MUNCIE 5 SPD. EXCHANGE PROGRAM PROGRAM OUTLINED AND P/N'S

TO GAIN DIRECT PRODUCT FEEDBACK ON THE SUBJECT TRANSAXLES, AND TO MINIMIZE VEHICLE DOWN TIME, A TRANSAXLE RETURN PROGRAM IS NOW IN EFFECT AND WILL CONTINUE UNTIL FURTHER NOTICE. THE RETURN PROGRAM WILL BE ADMINISTERED BY HYDRA-MATIC AND ALL REQUESTS FOR SERVICE REPLACEMENT UNITS WILL BE HANDLED THROUGH GM PARTS. THE FOLLOWING INFORMATION THOROUGHLY EXPLAINS ALL REQUIREMENTS REGARDING DIAGNOSIS, SERVICEABLE AND NON-SERVICEABLE ITEMS, SERVICEABLE PART NUMBERS, AND SHIPPING INSTRUCTIONS. IN THE EVENT YOUR DEALERSHIP RECEIVES A COMPLAINT ON A MG1/MG2 5 SPEED TRANSAXLE, FOLLOW THE PROCEDURE LISTED BELOW. YOUR COOPERATION WILL GREATLY IMPROVE THE EFFECTIVENESS OF THE PROGRAM. NOTE: - SERIAL NUMBER TAG LOCATION IS ITEM (A), FIGURE 1. - NUMBERS IN BRACKETS REFER TO ITEM NUMBERS ON DISASSEMBLED VIEWS, FIGURE 1 AND 2. - A SERVICEABLE PARTS ITEM NUMBER/GM PART NUMBER CROSS REFERENCE IS PROVIDED FOR YOUR CONVENIENCE, FIGURE 3. A. PRELIMINARY DIAGNOSIS O REFER TO DIAGNOSIS CHART, FIGURE 4. O INSURE CORRECT OIL LEVEL. O INSURE THAT THE SHIFT LINKAGE IS PROPERLY ADJUSTED. O INSURE THAT THE CLUTCH LINKAGE IS PROPERLY ADJUSTED. O INSURE THAT ALL ENGINE AND TRANSMISSION MOUNTS ARE TIGHT. B. ON-CAR SERVICE NOTE: NUMBERS IN BRACKETS REFER TO ITEM NUMBERS ON DISASSEMBLED VIEWS, FIGURES 1 AND 2. O OIL LEAKS AT: O SPECIAL TOOL REQUIREMENTS AND TORQUE SPECIFICATIONS - AXLE SEALS (23) - INSTALL USING J26938 AND J8092 - SHIFT SHAFT COVER (140) - NO SPECIAL TOOL REQUIRED - SHIFT SHAFT SEAL (208) - INSTALL USING J35823 - CLUTCH FORK SEAL (164) - NO SPECIAL TOOL REQUIRED - END PLATE-TO-CASE LEAKS (85/90) - BOLT TORQUE 21 NM (15 LB.FT.) - BACK-UP LIGHT SWITCH (B) - BOLT TORQUE 23 NM (24 LB.FT.) - SPEEDOMETER DRIVEN GEAR (C) - BOLT TORQUE 5.5 NM (4 LB.FT.) - TRANSAXLE DRAIN PLUG/WASHER - DRAIN PLUG TORQUE 24 NM (79/80) (15 LB.FT.) - FLUID LEVEL INDICATOR/WASHER - FULLY SEATED, NOT STRIPPED (100/101) - FILL PLUG AND WASHER (82/83) - FILL PLUG TORQUE 24 NM (15 LB.FT.) - PLUG (204), SHIFT RAIL - NO SPECIAL TOOL REQUIRED C. OUT-OF-CAR REPAIRS (REFER TO FIGURE 3 - SERVICEABLE PARTS ITEM NUMBER/GM PART NUMBER CROSS REFERENCE LIST). O OIL LEAK AT DETENT COVER (174) O CLUTCH FORK BUSHING REPLACEMENT (163/177) O CLUTCH FORK REPLACEMENT (165) O CLUTCH RELEASE BEARING SERVICE/REPLACEMENT (22) O ANY CLUTCH REPAIR/REPLACEMENT - SPECIAL TOOL REQUIREMENT: O BUSHING (163), USING J36037 (REMOVE/INSTALL) BUSHING (177), USING J36032 AND J23907 TO REMOVE/INSTALL USING J36033 AND J36190 O CLUTCH FORK (165), USING J36037 TO REMOVE/INSTALL BUSHING (163) NOTE: ANY REPAIR WHICH NECESSITATES SPLITTING THE CLUTCH HOUSING AND THE TRANSAXLE CASE (20/85) MUST BE SERVICED USING A SERVICE REPLACEMENT UNIT. D. ORDERING A SERVICE REPLACEMENT UNIT: O ORDER THE SERVICE REPLACEMENT TRANSAXLE THROUGH GM PARTS. O THE SERVICE REPLACEMENT UNIT WILL HAVE AN ENVELOPE ATTACHED TO IT. THIS ENVELOPE WILL CONTAIN: - RETURN SHIPPING LABEL - ADMINISTRATIVE PROCEDURES - MG1/MG2 REPORTING FORM - IDENTIFICATION TAG E. PREPARATION FOR SHIPPING (1) THE MG1/MG2 