CAMPAIGN: CLUTCH LINKAGE REPAIR PROCEDURE

CONDITION

GENERAL MOTORS HAS DETERMINED THAT SOME 1980 AND 1981 OMEGA MODELS EQUIPPED WITH MANUAL TRANSMISSIONS, MAY HAVE CLUTCH LINKAGE MECHANISMS WHICH WILL NOT PROPERLY HOLD SELF ADJUSTMENT. THESE MECAHNISMS MAY ALLOW CLUTCH LINKAGE SLIPPAGE, OR MAY EXHIBIT AN AUDIBLE CLICKING OR RATCHETING WHEN THE CLUTCH PEDAL IS DEPRESSED. IMPROPER SELF ADJUSTMENT MAY ALLOW QUICKER ENGAGEMENT OF THE CLUTCH THAN THE VEHICLE OPERATOR MIGHT ORDINARILY EXPECT.

IN ORDER TO ELIMINATE THIS CONDITION A NEW CLUTCH ADJUSTING KIT WILL BE INSTALLED ON ALL VEHICLES INVOLVED. INSTALLATION OF THIS KIT ELIMINATES THE SELF ADJUSTING FEATURE. THEREFORE, THE CLUTCH LINKAGE SHOULD BE ADJUSTED EVERY 5,000 MILES (8,000 KM) OR LESS IS REQUIRED. THIS ADJUSTMENT MAY BE ACCOMPLISHED BY PULLING THE CLUTCH PEDAL UP LIGHTLY UNTIL IT STOPS (AGAINST BUMPER) AND THEN DEPRESSING THE PEDAL SLOWLY.

NOTE: TO AVOID CLUTCH LINKAGE DAMAGE, DO NOT CONTINUE TO PULL UP ON THE PEDAL AFTER IT STOPS.

CARS AFFECTED

ALL 1980 OMEGAS WITH A MANUAL TRANSMISSION.

ALL 1981 OMEGAS WITH A MANUAL TRANSMISSION PRODUCED AT THE WILLOW RUN (CODE W) ASSEMBLY PLANT FROM THE START OF PRODUCTION THROUGH VIN 3AB69X6BW134576.

DEALER ACTION

DEALERS ARE TO INSTALL A NEW CLUTCH ADJUSTING KIT ON ALL VEHICLES LISTED ON THE PRINTOUT.

DEALERS ARE TO PERFORM THIS RECALL CAMPAIGN AT NO CHARGE TO THE OWNER ON AFFECTED VEHICLES, REGARDLESS OF TIME, MILEAGE OR OWNERSHIP, AND ARE TO CORRECT ALL AFFECTED VEHICLES IN DEALER NEW AND USED CAR INVENTORY PRIOR TO THEIR SALE.

WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN IS TAKEN INTO YOUR NEW OR USED CAR INVENTORY IN THE FUTURE, YOU SHOULD TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE RESELLING THE VEHICLE.

CORRECTION PROCEDURE

1. RAISE HOOD, INSTALL FENDER COVER. REMOVE THE CLUTCH CABLE FROM THE TRANS/AXLE. FROM INSIDE THE CAR DISCONNECT THE CLUTCH CABLE FROM THE CLUTCH PEDAL QUADRANT PER SECTION 7C OF THE 1981 OMEGA SERVICE MANUAL.

2. AFTER LIFTING THE PAWL AND RAISING THE CABLE OUT OF THE QUADRANT GROOVE, PUSH THE CABLE END FORWARD ON THE RIGHT SIDE OF THE QUADRANT SO THE CABLE IS FREE FROM THE PEDAL ASSEMBLY.

3. REMOVE THE NEUTRAL START SWITCH FROM BOTH BRACKET ASSEMBLY AND PEDAL ASSEMBLY.

4. REMOVE PEDAL PIVOT NUT AND BOLT AND REMOVE PEDAL ASSEMBLY FROM BRACKET ASSEMBLY AND THEN FROM VEHICLE. (CAREFULLY NOTE PART POSITIONS OF SELF ADJUSTING MECHANISM AND PARTICULARLY LOCATIONS OF PAWL AND QUADRANT SPRINGS).

