Product Safety - Brake Pedal Pushrod Retainer

THIS BULLETIN IS BEING REVISED TO INCLUDE ADDITIONAL STEPS AND CLARIFICATION IN THE SERVICE PROCEDURE. DISCARD ALL VERSIONS OF BULLETIN 05038, ISSUED APRIL 2005.

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005 Buick Allure and LaCrosse vehicles. The clip that secures the brake pushrod to the brake pedal arm pin could have been bent when it was installed. A bent clip may come off, allowing the brake booster pushrod to separate from the brake pedal. If this happens, pushing on the pedal will not apply the brakes and a vehicle crash could occur without prior warning.

Dealers are to install a new brake pedal pushrod bushing and retaining clip and, if the clip was missing, a new brake pedal arm assembly.

Involved are certain 2005 Buick Allure and LaCrosse vehicles built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

For US and Canada

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned.

The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall.

Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

Inspection Procedure

1. Remove the insulator panel on left side.
2. Inspect for the presence of the brake rod retaining clip and orientation of the brake pedal bushing.




•	If the clip is present and the bushing retaining flange is on the retaining clip side of the brake pedal pushrod (refer to illustration), only the retaining clip requires replacement.

•	If the clip is present and the bushing retaining flange is on the side opposite of the retaining clip, the bushing between the brake pedal and the activation rod, the retaining clip, and the brake pedal position sensor must be replaced. Proceed to Brake Bushing Replacement Procedure.

•	If the clip is missing, the brake pedal assembly, retaining clip, and the brake pedal position sensor must be replaced. Proceed to the Brake Pedal Assembly Replacement Procedure (very few vehicles will require brake pedal assembly replacement).

Brake Bushing Replacement Procedure

1. Unplug and remove the brake pedal position sensor.
2. Remove the brake pedal pushrod retaining clip from the brake pedal.
3. Remove the brake pedal pushrod and bushing from the brake pedal.
4. Coat the new bushing with white lithium grease (P/N 12345996) before installation.
5. Install a new bushing into the brake pedal pushrod from the outboard side.

Important: The bushing retainer flange should be on the retaining clip side of the brake pedal pushrod.

6. Install the brake pedal pushrod and bushing to the brake pedal.
7. Install a new brake pedal pushrod retaining clip to the brake pedal.
8. Install a new brake pedal position sensor.

Tighten
Tighten the screw to 2.0 N·m (18 lb in).

9. Install the insulator panel.
10. Calibrate the new brake pedal position sensor by turning ON the ignition with the engine OFF.
11. Install a scan tool, select proper vehicle and options.
12. Navigate to the BCM menu.
13. Select Special Functions menu item.
14. Select the BPPS sensor calibration procedure and follow the directions displayed on the screen.

Brake Pedal Assembly Replacement Procedure

1. Unplug and remove the brake pedal position sensor.
2. Remove the brake pedal pushrod and bushing from the brake pedal.



3. Remove the brake pedal nut and bolt.

Important: It is not necessary to completely remove the bolt from the bracket. Leaving the bolt slightly engaged will assist in re-assembly.

4. Remove the brake pedal and bushings.
5. Install the new brake pedal and bushings.
6. Install the brake pedal nut and bolt.

Tighten
Tighten the brake pedal nut and bolt to 40 N·m (30 lb ft).

7. Coat the new bushing with white lithium grease (P/N 12345996) before installation.
8. Install a new bushing into the brake pedal pushrod from the outboard side.

Important: The bushing retainer flange should be on the retaining clip side of the brake pedal pushrod.

9. Install the brake pedal pushrod and bushing to the brake pedal.
10. Install a new brake pedal pushrod retaining clip to the brake pedal.
11. Install a new brake pedal position sensor.

Tighten
Tighten the screw to 2.0 N·m (18 lb in).

12. Install the insulator panel.
13. Calibrate the new brake pedal position sensor by turning ON the ignition with the engine OFF.
14. Install a scan tool, select the proper vehicle and options.
15. Go into Computer Integrating Systems.
16. Go into BCM setup.
17. Go into module setup.
18. Select Recalibration Brake Pedal Position Sensor.
19. Follow the directions displayed on the screen.

The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines.

Submit a Product Recall Claim with the information indicated below:

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

General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall 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 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. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

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

Dealers are to service all vehicles subject to this recall 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. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall 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 recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear General Motors 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 2005 Buick Allure and LaCrosse vehicles. The clip that secures the brake pushrod to the brake pedal arm pin could have been bent when it was installed. A bent clip may come off, allowing the brake booster pushrod to separate from the brake pedal. If this happens, pushing on the pedal will not apply the brakes and a vehicle crash could occur without prior warning.

Your GM dealer will install a new brake pedal pushrod bushing and retaining clip and, if the clip was missing, a new brake pedal arm assembly. This service will be performed for you at no charge.

It will take approximately 20 minutes to install the bushing and retaining clip. If the brake pedal arm assembly requires replacement, another 40 minutes will be necessary. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the listed number below. The Customer Assistance Center’s hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

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 1-888-327-4236.

The enclosed customer reply form identifies your vehicle. Presentation of this form 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 form and mailing it back to us.

If your vehicle is within the New Vehicle Limited Warranty 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.

This free online service offers vehicle and ownership related information and tools tailored to your specific vehicle. To get the most personalized information for your vehicle, visit www.mygmlink.com , and enter your vehicle's 17-character vehicle identification number (VIN) shown on the enclosed customer reply form.

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

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.

General Motors Corporation

Enclosure

05038