Product Safety - Removable Convertible Hardtop Rear Glass Debond

General Motors has determined that 68 1994 Chevrolet Corvette convertible hardtop model vehicles may have a loose/debonded rear glass. This could result in the rear glass coming loose during normal operation of the vehicle.

To prevent this condition from occurring, dealers are to remove and reinstall the rear glass in all involved vehicles.

Involved are the following 68 1994 Chevrolet Corvette convertible hardtop model vehicles:

No owner notification letters will be sent as the majority of involved vehicles should be in dealer inventory. In the event that an involved vehicle has been recently delivered or dealer transferred, immediately contact the respective purchaser or dealer to have the campaign repair performed. The Chevrolet Customer Assistance Center will also be contacting owners of record as of October 15, 1993.

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

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.

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 the instructions contained in this bulletin.

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.

Replacement rear glass reveal moldings required to complete this campaign are being pre-shipped by American Sunroof Company (ASC) to dealers of record. If problems are experienced with this reveal molding, or if a replacement rear glass is required, call ASC at the following number:

1-800-ASC-BGKY (1-800-272-2459)

A windshield bonding kit will also be required to complete the required repairs. Bonding kits 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).

Removal

Notice: Some rear window assemblies may be removed easily (pushed out of opening), while others may require standard methods (cut out, short method) due to partial bonding.

1. Remove hardtop from vehicle, disconnect rear window defogger electrical connections, and place on a clean protected work surface.
2. Remove reveal molding by "rolling out of channel" towards center of glass.
3. Cut around edge of glass using utility knife.
4. Using tool J 24402-A (cold knife), cut remaining adhesive from glass surface.

Notice: An alternative to cold knife method may be either a pneumatic or electric knife used from inside the vehicle. Follow manufacturer's directions for use.

5. Remove glass from opening, and any loose pieces of adhesive. It is not necessary to removal all old adhesive from opening.

Installation

1. Position glass on a clean work surface with inside facing up.

Notice: If original glass is being reinstalled, it may be necessary to remove heavy concentrations of adhesive residue from inside surface (ceramic edge area) with a razor blade prior to cleaning operation.

2. Thoroughly clean edge and inside bonding surface of glass (approximately 25 mm or 1") with a clean, denatured alcohol dampened cloth and allow to air dry.
3. Apply primers from GM kit #12345633 around glass edge and between 13 mm (1/2 in) to 25 mm (1 in) of glass inner surface.

Two primers are provided in adhesive kit.

-	Clear primer must be applied to glass first immediately followed by black primer.

-	Black primer must be allowed to dry for five (5) minutes prior to adhesive application.

4. After primer is dry, carefully install and position reveal molding to edge of glass prior to adhesive application.
5. Using suction cups, and with reveal molding installed on edge of glass, "dry fit" glass assembly to opening to ensure a good fit can be obtained.

Notice: If glass does not go fully into opening and molding edge lay flat to body surface, remove only enough of old urethane adhesive from roof opening to ensure a good fit.

6. With glass assembly in opening, mark position with a grease pencil or pieces of masking tape.
7. Apply a smooth, continuous bead of adhesive material from kit, 5 mm high by 5 mm wide (3/16 in high by 3/16 in wide) to glass inner surface, just inboard of molding edge.
8. Carefully position glass to marks in opening and install by pressing lightly to "wet out" urethane material.
9. Using 2" wide masking tape, tape glass assembly to opening (typically one piece in each corner) to retain position while curing and apply warm water over edge areas to accelerate urethane curing and water test installation. Leaks can be corrected by paddling additional urethane material in area of leak.

Reconnect rear window defogger wiring connectors, and reinstall hardtop to vehicle.

Allow vehicle to remain in room temperature at least 6 hours to properly cure adhesive.

10. Install 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 support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner. Additional "campaign identification labels" can be obtained from DAC.

Apply "campaign identification label" only on a clean, dry surface.

Submit a product campaign claim with the information indicated below:

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.