CAMPAIGN: POWERMASTER BRAKE SYSTEM/FAULTY PRESSURE SWITCH
Model and Year: 1986 CHEVROLET CAPRICE STATION WAGON
General Motors has determined that certain 1986 Chevrolet Caprice Station Wagons with Powermaster Brake Systems were built with combination valves and pressure switches which may become faulty. If left uncorrected, these vehicles may experience a "hard brake pedal" or "increased brake pedal travel". These conditions may be caused by a Cast Iron combination valve allowing air to enter the brake system or by a pressure switch on the Powermaster Brake Assembly leaking brake fluid.
To prevent either of the above conditions from occurring, vehicles will be inspected and those equipped with the Cast Iron combination valve will receive a new Brass combination valve. Also, the pressure switch will be inspected and replaced, if necessary.
VEHICLES INVOLVED
Involved are CERTAIN 1986 Chevrolet Caprice Station Wagons with Powermaster Brake Systems built within the following VIN breakpoints:
YEAR Model PLANT FROM THROUGH ---- ---------- ------- -------- --------- 1986 "B" Wagons Fairfax GX100001 GX207019 " " Detroit G9100003 G9151396
Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to 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 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. GSD 148D
OWNER NOTIFICATION
Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin).
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 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 correction according to instructions contained in this bulletin.
PARTS INFORMATION
Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).
Quantity/ Part Number Description Vehicle ----------- ----------------- ---------- 25509419 Brass Combination 1 Valve
18018141 Pressure Switch (Includes 1 2 O-Rings - one loose, one on Pressure Switch)
SERVICE PROCEDURE
1. Inspect pressure switch. If the current pressure switch terminal body is GRAY, move on to step 2. If the current switch terminal body is BLACK, place a fender blanket on the left fender, remove and replace pressure switch according to the procedure below and then move on to step 2.
a. Depressurize Powermaster unit by turning ignition "OFF", and apply and release brake pedal a minimum of ten (10) times using approximately fifty (50) pounds of force on pedal to fully deplete the power assist.
NOTICE: Failure to fully depressurize Powermaster unit could result in brake fluid being sprayed on service personnel and could cause damage to painted surfaces.
b. Disconnect 3-wire electrical connector (Fig. 1, 40) from pressure switch (Fig. 1, 1).
c. Remove old pressure switch (Fig. 1, 1). Original O-ring should be on old pressure switch. If not, check powermaster unit for the loose O-ring and remove it. Take care not to drip brake fluid on painted surfaces.
d. Lubricate existing O-ring on new pressure switch with clean, fresh brake fluid. Lubricate new loose O-ring (Fig. 1, 2) and install in groove between threads and existing O-ring on new pressure switch.
e. Install new pressure switch (Fig. 1, 1), tighten to 20-27 Nm (15-20 lb. ft.).
NOTICE: Torque values specified are for dry, unlubricated fasteners.
f. Reconnect 3-wire electrical connector (Fig. 1, 40) to pressure switch (Fig. 1, 1). Be sure electrical connector is securely seated.
2. Locate combination valve (on frame rail below master cylinder). If the current combination valve is a Cast Iron valve, the valve must be replaced with a Brass valve by following the procedure on page 5. If the vehicle already has the Brass valve, the combination valve does not need to be replaced. Proceed to step 3 on page 5. Figure 2 on the next page illustrates the differences in the two valve types.
a. Remove the electrical wiring harness connector from the pressure differential switch by squeezing the elliptical-shaped plastic lock ring and pulling up. A pair of pliers may aid in removing the connector.
b. Disconnect hydraulic lines at combination valve. Plug lines to prevent loss of fluid and entrance of dirt.
C. Remove cast iron combination valve.
d. Install brass combination valve. Torque mounting bolts to 20 Nm (14 lb. ft.).
e. Remove plugs and connect hydraulic lines at combination valve. Torque lines to 24 Nm (18 lb. ft.).
f. Connect electrical wiring harness connector to pressure control differential switch.
g. Bleed entire brake system. Do not move vehicle until a firm brake pedal is obtained.
h. Check brake lines for leaks and proper clearances.
3. Install Campaign Identification Label.
CAMPAIGN IDENTIFICATION LABEL
Each vehicle corrected in accordance with the instructions outlined in this bulletin will require a "Campaign Identification Label". Each label provides a space to include 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 owner. Apply "Campaign Identification Label" only on a clean, dry surface.
CLAIM INFORMATION
Submit a Product Campaign Claim with the information indicated below.
