06020 Special Policy Adjustment/S10-Sonoma tailgate cables

[GMCSonoma]

Another recall that was missed...

08-Body and Accessories
06020
July 2006

SPECIAL POLICY

SUBJECT: Special Policy Adjustment - Tailgate Support Cable Replacement
MODELS: 2000-2003 Chevrolet S10
2000-2003 GMC Sonoma
Due to part availability, this Special Policy is being mailed to customers in phases. This
first phase will consist of 2000 model year vehicles. As parts become available, additional
model years will be released and you will be notified.
If a customer is concerned that the inspection procedure is not an appropriate way to
assure the intended performance of the cables, or is unwilling to perform the required
inspection, dealers are instructed to assist the customer by replacing the galvanized
support cables with stainless steel support cables.
CONDITION

Some customers of 2000-2003 Chevrolet S10 and GMC Sonoma vehicles may experience broken
galvanized steel tailgate support cables.

SPECIAL POLICY ADJUSTMENT

This special policy covers the condition described above for a period of 12 years from the date the
vehicle was originally placed in service, regardless of mileage. The repairs will be made at no
charge to the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after
July 21, 2006 are covered by this special policy and must be submitted using the labor operation
codes provided with this bulletin. Claims with repair orders prior to July 21, 2006 must be
submitted to the Service Contract provider.

VEHICLES INVOLVED

Involved are

certain 2000-2003 Chevrolet S10 and GMC Sonoma vehicles built within the
following VIN breakpoints:

YEAR DIVISION MODEL FROM THROUGH

2000 Chevrolet S10 Y8100001 Y8315639
YK000001 YK301160
Page 2 July 2006 Bulletin No.: 06020

VEHICLES INVOLVED, Cont'd.
YEAR DIVISION MODEL FROM THROUGH

2001 Chevrolet S10 18100001 18260364
1K100008 1K266833
2002 Chevrolet S10 22K8110000000153 22K8226451769866
2003 Chevrolet S10 33K8110000000051 33K8219807590306
2000 GMC Sonoma YYK8100000000076 YYK8331051613577
2001 GMC Sonoma 11K8110000000092 11K8226606384451
2002 GMC Sonoma 22K8110000000213 22K8226451769743
2003 GMC Sonoma 33K8110000000015 33K8219807394465

PARTS INFORMATION

Parts required to complete this special policy are to be obtained from General Motors Service
Parts Operations (GMSPO).

Part Number Description Quantity/Vehicle

15939908 Cable Kit - E/Gate 1
89022217 (US)
89022218 (CN) Lubricant, Rust Penetrating 1
(will service 50 vehicles)

CUSTOMER NOTIFICATION

General Motors will notify customers of this special policy on their vehicles (see copy of typical
customer letter included with this bulletin - actual divisional letter may vary slightly).

SERVICE PROCEDURE
Important:

Remove the bed liner, if equipped, before performing the procedure below.
1. Open and support the endgate.
2. Disconnect the endgate cable from the bolt head of the endgate striker bolt.
3. Remove the latch bolts from the latch assembly.
4. Remove the endgate handle clips.
5. Remove the endgate handle bezel from the endgate.
6. Disconnect the latch rods from the handle.
7. Remove the latch assembly from the endgate and disconnect the latch rods from the latch
assembly.
Page 3 July 2006 Bulletin No.: 06020

1833130

8. Drill out the rivet (1) on the latch assembly using a 9.5 mm (3/8 in) drill bit. Drill out the rivet
from the back side of the latch assembly.

1833132

Important:

Place the latch assembly on a workbench. Ream the latch assembly hole (2)
from the back side of the latch assembly. The illustration shows the front side of the latch
assembly.
9. Ream the latch assembly hole (2) using a 9.5 mm (3/8 in) drill bit.

Important:

Remove the opposite side endgate latch assembly while waiting for the rust
penetrating lubricant to dry. Allow the lubricant to dry for 3-5 minutes between coats.
Perform Steps 1-9.
10. Apply two thin coats of rust penetrating lubricant (corrosion inhibitor) to the area around the
latch assembly hole.
11. Apply black touch-up paint to the area around the latch assembly hole after the rust
penetrating lubricant is dry (about 10 minutes).
Page 4 July 2006 Bulletin No.: 06020

1833135

12. Install the new cables, latch assembly, and new fastener to the endgate.
12.1 Install the new cable to the latch assembly with the new fastener.

Tighten

Tighten the fastener to 9 N·m (80 lb in).
12.2 Attach the latch rod to the latch assembly.
12.3 Install the latch assembly to the tailgate.

