CAMPAIGN: 3T40 PISTON SEAL INTERMEDIATE SERVO COVER
SUBJECT: INTERMEDIATE SERVO COVER PISTON BORE
MODELS AFFECTED: CERTAIN 1990 SKYLARK WITH 2.5L ENGINE (VIN CODE U) AND 3T40 (125) TRANSAXLE (RPO MD9)
CONDITION
General Motors has determined that some 1990 Buick Skylark model vehicles equipped with 2.5L (VIN Code U; RPO L68) engine and 3T40 (RPO MD9) transaxle may have been assembled with a Transaxle Intermediate Servo Cover with a rough piston bore. The rough finish could eventually wear the lip of the (inner) Intermediate Servo Seal (134 in Figure 2), causing a leak in the second clutch circuit (intermediate servo apply). This leak may cause Intermediate Band and Direct Clutch wear. This may cause a "no second gear" condition.
To prevent this condition from occurring, dealers are to inspect the transaxle I.D. plate on involved vehicles for Julian Dates, and if necessary, install an Intermediate Servo Cover Kit or replace the transaxle as instructed in the SERVICE PROCEDURE section of this bulletin.
VEHICLES INVOLVED
Involved are certain 1990 Buick Skylark model vehicles with 2.5L (VIN Code U; RPO L68) engine and 3T40 (RPO MD9) transaxle within the following VIN breakpoints and Julian dates:
TRANSAXLE THROUGH AND YEAR MODEL JULIAN DATES BEGINNING INCLUDING ---- ------- ------------ --------- ----------- 1990 SKYLARK 194 thru 200 LM084485 LM085568
While all involved vehicles will require inspection of the transaxle I.D. plate for Julian dates, it is expected that only about 11% of inspected vehicles will require installation of the Intermediate Servo Cover Kit. Very few, if any, vehicles should require a SRTA Transaxle.
All vehicles listed on the dealer printout will require inspection, and repair, if necessary. Other suspect vehicles should be checked for campaign involvement by utilizing the Vehicle Information Service System (V.I.S.S.).
DEALER CAMPAIGN RESPONSIBILITY
Dealers are to service all vehicles involved in this campaign, at no charge to owners, regardless of mileage, age of vehicle, or ownership from this time forward.
Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle.
Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin.
DEALER MATERIAL
If your dealership has vehicles involved in this campaign, you will receive the following items:
o List of all vehicles involved in this campaign assigned to your dealership.
o One (1) campaign Identification Label per vehicle involved.
Involved vehicles have been identified by Vehicle Identification Number Computer listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.
These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.
OWNER NOTIFICATION
Owners will be notified of this campaign on their vehicles by Buick Motor Division (see copy of owner letter included with this bulletin).
CHANGE OF OWNER INFORMATION
Dealers are to use the Dealer Communication System (DCS) to provide Buick Motor Division with subsequent Buick owner information. By reporting a change of owner name or address of a vehicle in campaign status over the DCS, the need to send a CVAR form for that vehicle is eliminated. Terminal input instructions are covered in the DCS Manual under Section 9, Page 9-J01A and B.
PART INFORMATION
Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).
DESCRIPTION PART NUMBER QTY. PER VEHICLE --------------------------------------- ----------- --------- Servo Cover Kit 8681967 1 (As Required) Servo Cover Kit consists of:
Intermediate Servo Piston and Seals (Assy) 8652911 1 Intermediate Servo Piston (.64 ratio) 8652447 1 Intermediate Servo Piston Inner Seal 8652443 1 Intermediate Servo Piston Outer Seal 8652446 1
Intermediate Servo Cover and Gasket 8631704 1
3rd Accumulator Exhaust Valve & Spring (Assy) 8643996 1 3rd Accumulator Valve 8643408 1 3rd Accumulator Spring 8643965 1
Fluid Pan Gasket 8678168 1
Service Replacement Transmission Assy (SRTA) 8665980 (OPNC) 1 (If Required)
It is expected that only about 11% of inspected vehicles will require replacement of the Intermediate Servo Cover; order parts accordingly.
SERVICE PROCEDURE
1. Inspect the Transaxle I.D. Plate (see Figure 1). If the Julian Dates are within the range 194 thru 200, inclusive (July 13, 1990 thru July 19, 1990), proceed to Step 2. If the Julian Dates are not within the range 194 thru 200, skip to Step 4 and install a Campaign Identification Label.
2. If the vehicle odometer reads less than 12,000 miles, go to Step 3 and install Kit P/N 8681967 as instructed.
If the vehicle odoimeter reads 12,000 miles or more, perform the following test drive:
A. Start vehicle and let idle on a flat surface for three (3) minutes.
B. Verify correct transaxle fluid level and fluid color.
C. Evaluate the vehicle in drive range and verify the following proper vehicle operation conditions:
1-2 upshift at 1/4 throttle, should occur between 12 to 20 m.p.h. 2-3 upshift at 1/4 throttle, should occur between 20 to 35 m.p.h. Manually select low range and verify 3-2 and 2-1 coastdown shifts.