* *** FAILED PARTS CC-FC LABOR LAB OTH NET REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS AMT ----------------- -- -------- ----- ------ ----- --- --- ---- Inspect Pressure Switch & Combination Valve - No SK-00 V6160 0.2 0.1 $0.00 Replacement Needed
Inspect Combo Valve & Pressure Switch 1 118018141 ** SK-00 V6161 0.4 0.1 $0.00 Replace Pressure Switch Only
Inspect Combo Valve & Pressure Switch 1 125509419 ** SK-00 V6162 0.9 0.1 $0.00 Replace Combo Valve Only
Inspect/Replace Combo Valve And 2 25509419 ** SK-00 V6163 1.2 0.1 $0.00 Pressure Switch
*Campaign Administrative Allowance.
**The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.
***The amount identified in the "Net Amount" column should represent the current cost plus 30% for one (1) pint of brake fluid used in conjunction with labor operations V6162 or V6163.
Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.
Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim Submission.
REIMBURSEMENT
Customer requests for reimbursement of prior replacement of the Powermaster Brake Assembly, combination valve and/or pressure switch are to be submitted according to the instructions in this bulletin using the attached "Request for reimbursement" form. Additional copies of the form are to be reproduced by the dealer.
Owners must submit original repair invoices along with proof of payment (charge card receipt, copy of cancelled check, or a receipt marked "PAID" if paid-in-cash). The customer repair invoice should provide the description of the repair made and the person or facility performing the repair. These documents are to be retained by the dealer with the dealer repair order and supporting warranty records.
INSTRUCTIONS
1 R.O. # & DATE The dealership should enter the repair order number and date of the owner's or dealer's paid receipt or invoice.
2 REQUEST DATE (MONTH, DAY) Date owner or dealer requested reimbursement.
3 VEHICLE IDENTIFICATION NUMBER VIN involved.
4 MILEAGE Enter mileage at time of transaction. (If not available, enter "O".) 5 CC/FC Code is preprinted on form.
6 LABOR OPERATION Labor Operation as referenced in bulletin.
7 & 8 SUBLET DMN & Enter total amount of reimbursement. (Do not enter LINE TOTAL parts or labor hours on claim.)
9 AUTH CODE If the amount of reimbursement approved is $600 or less, no authorization is needed. If the amount exceeds $600, advise customer to contact Chevrolet Customer Assistance at 1-800-222-1020.
10 REQUESTED Dealer Service Manager enter amounts determined REIMBURSEMENT from owner supplied invoices or paid receipts, which are covered. 11 APPROVED AMOUNT Dealer Service Manager to determine based on reimbursement policy of this bulletin.
12 740 STAMP See Item #11 to determine need for authorization.
13 DEALER REFERENCE INFORMATION A Enter Document Number and Line Number on which claim was submitted.
B Enter Claim Memo Number and Date when claim is credited.
C Enter number of dealer check to owner, if applicable. Date check was written, if applicable. Date copy of check was attached to OWNER REQUEST FOR REIMBURSEMENT file.
14 OWNER INFORMATION Must include telephone number.
15 DEALER INFORMATION Includes Dealer Code, Dealer Name, Service Manager's signature and social security number. To be completed by Service Manager.
16 EXPLAIN Should the dealer Service Manager determine, after review of owner's invoices/receipts, that the reimbursement case is not eligible; Service Manager should write reason on worksheet, explain to owner, and place a copy of the worksheet in the file.
17 The dealer is then to issue the owner a check for the reimbursement in the approved amount. A copy of the check issued to the owner is to be attached to the dealer's file copy of the request and retained for 24 months from date of credit.
Dear Chevrolet Owner:
This notice is sent to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.
REASON FOR THIS RECALL
General Motors has determined that 1986 Chevrolet Caprice Station Wagons with Powermaster Brake Systems were built with combination valves and pressure switches which may become faulty. If left uncorrected, these vehicles may experience a "hard brake pedal" or "increased brake pedal travel". These conditions may be caused by the Cast Iron combination valve allowing air to enter the brake system or by a pressure switch on the Powermaster Brake Assembly leaking brake fluid.
WHAT WE WILL DO
To prevent either of the above conditions from occurring, vehicles will be inspected and those equipped with the Cast Iron combination valve will receive a new brass combination valve. Also, the pressure switch will be inspected and replaced, if necessary.
This service will be performed for you at no charge.
WHAT YOU SHOULD DO
Please contact your Chevrolet dealer as soon as possible to arrange a service date. Instructions for making this inspection/correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. If your Caprice Station Wagon has previously had the Powermaster Brake Assembly, combination valve and/or pressure switch replaced and you paid for all or part of the repair, you may request reimbursement through your Chevrolet dealer. When doing so, you should present the dealer with documentation which reasonably confirms the amount of unreimbursed repair expense due to the replacement of the parts listed above, the date of the repair, and the person or entity performing the repair. The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary inspection/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 continued satisfaction with our products.
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.
