F/CMVSS Noncompliance - Air Brake Application Valve Assembly

General Motors has decided that certain 2006 Chevrolet 7500/8500 Kodiak and 7500/8500 T Series; GMC 7500/8500 TopKick and 7500/8500 T-Series; and Isuzu HVR, FVR, and FXR non-towing vehicles equipped with air brakes fail to conform to Federal/Canada Motor Vehicle Safety Standard 121 in emergency stopping distance. In these vehicles, an internal control and check valve within the air brake application valve assembly was configured improperly, preventing air from flowing through the brake system as designed. In the event of an emergency stop, the vehicle's stopping distance would be increased. If stopping distance was limited, a vehicle crash could result.

Dealers are to replace the air brake application valve assembly on C-Series vehicles, or reroute the air brake lines on T-Series vehicles.

Involved are certain 2006 Chevrolet 7500/8500 Kodiak and 7500/8500 T Series; GMC 7500/8500 TopKick and 7500/8500 T-Series; and Isuzu HVR, FVR, and FXR non-towing vehicles equipped with air brakes and built within these VIN breakpoints:

Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved.

For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers will not have a report available if they have no involved vehicles currently assigned.

-- US dealers - GM DealerWorld Recall Information

-- Canadian dealers - GMinfoNet Recall Reports

-- Export dealers - sent directly to dealers

The listing 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 and 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.

Parts required to complete this recall are to be obtained from American Isuzu Parts Distribution Network (AIPDN). Please refer to your "involved vehicles listing" prior to ordering requirements.

Kodiak, TopKick, HVR Trucks (C-Series)

1. Remove the air brake application valve. Refer to the Air Brake Application Valve Replacement procedure in SI.
2. Install the new air brake application valve. Refer to the Air Brake Application Valve Replacement procedure in SI.

T-Series, FVR, FXR Trucks

1. Park the truck and turn the steering wheel to the full lock left turn position to facilitate maximum access to the brake application valve.
2. Turn the ignition to OFF.
3. Tilt the truck cab forward and lock it in place.



4. Cut and discard the air harness tie strap (1) at the formed steel bracket.
5. Cut and discard the two black harness bundle tape wraps (2) below the tie strap.



6. Disconnect the 9.5 mm (3/8 in) OD orange "KS" air supply tube (1) from the brake application valve.



7. Install a "golf tee" sealing plug (1) in the vacant connector.
8. Extract the 9.5 mm (3/8 in) OD orange "KS" tube from the air supply harness.
9. Re-route the 9.5 mm (3/8 in) OD orange "KS" tube to the center of the front modulator valve assembly and shorten the "KS" tube by 178 mm (7 in).



10. Bundle the air harness, minus the "KS" tube, and secure it with black tape or tie straps (2) in the same locations that the tape was cut.
11. Install a new tie strap (1) to secure the air supply harness to the formed steel bracket.



12. Disconnect the 13 mm (1/2 in) OD orange "KH" air supply tube (1) from the straight connector (2).
13. Remove the existing straight connector (2) from the top (female) connection of the existing tee fitting (3) in the center of the front modulator valve assembly. DO NOT discard the straight connector (2).



14. Apply Loctite 567 (or equivalent) thread sealant to the male threads of the tee fitting (1).



15. Install a new tee fitting (1) to the top (female) connection of the existing tee fitting (2) of the front valve modulator valve assembly.
16. Apply Loctite 567 (or equivalent) thread sealant to the male threads of the elbow (3).
17. Install the elbow (3) into the left hand side port of the new tee fitting (1).

Important: Remove old thread sealant before applying new thread sealant.

18. Apply Loctite 567 (or equivalent) thread sealant to the previously removed straight connector (4).
19. Install the previously removed straight connector (4) to the top port of the new tee fitting (1).



20. Reconnect the "KH" tube (5) to the straight connector.
21. Connect the 178 mm (7 in) shorter re-routed "KS" tube (6) to the elbow (3).
22. Remove the cab tilt lock, lower the cab, and lock it in place.

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).

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that 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.

This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale.

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, you must 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 certain 2006 model year Chevrolet 7500/8500 Kodiak and 7500/8500 T Series; GMC 7500/8500 TopKick and 7500/8500 T-Series; and Isuzu HVR, FVR, and FXR non-towing vehicles equipped with air brakes fail to conform to Federal/Canada Motor Vehicle Safety Standard 121 in emergency stopping distance. As a result, GM is conducting a recall. We apologize for this inconvenience. However, we have taken this action for your safety and continued satisfaction with our products.

In these vehicles, an internal control and check valve within the air brake application valve assembly was configured improperly, preventing air from flowing through the brake system as designed. In the event of an emergency stop, the vehicle's stopping distance would be increased. If stopping distance was limited, a vehicle crash could result.

If your vehicle is a Chevrolet Kodiak, GMC TopKick, or Isuzu HVR, your dealer will replace the air brake application valve assembly. This replacement will take approximately 3 hours and 50 minutes to complete.

If your vehicle is a Chevrolet or GMC T-Series or an Isuzu FVR, FXR, your dealer will reroute the air brake lines. This reroute will take approximately 30 minutes.

This service will be performed for you at no charge . Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the service correction time shown above.

You should contact your dealer to arrange a service appointment as soon as possible. Bring the enclosed customer reply form with you when you visit your dealer. The form identifies the repairs required. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us.

If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below.

If after contacting your dealer and the Customer Assistance Center, you are still not satisfied 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 St., SW, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov.

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

General Motors Isuzu Commercial Truck, LLC

Enclosure

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