Tighten

Tighten the latch bolts to 25 N·m (18 lb ft).
12.4 Install the handle clips.
12.5 Attach the latch rods to the endgate handle.
12.6 Install the endgate handle bezel into place.
12.7 Attach the new cable onto the bolt head of the endgate striker bolt.
13. Perform Steps 10-12 for the opposite side of the endgate.
14. Install the bed liner, if equipped.
15. Close the endgate.
Page 5 July 2006 Bulletin No.: 06020

CLAIM INFORMATION

For vehicles repaired under the terms of this special policy, submit a claim with the information
indicated below:

REPAIR PERFORMED
PART
COUNT
PART
NUMBER
PARTS
ALLOW
CC-FC
LABOR
OP
LABOR
HOURS
NET
ITEM

Inspect Endgate Cables - No
Further Action Required 0 N/A N/A MK-95 T5644 0.2 N/A
Install Endgate Cable Kit 1 --- * MK-95 T5645 0.3 **
Add: If Equipped with Bedliner 0.2
Customer Reimbursement

(Canadian & Export Dealers/US CAC)

N/A N/A N/A MK-95 T5646 0.2 ***

* The "Parts Allowance" should be the sum total of the current GMSPO Dealer net price plus
applicable Mark-Up or Landed Cost Mark-Up (for Export) for the endgate cable kit needed
to complete the repair.
** The amount identified in the “Net Item” column should represent the actual sum total of the
current GMSPO Dealer net price plus applicable Mark-Up or Landed Cost Mark-Up (for
Export) for the rust penetrating lubricant needed to perform the required repairs, not to
exceed $0.33 USD, $0.36 CAD.
*** The amount identified in the “Net Item” column should represent the customer
reimbursement amount.
CUSTOMER REIMBURSEMENT - For US
All customer requests for reimbursement for previous repairs for the special policy condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.

IMPORTANT

: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for
specific procedures regarding customer reimbursement and the form.
CUSTOMER REIMBURSEMENT - For Canada and Export
Customer requests for reimbursement of previously paid repairs for the special policy condition
are to be submitted the dealer prior to or by November 30, 2007. Repairs must have occurred
within the 12 years of the date the vehicle was originally placed in service, regardless of mileage.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including
Service Contract deductibles), a description of the repair, and the person or entity
performing the repair.
Page 6 July 2006 Bulletin No.: 06020
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these 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 tools, equipment, 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 your dealer/retailer for information
on whether your vehicle may benefit from the information.

We Support
Voluntary Technician
Certification

Page 7 July 2006 Bulletin No.: 06020

SPECIAL POLICY NOTICE

IMPORTANT

•

Your vehicle is involved in special policy 06020.

•

You or your GM dealer should inspect the tailgate cables for corrosion
per the attached inspection procedure or online video found at
www.gm.com/cables

•

Your dealer will perform this inspection for you at no charge.
Dear General Motors Customer:
As the owner of a 2000, 2001, 2002, or 2003 model year Chevrolet S10 or GMC Sonoma vehicle,

your satisfaction with our product is very important to us.
This letter is intended to make you aware that some 2000, 2001, 2002, and 2003 model year
Chevrolet S10 and GMC Sonoma vehicles equipped with galvanized steel tailgate support cables
may have a condition where the cables can corrode and fracture when loads are applied to them.
If one or both tailgate support cables were to break, cargo and/or individuals positioned on the
tailgate could drop to the ground, possibly resulting in cargo damage and/or personal injury.
Owners should NEVER permit an individual to sit on the opened (horizontal) tailgate when a
vehicle is in motion. Even when the vehicle is operated at low speeds, individuals seated on the
tailgate can easily lose their balance in response to vehicle maneuvers, unexpected jolts due to
road conditions, etc. Individuals who fall to the ground or pavement from a moving vehicle may
be seriously injured or killed.

What have we
done?

General Motors is providing you with additional warranty coverage
to cover corrosion on galvanized steel tailgate support cables. If this
condition occurs on your vehicle within 12 years of the date that
your vehicle was originally placed in service, regardless of vehicle
mileage, the condition will be repaired for you at

no charge.

What should
you do?