5. ROUTE "E" RING AND DISASSEMBLE THE MECHANISM. DISCARD QUADRANT, PAWL, PAWL SPRING, AND SUPPORT. CLEAN ALL SURFACES OF PEDAL ASSEMBLY THAT CON- TACT QUADRANT AND PAWL WITH SPECIAL ATTENTION TO PEDAL STUD WHICH IS PIVOT AXIS FOR PAWL.

6. USING THE NEW QUADRANT, PAWL, PAWL SPRING, AND SUPPORT CONTAINED IN THE REPAIR KIT, REASSEMBLE THE SELF ADJUSTING MECHANISM TO PEDAL AS FOLLOWS:

A. INSERT QUADRANT SPRING FULLY INTO QUADRANT POCKET AND ASSEMBLE QUADRANT PART WAY ONTO PEDAL ASSEMBLY WITH SPRING TANG INSERTED INTO PEDAL'S UPPER HOLE. ROTATE QUADRANT APPROXIMATELY 90 DEGREES TO WIND UP SPRING AND ALLOW QUADRANT STOP TO CLEAR FRON SIDE (CAR POSITION ) OF PEDAL. THEN PUSH QUADRANT AND PEDAL ASSEMBLY TOGETHER, HOOKING QUADRANT STOP ON FRONT OF PEDAL. FACES OF PEDAL AND QUADRANT SHOULD NOW BE IN CONTACT WITH SPRING LOAD HOLDING STOP AND PEDAL IN CONTACT (AS SHOWN IN FIG. 1).

B. ASSEMBLE PAWL SPRING OVER PAWL END (AS SHOWN IN FIG.2) AND INSTALL AS UNIT ONTO STUD AT TOP OF PEDAL. WIDE HOOK END OF SPRING MUST BE ASSEMBLED OVER FRONT OF PEDAL AS PAWL IS PUSHED ONTO PEDAL STUD WITH PAWL AND QUADRANT TEETH IN MESH.

AS ASSEMBLED, SPRING MUST FORCE PAWL TEETH INTO TEETH OF QUADRANT TO PREVENT FORWARD ROTATION OF QUADRANT.

C. PLACE SUPPORT ON UPPER PEDAL STUD AND ROTATE CLOCKWISE TO ENGAGE NARROW HOOK END OF PAWL SPRING, LOADING OUTER END OF PAWL SPRING. CONTINUE TO ROTATE UNTIL LARGE HOLE IN SUPPORT FITS ONTO LARGE HUB PEDAL AND SEATS AGAINST QUADRANT FACE. INSTALL "E" RING IN PEDAL STUD GROOVE.

CAUTION:

SUPPORT MUST BE ASSEMBLED WITH FLANGED EDGE AWAY FROM QUADRANT (AS SHOWN IN FIG.3). ENDS OF PAWL SPRING MUST BE HOOKED (AS SHOWN IN FIG. 4).

D. LUBRICATE THE INNER AND OUTER DIAMETER SURFACES OF EACH BUSHING AND INSTALL BUSHINGS AND SPACER INTO PEDAL ASSEMBLY.

CAUTION:

ENSURE THAT LEFT HAND BUSHING IS INSERTED INTO PEDAL ASSEMBLY HOLE AFTER SUPPORT IS INSTALLED ON PEDAL HUB AS FLANGE OF BUSHING ALSO RETAINS SUPPORT ON PEDAL HUB.

7. CHECK BRACKET IN VEHICLE TO ENSURE THAT BUMPER (AS SHOWN IN FIG. 5) IS IN PLACE ON PEDAL STOP. INSTALL IF MISSING. ASSEMBLE PEDAL TO MOUNTING BRACKET BY INSTALL ING BOLT AND NUT AND TIGHTENING NUT TO 30-50 N.M (22-37 FT.LBS.). NUT IS ASSEMBLED ON STEERING COLUMN SIDE OF BRACKET. MAKE SURE HEAVY QUADRANT SPRING IS FULLY SEATED IN QUADRANT BEFORE IN- STALLING PEDAL ASSEMBLY IN VEHICLE.