REPORTING FORM AND IDENTIFICATION TAG THAT HAVE BEEN PROVIDED WITH THE SERVICE REPLACEMENT UNIT MUST BE COMPLETELY FILLED OUT AND ATTACHED TO THE COMPLAINT UNIT. (2) CHECK FLUID LEVEL, SHIFT LINKAGE AND CLUTCH LINKAGE ADJUSTMENT AND NOTE FINDINGS ON ATTACHED MG1/MG2 REPORTING FORM. (3) IF TRANSAXLE LEAKS, CLEAN LEAK AREA, COVER AREA WITH POWDER, MARK LEAK AREA ON TRANSAXLE. NOTE ALL FINDINGS ON REVERSE SIDE OF THE MG1/MG2 REPORTING FORM (SEE LEAK CHART). (4) AFTER COMPLAINT UNIT HAS BEEN REMOVED: DRAIN OIL AND REINSTALL THE DRAIN PLUG. REMOVE ALL PLASTIC SHIPPING PLUGS FROM THE SERVICE REPLACEMENT UNIT AND REINSTALL IN THE COMPLAINT UNIT. (5) FOLD THE REPORTING FORM, STAPLE IT TO THE IDENTIFICAITON TAG, AND SECURE THE TAG TO THE CLUTCH HOUSING OF THE COMPLAINT UNIT. (6) PACKAGE THE COMPLAINT UNIT INTO THE SERVICE REPLACEMENT UNIT SHIPPING CONTAINER AND PLACE SHIPPING LABEL ON THE EXTERIOR OF THE CONTAINER. F. SHIPPING PROCEDURE. O USE A COMPLETED GMP83 REQUEST TO RETURN NEW UNSERVICEABLE PARTS AS THE PACKING SLIP TO RETURN THE CORE. NO OTHER STOCK SHOULD BE RETURNED ON THIS GMP83. ALL EDMONTON, MONCTON, VANCOUVER AND WINNIPEG SERVICED DEALERS ARE TO RETURN CORES, FREIGHT PREPAID, TO THEIR SERVICING PDC. ALL MONTREAL SERVICED DEALERS ARE TO RETURN CORES, FREIGHT PREPAID, TO: GENERAL MOTORS OF CANADA LIMITED C/O ENTREPOTS SCHENKER 2000 RUE HALPERN ST. LAURENT, P.Q. H4S 1N7 ALL WOODSTOCK SERVICED DEALERS ARE TO RETURN CORES, FREIGHT PREPAID, TO: GENERAL MOTORS OF CANADA LIMITED C/O SCHENKER WAREHOUSING 3220 CARAVELLE DRIVE MISSISSAUGA, ONTARIO L4V 1K9 UPON RECEIPT AND INSPECTION OF THE RETURNED CORE, A SUNDRY RETURN AUTHORIZAITON WILL BE PRODUCED AND RELEASED TO CREDIT YOUR ACCOUNT FOR THE CORE CHARGE. FIGURE 3. SERVICEABLE PARTS ITEM NUMBER GM PART NUMBER CROSS REFERENCE ITEM NUMBER NAME GM PART NUMBER 22 BEARING, CLUTCH RELEASE 14080591 23 SEAL, AXLE 8631156 79 PLUG, OIL DRAIN 14056604 80 WASHER 476755 81 BOLT (CASE TO C1 HSG) 11500923 82 WASHER 14080243 83 PLUG, FILL 476753 89 WASHER, OIL SLINGER 14092033 90 END PLATE, TRANSMISSION CASE 10051657 91 BOLT (END PLATE TO CASE) 10051637 100 WASHER 14080243 101 DIPSTICK (OIL LEVEL INDICATOR) 10051636 120 RETAINER, SELECTOR PIN 10040797 121 RETAINER, SELECTOR LEVER 10054291 122 PIN, SELECTOR LEVER PIVOT 14091786 123 BOLT 14060613 124 LEVER, SELECTOR 10054292 125 COLLAR, SHIFT SHAFT 14091789 126 PIN 11513384 127 LEVER, SHIFT 10038869 128 WASHER 14091790 129 NUT 11507027 130 RETAINER, SELECTOR LEVER 14091785 130 RETAINER, SELECTOR LEVER 14091794 131 PIN, SELECTOR LEVER PIVOT 14091786 132 BOLT 11508106 132 BOLT 11508106 133 LEVER, SELECTOR 14091781 134 COLLAR, SHIFT SHAFT 14091789 135 LEVER, SHIFT 14091787 136 WASHER 14091790 137 NUT 11507027 138 PIN 11513384 139 RING, SNAP 14080596 140 COVER, SHIFT SHAFT 14080595 163 BUSHING, UPPER CLUTCH FORK 14092055 164 SEAL, CLUTCH FORK 14092820 165 SHAFT, CLUTCH FORK 14092026 174 COVER, DETENT 14082039 177 BUSHING, LOWER CLUTCH FORK 14092054 204 PLUG, SHIFT RAIL 14080573 208 SEAL, SHIFT SHAFT 14080587

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