Product Safety 99056 - Manual Trans Clutch Master Cyl Undersize Retainer Ring

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999 Chevrolet Camaro and Pontiac Firebird model vehicles equipped with manual transmissions (RPO M49 or MM6). Some of these vehicles exhibit a condition in which the clutch master cylinder may have been built with an incorrect, undersize ring that is designed to retain the end plug of the cylinder where the pedal rod enters.

An undersize retaining ring may come out of place, allowing the end plug of the cylinder to disengage from the body. If the plug disengages, the clutch system will fail to disengage the clutch assembly when the clutch pedal is depressed. This may result in unintentional vehicle movement, increased stopping distances, engine stalls and difficulty in shifting. Unintended vehicle movement or increased stopping distances could cause a vehicle crash without prior warning.

To prevent the possibility of this condition occurring, dealers are to replace the hydraulic clutch master cylinder with a new cylinder.

Involved are certain 1999 Chevrolet Camaro and Pontiac Firebird model vehicles equipped with manual transmission (RPO M49 or MM6) and built within the following VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) or Access Screen (Canada only) or DCS Screen 445 (IPC only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.]

The following list shows the dealer codes of record and vehicles by VIN involved in this campaign. Do NOT order parts for vehicles not on this list.

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer 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/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

Important: An initial supply of clutch master cylinders, equivalent to 100% of involved vehicles, required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of August 30, 1999. Parts received for a recently transferred vehicle should be forwarded by the original dealer (with a phone call) to the dealer that received the transferred vehicle. Pre-shipped parts will be charged to dealer's open parts account.

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles 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.

Important: Due to the small number of vehicles involved (69), dealers are encouraged NOT to order campaign parts for use as shelf stock.

Tools Required

J 36221 Hydraulic Clutch Line Separator

Removal Procedure

1. Remove the I/P retainers (2).
2. Unhook the flange of the I/P insulator (1) from the side kick panel.
3. Detach the tab on the I/P insulator (1) from the retainer on the I/P.
4. Remove the I/P insulator (1) from the I/P.



5. Remove the rear compartment lid release switch, if equipped.



6. Remove the I/P knee bolster bolts (3).
7. Remove the I/P driver knee bolster (2).



8. Remove the clutch pedal pin retainer (1).
9. Remove the clutch master cylinder push rod (3) from the clutch pedal pin (2).
10. Remove the clutch master cylinder nuts (7).
11. Remove the clutch master cylinder push-on nuts (6).
12. Remove the clutch master cylinder U-bolts (4).
13. Remove the clutch master cylinder (5) from the front of the dash.
14. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



15. Using the J 36221, depress the white circular release ring on the actuator hose and at the same time, pull lightly on the master cylinder hose to disconnect.
16. Protect both hose coupling ends from dirt and damage.
17. Lower the vehicle.



18. Remove the clutch master cylinder reservoir push-in retainer.
19. Slide the clutch master cylinder reservoir out from the hood strut bracket.
20. Remove the clutch master cylinder and reservoir from the vehicle.

Installation Procedure

1. Install the clutch master cylinder into the opening in the front of the dash.
2. Slide the clutch master cylinder reservoir into the opening on the hood strut bracket.
3. Install the clutch master cylinder reservoir push-in retainer.
4. Raise the vehicle.




Important: DO NOT rely on an audible click or a visual verification of the clutch hydraulic hose quick connect fitting connection.

5. Connect the clutch master cylinder hose to the clutch actuator.

Push together the clutch hydraulic quick connect fittings, then pull back on the fittings to verify engagement.

6. Look for twists or kinks in the clutch hydraulic hoses.
7. Lower the vehicle.



8. Install the clutch master cylinder U-bolt (4).
9. Install the clutch master cylinder push-on nuts (6).

Notice: Refer to Fastener Notice in Cautions and Notices.

10. Install the clutch master cylinder nuts (7).

Tighten
Tighten the clutch master cylinder nuts (7) to 20 N·m (15 lb ft).

11. Install the clutch master cylinder push rods (3) onto the clutch pedal pin (2).
12. Install the clutch pedal pin retainer (1).




Notice: DO NOT use fluid which has been bled from a hydraulic clutch system, in order to fill the clutch master cylinder reservoir; due to the possibility that the fluid may be aerated, have too much moisture content or be contaminated and may cause system or vehicle damage.

13. Clean all dirt and debris from the clutch actuator master cylinder cap to ensure that no foreign substances will enter the system.
14. Remove the clutch master cylinder reservoir cap with the diaphragm.
15. Fill the clutch master cylinder reservoir with clutch hydraulic fluid, GM P/N 12345347 or the equivalent, if necessary.
16. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
17. Have an assistant depress the clutch pedal fully and hold.
18. Loosen the bleeder on the clutch actuator cylinder to purge air.
19. Tighten the bleeder.
20. Release the clutch pedal.
21. Repeat Steps 17 through 20 until all air is completely evacuated.
22. Fill the clutch master cylinder reservoir with clutch hydraulic fluid, GM P/N 12345347 or the equivalent, if necessary.
23. Lower the vehicle.



24. Install the I/P driver knee bolster (2).
25. Install the I/P knee bolster bolts (3).

Tighten
Tighten the I/P knee bolster bolts (3) to 1.9 N·m (17 lb in).




26. Install the rear compartment lid release switch, if equipped.



27. Attach the tab on the insulator (1) on the I/P.
28. Hook the flange on the insulator (1) to the side kick panel.
29. Install the I/P insulator (1) to the I/P.
30. Install the I/P insulator retainer (2).
31. Verify the proper release and engagement of the clutch system.
32. Install the GM 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 by the customer for periodic servicing. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels can be obtained from Dealer Support Materials by calling 1-888-414-6322 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

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

Submit a Product Campaign Claim with the information indicated below.

Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submission.

The U.S. Highway 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 customer 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 remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. If the condition is not remedied within a reasonable time, they are instructed on how to contact the U.S. National Highway Traffic Safety Administration.

***THE ABOVE PARAGRAPH IS ONLY FOR U.S. REGISTERED VEHICLES--NOT FOR CANADA OR IPC***

All unsold new vehicles in dealers' possession and subject to this campaign MUST 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 who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be 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 customer 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.

Dear <Division(s)> Customer:

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

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999 Chevrolet Camaro and Pontiac Firebird model vehicles equipped with manual transmissions. Some of these vehicles exhibit a condition in which the clutch master cylinder may have been built with an incorrect retaining ring. This condition may not allow the clutch system to disengage the clutch when the clutch pedal is depressed. This may result in unintentional vehicle movement, increased stopping distances, engine stalls and difficulty in shifting. Unintended vehicle movement or increased stopping distances could cause a vehicle crash without prior warning.

To prevent the possibility of this condition occurring, your dealer will replace the hydraulic clutch master cylinder with a new cylinder. This service will be performed for you at no charge .

The length of time required to perform this clutch master cylinder replacement is approximately one hour and forty minutes. Additional time may be required to schedule and process your vehicle. If you dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed to schedule, process and repair your vehicle.

Please contact your <<Division>>dealer as soon as possible to arrange a service date. Parts are available and instructions for making this correction have been sent to your dealer.

Your <<Division>> dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed below:

If, after contacting the appropriate customer assistance center, 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 SW, Washington, DC 20590 or call 1-800-424-9393 (Washington, DC residents use 202-366-0123).

The enclosed customer 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 no longer own this vehicle, please let us know by completing the postage paid reply card and returning it to us.

Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation.

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.

<Division(s)>

General Motors Corporation

Enclosure