8. CHECK OPERATION OF PAWL AND QUADRANT BY OBSERVING THAT PAWL DISENGAGES WHEN PEDAL IS RAISED TO RELEASED POSITION (PEDAL AGAINST BRACKET BUMPER) AND THAT QUADRANT CAN BE ROTATED FORWARD OFF STOP WITH PAWL DISENGAGED. DO NOT LET QUADRANT SNAP BACK, AS QUADRANT CAN BE DAMAGED. CHECK THAT PEDAL ASSEMBLY SWINGS FREELY ON ITS PIVOT BOLT.

9. TO REINSTALL CABLE, ROTATE CABLE AND BACK ON RIGHT SIDE BETWEEN QUADRANT AND PEDAL ASSEMBLY. LIFT PAWL AND RAISE CABLE INTO QUADRANT GROOVE AND CONNECT CABLE END TO QUADRANT (AS SHOWN IN FIG. 6). ENSURE THAT CABLE IS ROUTED UNDER TANG ON BRACKET THAT CONTACTS PAWL, AS SHOWN IN ILLUSTRA- TION.

10. TO REINSTALL OTHER END OF CABLE HAVE A HELPER HOLD PEDAL ASSEMBLY AGAINST BUMPER TO DISENGAGE PAWL AND DETENT TEETH. REINSTALL LOWER END OF CABLE INTO TRANS/AXLE LEVER AND MOUNTING BRACKET BEING CAREFUL NOT TO PULL MORE THAN 20 KG. (44 LBS.) ON CABLE, OR SELF ADJUSTING QUADRANT CAN BE DAMAGED 11. REINSTALL NEUTRAL START SWITCH TO PEDAL AND BRACKET AND RECONNECT WIRE CONNECTOR TO SWITCH.

12. CHECK OVERALL CLUTCH OPERATION PER SECTION 7C IN SHOP MANUAL. PRIOR TO VEHICLE DELIVERY TO CUSTOMER, LIFT CLUTCH PEDAL AGAINST BUMPER STOP TO RESET LINKAGE AND DEPRESS PEDAL SEVERAL TIMES FOR FINAL ADJUSTMENT.

13. PLACE ONE COPY OF NOTICE 14047652 IN "OWNER'S MANUAL" AND ATTACH SECOND COPY OF 14047652 TO OWNER'S COPY OF THE "REPAIR ORDER".

14. RECORD CAMPAIGN NUMBER AND DEALER CODE ON THE YELLOW CAMPAIGN CORRECTION LABEL AND INSTALL ON THE RADIATOR BAFFLE WHERE IT IS READILY VISIBLE.

PARTS INFORMATION

THE PARTS REQUIRED TO COMPLETE THIS PROCEDURE ARE CONTAINED IN KIT FORM UNDER PART NUMBER 10447653. THE KITS ARE AVAILABLE FROM GM PARTS (GMWDD) AND SHOULD BE ORDERED BY THE DEALER AS NEEDED TO COMPLETE THE VEHICLES LISTED ON HIS PRINTOUT.

EACH KIT, PART NUMBER 14047653 CONSISTS OF THE FOLLOWING:

PART NUMBER QUANTITY DESCRIPTION

14040589 1 PER KIT SPRING 474690 1 PER KIT PAWL 14036183 1 PER KIT QUADRANT 14004822 1 PER KIT SUPPORT 14047654 1 PER KIT INSTRUCTION SHEET 14047652 2 PER KIT OWNER'S NOTICE

PARTS ARE TO BE RETAINED FOR DISPOSITION BY ZONE PERSONNEL.

WARRANTY CLAIM INFORMATION

DEALERS ARE TO SUBMIT CLAIMS ON THE CAMPAIGN CARD FURNISHED WITH THE PRINTOUT USING THE FOLLOWING INFORMATION. PARTS WILL BE CREDITED AT DEALER NET, PLUS 30% DEALER HANDLING ALLOWANCE.

YEAR LABOR OPERATION DESCRIPTION TIME 1980-81 V0960 INSTALL CLUTCH ADJUSTING KIT .4 HOUR

.1 HOUR FOR CLERICAL ADMINISTRATION WILL BE ADDED TO THE ABOVE OPERATIONS. TO SUBMIT A CLAIM ON CARS CORRECTED BUT NOT ON YOUR PRINTOUT, USE A YELLOW STRIPE CARD.

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.