D. Verify vehicle has correct reverse engagement and no slippage in reverse range.
E. During the test drive, the driver should not feel any slips and/or bumps.
If the vehicle has normal transaxle operation, proceed to Step 3 and install Kit P/N 8681967, as instructed.
If the vehicle does not have normal transaxle operation, replace the transaxle with a Hydra-Matic 3T40 SRTA Assembly, (OPNC 8665980), following the instructions and cautions listed in the 1990 Buick Skylark Service Manual, pages 7A-26 through 29.
If the transaxle is replaced, please advise the owner that memory functions may have been lost due to disconnection of the battery.
NOTICE: COOLER FLUSHING MUST BE PERFORMED; THE TIME ALLOWANCE FOR TRANSAXLE REMOVAL AND REPLACEMENT PROVIDES FOR THIS.
If the transaxle is replaced, do NOT install Kit P/N 8681967, go to Step 4.
3. Install Kit P/N 8681967 as follows:
A. Raise vehicle and suitably support (see section 0A in service manual).
B. Remove fluid pan and gasket. Discard gasket.
C. Remove strainer and multi-lip seal. Save both parts for reinstallation.
D. Remove reverse fluid pipe retainers and bolts (140-143 in Figure 2)
E. Remove intermediate servo cover (137) and gasket (136) and discard.
F. Remove third accumulator exhaust valve (126) and exhaust spring (125) and discard.
G. Remove the intermediate servo assembly (shown as parts 128 thru 135 in Figure 2)
H. Install new seals (132 & 134) on new intermediate servo piston (133) from the kit. Transfer parts (128 thru 131, and 135) to the new intermediate servo piston to make a new intermediate servo assembly. Discard the old piston and old seals.
I. Install new third accumulator exhaust valve (126) and exhaust spring (125).
J. Install new intermediate servo cover and new gasket (137 and 136).
K. Reinstall reverse fluid pipe retainers and bolts (140-143). Torque to 24 N.m (18 lb.ft.).
L. Reinstall fluid strainer and multi-lip seal.
M. Reinstall fluid pan with a new gasket. Retain gasket with Transjel J 36850. Torque to 11 N.m (96 lb.in.).
N. Adjust fluid level as required.
4. Install a Campaign Identification Label.
CAMPAIGN IDENTIFICATION LABEL
Each vehicle corrected in accordance with the instructions outlined in this bulletin will require a "Campaign Identification Label". Each label provides a space to include the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.
Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner.
Apply "Campaign Identification Label" only on a clean, dry surface.
DISPOSITION OF PARTS
Replaced parts must be held for disposition by Buick Zone or Branch contact personnel. Parts must have a claim tag attached showing the repair order and the VIN of the vehicle from which they were removed.
WARRANTY INFORMATION
List the one applicable "V" labor operation.
PART FAILED PARTS FAILURE LABOR LABOR OTHER DLR. OPER. COUNT PART NO. ALLOW. CODE OP NO. HOURS HOURS MTL TWG ------ ----- ----- ------ ---- ----- ------- ----- ------ o Inspect Transaxle I.D. Plate only (No Repair and No Drive Audit Required) -- -- -- 96 V6550 0.2 *0.1 --
o Inspect Transaxle I.D. Plate and Install Kit (No Drive Audit) # 8681967 ** 96 V6551 0.6 *0.1
o Inspect Transaxle I.D. Plate, Perform Drive Audit, and Install Kit # 8681967 ** 96 V6552 1.1 *0.1
o Inspect Transaxle I.D. Plate, Perform Drive Audit, and Replace the Transaxle with a Hydra-Matic 3T40 SRTA Assembly ( No Kit) # 8665980 ** 96 V6553 5.0 *0.1
# Number of actual parts used including fluid quantities * Dealer Administration Allowance ** Current dealer price, plus 30% handling allowance
Dear Buick Owner:
This notice is sent to inform you that Buick Motor Division is conducting a recall that includes your vehicle.
REASON FOR THIS RECALL
General Motors has determined that some 1990 Buick Skylark model vehicles equipped with 2.5L engine and automatic transaxle may have been assembled with a Transaxle Intermediate Servo Cover with a rough piston bore. This may eventually cause a "no second gear" condition and internal damage to the transaxle.
WHAT WE WILL DO
To prevent this condition from occurring, dealers will inspect involved vehicles, and if necessary, install an Intermediate Servo Cover Kit or replace the transaxle. This service will be performed for you at no charge.
WHAT YOU SHOULD DO
Please contact your Buick dealer as soon as possible to arrange a service date. Instructions for making the necessary inspection/correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle.
If your dealer determines that the transaxle in your vehicle needs to be replaced, a replacement transaxle will probably have to be ordered; then, after the transaxle arrives, your dealer will call you to schedule a new appointment.
The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary inspection/ correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.
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.
