ORDER CAMPAIGN PARTS FOR USE AS SHELF STOCK PARTS SHOULD ONLY BE ORDERED WHEN INSPECTION DETERMINES THAT IT IS NECESSARY TO REPLACE THE KNUCKLE/BALL JOINT.

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your involved vehicle listing prior to ordering requirements. Normal orders should be placed on a DRO (Daily Replenishment Order). An emergency requirement should be ordered on a CSO (Customer Special Order).

Part Number Description Quantity/Vehicle ----------- ----------- -----------------

09767113 Ball Joint (9/16) As Required 18016023 Knuckle, Left Hand (9/16) As Required 18016024 Knuckle, Right Hand (9/16) As Required 12337997 Cotter Pin, Up to 3 per side as required 03965092 Seal, Spindle As Required

CUSTOMER NOTIFICATION

Customers will be notified of this campaign on their vehicles by Buick Motor Division (see copy of customer letter included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

All unsold new vehicles in dealers' possession and subject to this campaign may be held and inspected/repaired per the service procedure of this campaign bulletin before customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers of vehicles recently sold from your new vehicle inventory with no customer information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customers letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign enters your 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.

SERVICE PROCEDURE

INSPECTION - NUT TORQUE (To Be Performed On Both Sides) -------------------------------- 1. Rotate vehicle steering wheel to the extreme right stop position.

2. Gain access to right front lower ball stud attachment area through the forward area of the wheel well, remove lower ball joint cotter pin.

3. Utilizing a clicker type torque wrench set at 60 Nm(44 lb.ft.) and while attempting to tighten lower ball stud nut, determine which of the following conditions exists and proceed as required:

A. Torque Wrench Clicks Prior To Nut Rotation [Nut torqued to more than 60 Nm (44 lb.ft.) as installed]

I. Reset torque wrench to between 95 Nm(70 lb. ft.) to 112 Nm (83 lb.ft.). Tighten ball joint nut until wrench clicks.

II. Install new cotter pin. If pin can not be installed, tighten nut enough to align slot in nut with hole in ball stud and install new cotter pin. Nut rotation to align cotter pin hole is not to exceed one flat (60 degrees).

III. Proceed to Step 4.

B. Nut Rotates Prior To Torque Wrench Clicking (Nut torqued to less than 60 Nm (44 lb.ft.) as installed).

I. DO NOT perform any further work on this attachment at this time. Proceed to Step 4.

4. Rotate steering wheel to extreme left stop position and repeat Steps 2 and 3 on left ball stud attachment.

5. If either the right/left or both lower ball stud nuts were torqued to LESS than 60 Nm (44 lb.ft.) as determined in Step 3, proceed to Step 6, "Nut Gap Inspection". If both lower ball joints were found to be torqued to MORE than 60 Nm (44 lb.ft.) as determined in Step 3, proceed to Step 10.

6. Raise and suitably support vehicle in such a manner that front suspension is hanging fully extended (full rebound position).

7. Loosen ball stud nut(s) at suspect attachments(s) four (4) complete revolutions. Inspect gap between nut lower surface and upper contact surface of knuckle (see Figure 1).

8. NO GAP: (Ball stud IS NOT seated in knuckle)

Replace knuckle and lower ball stud following applicable Service Manual Procedure, Section 3C-3, Front suspension. Check and adjust wheel alignment and toe-in after new knuckle and lower ball stud is installed. Proceed to Step 10.

GAP: (Ball stud IS seated in knuckle)

Tighten nut and torque to between 95 Nm(70 lb. ft.) to 1 12 Nm (83 lb.ft.), then tighten nut enough to align slot in nut with hole in ball stud and install new cotter pin. Nut rotation to align cotter pin hole is not to exceed one flat (60 degrees).

9. Lower vehicle.

10.Install Campaign Identification Label.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this Product Campaign BulLetin will require a "Campaign IdentifIcation Label". Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the customer. When using the new campaign identification label, be sure to install the clear protective covering. Additional "Campaign Identification Labels" can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday through Friday 8:00 a.m. to 4:30 p.m. EST). Ask for Item Number S-1015 when ordering.

Apply "Campaign Identification Label" only on a clean, dry surface.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

OPERATION PARTS FAILED PARTS LABOR LABOR PERFORMED COUNT PART NO. ALLOW CC-FC OP HOURS

Inspect Only 2 12337997 ** MA-96 V9865 0.4 -BOTH Ball Stud Nuts Torqued Correctly Add: Gap Test One Side 0.1 Add: Gap Test Two Sides 0.2

Inspect/Repair 7 18021052 ** MA-96 V9866 2.2 -Ball Stud Nut Torqued Correctly ONE SIDE -Check ONE SIDE For Nut Gap & Replace Ball Stud/Knuckle

Add: Both Sides Gap Test, 0.1 Retorque One Side AND Replace Ball Stud & Knuckle One Side -Check BOTH SIDES 12 18021052 ** MA-96 V9867 3.3 For Nut Gap & Replace Ball Stud & Knuckle BOTH

* For Campaign Administrative Allowance, add 0. I hours to the "Labor Hours". For locking wheel covers, add ) 0.1 hours to the "Labor Hours"V9866 & V9867, for removal/reinstall (one or both).

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 40% of all parts required for the repair.

*** Labor Operation V9866 & V9867 includes Wheel Alignment and Front Toe adjustment.

Courtesy transportation supplied to customers within the program guidelines should be entered on the same repair order as the campaign repair using the Z79XX operations as appropriate.

Dear Buick Roadmaster Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

SAFETY RECALL

General Motors has decided that a defect which relates to motor vehicle safety exists in some 995-96 Buick Roadmaster model vehicles. The lower control arm ball joint attachment nut may be loose. This condition can cause the lower control arm ball joint to loosen, fatigue and separate from the front suspension knuckle. If separation were to occur with the vehicle in motion, loss of vehicle control may occur which could result in a vehicle crash without prior warning.

ACTION

HOW LONG WILL REPAIR TAKE?

The labor time necessary to perform this inspection/service correction is approximately 25 minutes to 3 1/2 hours. Additionally, one or two hours may be required to schedule and process your vehicle. Please ask your dealer if you wish to know how much additional time will be needed.

CONTACTING YOUR BUICK DEALER:

Please contact your Buick dealer as soon as possible to arrange a service appointment and courtesy transportation, if required. Instructions for making this inspection/correction have been sent to your dealer and parts are available.

Your Buick dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within five (5) days, we recommend you contact the Buick Customer Relations Center by calling 1-800-521-7300.

After contacting your dealer and the Customer Relations Center, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call 1-800-424-9393 (Washington D.C. residents use 202-366-0123).

CUSTOMER REPLY CARD:

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us.

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

Buick Motor Division GENERAL MOTORS CORPORATION

Object Number: 85035 Size: FS

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.