Brakes - Park Brake Cables Hang Down Below Vehicle
BULLETIN NO.:92-T-56A
ISSUE DATE:
February, 1993
GROUP/SEQ. NO.:
Chassis-01
CORPORATION NO.:
286303
SUBJECT:
Park Brake Cables Hang Down Under Vehicle Body (Secure with Tie Straps)
This bulletin is being revised to change the procedure and add a template. There was also a misprint in the labor operation code of the previously published bulletin. Please discard Technical Information Bulletin 92-T-56 which this bulletin supercedes.
MODELS
AFFECTED:
All 1991 and some 1992 Saturns
CONDITION:
Some owners may comment that the park brake cables hang down under the vehicle body.
CAUSE:
The park brake cables sag due to reduced support.
CORRECTIVE
ACTION:
All production vehicles built after, and including VIN NZ157775 have tie straps installed to secure the cables to the underbody. If necessary, vehicles built before this breakpoint can be retrofitted using procedures and parts listed in this bulletin.
After this breakpoint, either brake pipe clips, or sections of brake pipe armor (or both) were installed to separate the left park brake cable from the brakes pipes. All rear brake pipes used in production during and after May, 1992 had brake pipe armor installed.
PROCEDURE
Perform the following procedure to prevent the park brake cable from hanging down under the vehicle body.
CAUTION:
MAKE SURE THE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED PRIOR TO LIFTING. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE TO BE REMOVED.
1. Raise vehicle on a hoist.
2. Visually inspect the right and left under side of the vehicle for presence of 6.1 mm 1/4 in.) holes in the underbody. Refer to illustration (left side shown in illustration, right side similar).
3. If holes are not present:
a. Make a copy of the templates (included in this bulletin) and cut on dashed lines.
b. Using templates, mark location of holes to be drilled.
CAUTION:
DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK NEAR THE FUEL SYSTEM IS TAKING PLACE.
NOTICE:
When drilling holes, be careful not to drill into or damage fuel lines.
IMPORTANT:
Early 1991 vehicles do not have a tab on the rocker flange as shown in the illustration. To correctly locate holes to be drilled, align template with straight flange and large underbody hole.
NOTICE:
To prevent damage to the vehicle, attach a drill stop to the drill bit and set it for 12.7 mm (1/2 in.).
c. Using a drill motor and 6.1 mm (1/4 in.) drill bit, drill holes at the two locations marked in Step 3b (one hole is required on each side to secure each cable.)
d. Protect holes against rust by applying underbody primer.
NOTICE:
If brake pipe clip or armor is not installed or is not correctly positioned, the park brake cable could contact the brake pipes. The protective coating on the brake pipe could be worn off allowing excessive corrosion. Eventually, pipe perforation and a loss of brake fluid may occur resulting in reduced brake system performance.
4. If brake pipe armor or clips are not present on the left side (the right side does not require armor or clips):
a. Hold the left park brake cable against brake pipes and note the location of contact between the cable and the brake pipes.
b. Install two brake pipe clips (P/N 21010764) at the locations determined in Step 4a to separate the cable and the pipes.
5. Push one tie strap base (P/N 25518466) into each underbody hole as shown in illustration (left side shown in illustration, right side similar).
6. Fasten each tie strap around the appropriate park brake cable, and pull end of tie strap until cable is secure.
7. Use side cutters or end cutters to remove excess tie strap.
8. Lower vehicle from hoist.
Park Brake Cable Tie Strap Installation
1. If tie strap is damaged, remove tie strap from underbody hole using pliers.
2. Inspect position of protective pipe clips or brake pipe armor. Reposition if necessary to fully separate brake pipes and left park brake cable as shown in illustration.
3. Push base of new tie strap (P/N 25518466) into underbody hole.
4. Fasten tie strap around the park brake cable, and pull end of tie strap until cable is secure.
5. Use side cutters or end cutters to remove excess tie strap.
PARTS
REQUIREMENTS:
21010764 - Clips (2)
25518466 - Straps Parking Brake Cable (2)
CLAIM
INFORMATION:
To receive credit for this repair, submit a claim through the Saturn Dealer System as follows:
Labor
Case Operation
Type Description Code Time
VW Park Brake Cable Tie Strap T9626 O.3 hrs
Installation and Replacement