You should determine which of the two options below better suits
your preference and vehicle usage.
Option 1: You may choose to have your galvanized steel tailgate
support cables inspected yearly. You can perform this inspection
yourself according to the inspection procedure included with this
letter, or as shown on the online video at www.gm.com/cables, or
you can take your vehicle to your GM dealer and they will inspect
the cables for you at no charge. If a cable shows signs of corrosion,
both cables will be replaced with stainless steel cables at no charge
to you. If you choose this option, and would like your dealer to
perform the inspection, you should contact the service department
to schedule an appointment that is convenient for you. Keep this
letter with your other important glove box literature for future
reference.
Page 8 July 2006 Bulletin No.: 06020
Option 2: If you have any concerns about frequency or
effectiveness of the inspection procedure, discuss them with your
dealer. If you are not satisfied that regular inspection is an
appropriate way to assure the intended performance of your cables,
or you are unwilling to inspect the cables, your dealer will replace
your galvanized support cables with stainless steel support cables.

Did you already
pay for this
repair?

The enclosed form explains what reimbursement is available and
how to request reimbursement if you have paid to have your
galvanized steel tailgate support cable replaced because of
corrosion.
All replacement tailgate support cables that had been purchased
prior to August 2006 were made of galvanized steel and will need to
be inspected annually as outlined in the enclosed inspection
procedure.
We are sorry for any inconvenience you may experience; however we have taken this action in
the interest of your continued satisfaction with our products.
Scott Lawson
General Director,
Customer and Relationship Services
Enclosure
06020
Page 9 July 2006 Bulletin No.: 06020

Galvanized Steel Tailgate Cable Inspection Procedure

An online video of the inspection is available for your viewing at www.gm.com/cables

Inspect the galvanized steel tailgate support cables following the steps below. Please use caution
when performing this inspection. We recommend that you inspect your cables now and whenever
using the tailgate.
1. Paying close attention to the middle of the cable (the bend point in the closed position),
inspect both tailgate cables for any of the following conditions:

•

Any nick, cut, crack, or abrasion in the black plastic coating material that exposes any
portion of the galvanized steel cable normally covered by the coating.

•

Any irregularity or distortion in the size or shape of the cable, such as swelling or
bulging.
2. If you find any of the conditions listed above, your cables should be replaced. Contact your
GM dealer to schedule an appointment.
3. Additional Information is also available at www.gm.com/cables.

Cuts and abrasions in the black plastic material
Irregularities in the size and shape of the cable
Swelling or bulging in the cable.

[asim]

So first it was broken cables in the GMT-800 Trucks, now this. This doesn't give me much hope for the 900s.

[GMCSonoma]

Originally Posted by asim

So first it was broken cables in the GMT-800 Trucks, now this. This doesn't give me much hope for the 900s.

Why?? Because some cables break on a previous generation truck, no longer built???

[Corr69]

Originally Posted by asim

So first it was broken cables in the GMT-800 Trucks, now this. This doesn't give me much hope for the 900s.

They used the exact same cables. My bros S-10 Extreme's cables just broke the other day, and he was pissed that there was no recall on the S-10s. Wow I guess this will make him happy.

[01cavalier]

The phases it is going in:
phase 1, 2000 model year 7/28
phase 2, 2001 model year 9/15
phase 3, 2002 model year 10/20
phase 4, 2003 model year 11/17

[AndrewGS]

I'm a pretty hefty guy and I have had myself and some pretty heavy stuff on my old '00 Sonoma's tailgate with nary a problem.

[hunchman]

.......hopefully this was not some 2 cent cable made in a toy factory over in china.............I'm sure gm won't repeat this with the 900's

[GMCSonoma]

Date: September 13, 2006

Subject: 06020A – Special Policy Adjustment
Tailgate Support Cable Replacement
Phase 3 Mailing

Models: 2000-2003 Chevrolet S10
2000-2003 GMC Sonoma

To: All Chevrolet and GMC Dealers

Attention: Service Manager, Parts Manager and
Warranty Administrator


Due to part availability, customer notification for Special Policy Adjustment 06020 is being implemented in phases. General Motors released Phase 1 on July 21, 2006 via GM Administrative Message WIR20060325. The total number of vehicles involved was 328,796 and included the 2000 model year vehicles.

On August 30, 2006, General Motors notified dealers via Administrative Message WIR 20060334 that customer letters for Phase 2 would be mailed on September 6, 2006. The total number of vehicles involved was 219,391 and included the 2001 model year vehicles.

Please be advised that the release of Phase 3 is scheduled with letters to begin mailing on September 20, 2006. This third phase will consist of the 2002 model year vehicles with 195,767 vehicles involved.

As additional parts become available, the final model year will be released and you will be notified.

Bulletin 06020 has been updated with bulletin 06020A via GM Administrative Message WIR20060336 sent on September 12, 2006 and is currently available in the GM Service Information System (SI).


END OF MESSAGE
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