STICKS IN GEAR/CLASH 1ST & 2ND 5SPEED M/T SERVICE INFORMATION

THIS BULLETIN PROVIDES SERVICE INFORMATION FOR 1983 CIMARRONS EQUIPPED WITH MANUAL FIVE-SPEED TRANSAXLES EXPERIENCING THE FOLLOWING CONDITIONS: TRANSAXLE REMAINS IN LAST SELECTED GEAR RANGE (SECTION I), DIFFICULT GEAR SELECTION/GEAR CLASH (SECTION II), NOISE IN CLUTCH MECHANISM (SECTION III), AND LOW TRANSAXLE FLUID LEVEL (SECTION IV). I.TRANSAXLE REMAINS IN LAST SELECTED GEAR RANGE EARLY 1983 CIMARRONS EQUIPPED WITH MANUAL FIVE-SPEED TRANSAXLES CAN EXPERIENCE LOSS OF THE RETAINER CLIP THAT SECURES THE SHIFTER CABLE TO THE MOUNTING BRACKET (REFER TO FIGURE 1). LOSS OF THE CLIP COULD OCCUR DURING A HARD 1-2 OR 3-4 UPSHIFT AND RESULT IN THE TRANSAXLE REMAINING IN THE LAST SELECTED GEAR RANGE. AT THE VEHICLE BROADCAST NUMBERS (LAST SIX DIGITS OF THE VIN) LISTED BELOW, SEVERAL CHANGES TOOK PLACE TO CORRECT THE CONDITION. THESE CHANGES INCLUDE: BROADCAST # 403069 CHANGE INSTALLATION OF CORRECTLY DIMENSIONED RETAINER CLIPS (P/N 14034650) IN PRODUCTION BEGINNING WITH THE LISTED BROADCAST NUMBER. BROADCAST # 403223 CHANGE CORRECTLY DIMENSIONED CABLE MOUNTING BRACKET (P/N 14051054) UTILIZED IN PRODUCTION. INITIAL SUPPLY OF BRACKETS WERE TOO THICK AND ALSO COULD HAVE THE CENTER REINFORCEMENT RIB MISPOSITIONED SUCH THAT THE CABLE RETAINING CLIP WOULD BOTTOM OUT ON THE RIB AND NOT FULLY SEAT ONTO THE SHIFTER CABLE (REFER TO FIGURE 2). II.DIFFICULT GEAR SELECTING/GEAR CLASH EARLY 1983 CIMARRONS EQUIPPED WITH MANUAL FIVE-SPEED TRANSAXLES CAN EXPERIENCE DIFFICULTY IN SELECTING (SHIFTING) FIRST AND SECOND GEAR RANGES AS WELL AS GEAR CLASH INTO SECOND AND/OR THIRD GEAR WITH MODERATE SHIFT SPEED AFTER AN OVERNIGHT SOAK WITH AMBIENT TEMPERATURES NEAR OR BELOW +40F. THE CONDITIONS MAY LESSEN AFTER THE VEHICLE HAS BEEN OPERATED FOR 5-10 MINUTES. THESE CONDITIONS MAY BE CAUSED BY TOO TIGHT OF A BEARING PRELOAD SHIM. BEGINNING AT VEHICLE BROADCAST NUMBER 409801, A CHANGE WAS MADE TO REDUCE THE INPUT SHAFT BEARING SHIM THICKNESS BY .08MM (.004") (REFER TO FIGURE 3). THESE TRANSAXLES CAN BE IDENTIFIED BY A DAB OF GREEN PAINT ON THE LEFT SIDE OF THE REAR COVER. TO CORRECT THE CONDITION(S) ON ANY VEHICLE BUILT PRIOR TO THE PRODUCTION CHANGE, IT WILL BE NECESSARY TO REMOVE THE TRANSAXLE AND PERFORM THE SHIM SELECTION PROCEDURE USING TOOL J-33373 AS OUTLINED ON PAGES 7B-20 AND 21 OF THE CIMARRON SECTION OF THE 1983 SERVICE INFORMATION MANUAL. III.NOISE IN CLUTCH MECHANISM 1983 MANUAL FIVE-SPEED CIMARRONS MAY EXHIBIT A "ROARING" TYPE OF NOISE IN THE CLUTCH MECHANISM. THE NOISE MAY BE CAUSED BY THE CLUTCH CABLE NOT BEING FULLY SEATED IN THE RUBBER ISOLATOR LOCATED ON TOP OF THE CLUTCH PEDAL BRACKET ASSEMBLY (REFER TO FIGURE 4). TO CORRECT THE CONDITION, PUSH THE CABLE AS FAR DOWN AS POSSIBLE INTO THE ISOLATOR. IV.LOW TRANSAXLE FLUID LEVEL EARLY 1983 CIMARRONS EQUIPPED WITH MANUAL FIVE-SPEED TRANSAXLES MAY EXPERIENCE A CONDITION OF INSUFFICIENT FLUID EVEN THOUGH THE FLUID LEVEL INDICATOR (DIPSTICK) READS SLIGHTLY BELOW THE "FULL" MARK. THE CONDITION IS THE RESULT OF A RESERVOIR EFFECT CAUSING AN AMOUNT OF OIL TO BECOME TRAPPED IN THE 90F ELBOW THREADED TO THE CASE THAT THE FILL TUBE AND DIPSTICK ENTER (REFER TO FIGURE 5). A FLUID LEVEL READING 2MM BELOW THE "FULL" MARK INDICATES THE TRANSAXLE COULD HAVE BETWEEN ZERO AND APPROXIMATELY TWO QUARTS OF FLUID IN IT. IF THIS CONDITION IS NOTED, ADD 5W-30 MOTOR OIL (IN ONE PINT INCREMENTS) TO BRING THE LEVEL AT LEAST EVEN WITH (OR AS MUCH AS 6MM ABOVE) THE "FULL" MARK. BEGINNING AT VEHICLE BROADCAST NUMBER A NEW DESIGN INDICATOR (P/N 14075760) IS USED.

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.