CAMPAIGN: 3T40 PISTON SEAL INTERMEDIATE SERVO COVER

Subject: PRODUCT CAMPAIGN 90C34 TRANSAXLE INTERMEDIATE SERVO COVER PISTON BORE

Model and Year: 1990 CHEVROLET CAVALIER, BERETTA AND CORSICA WITH 2.5L ENGINE (VIN CODE U) AND 3T40 TRANSAXLE (RPO MD9)

TO: ALL CHEVROLET DEALERS

General Motors has determined that certain 1990 Chevrolet Cavalier, Beretta and Corsica model vehicles equipped with 2.5L engines and 3T40 transaxles 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, causing a leak in the second clutch circuit (intermediate servo apply) . This leak may cause intermediate band and direct clutch wear, and result in 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 Chevrolet Cavalier, Beretta and Corsica model vehicles equipped with 2.5L engines and 3T40 transaxles built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ---------- ----- -------- ---------- 1990 J-Car Janesville "J" LJ305686 LJ313136

1990 L-Car Wilmington "Y" LY259395 LY266181

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 (Service Replacement Transaxle Assembly) Transaxle.

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 Chevrolet Motor Division (see copy of owner letter included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

Dealers are to service all vehicles subject to 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.

PARTS 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).

Quantity/ Part Number Description Vehicle ------------- ------------------------ ------- 08681967 Intermediate Servo Cover Kit 1

Each Kit Contains:

Intermediate Servo Piston & Seals (Assembly) 1 Intermediate Servo Piston (.64 ratio) 1 Intermediate Servo Piston Inner Seal 1 Intermediate Servo Piston Outer Seal 1 Intermediate Servo Cover & Gasket 1 3rd Accumulator Exhaust Valve and Spring (Assy) 1 3rd Accumulator Valve 1 3rd Accumulator Spring 1 Fluid Pan Gasket 1

0AYC 08665993 Service Replacement Transmission If Required Assembly (SRTA) - For Cavalier Model Vehicles

0LYC 08665994 Service Replacement Transmission If Required Assembly (SRTA) - For Beretta And Corsica Model Vehicles

It is expected that only about 11% of inspected vehicles will require replacement of the intermediate servo cover. Be certain to order parts accordingly.

SERVICE PROCEDURE

NOTICE: Two (2) sets of figures have been provided for the following procedure. Figures on page 5 are for Cavalier model vehicles, while the figures on page 6 reference Beretta and Corsica model vehicles.

1. Inspect Transaxle ID Plate (see Figure 1). If Julian Dates are within the range 194 through 200, inclusive (July 13, 1990 through July 19, 1990), proceed to Step 2. If Julian Dates are not within the range 194 thru 200, skip to Step 4 and install a Campaign Identification Label.

2. If vehicle odometer reads less than 12,000 miles, skip to Step 3 and install intermediate servo cover kit as instructed.

If vehicle odometer reads 12,000 miles or more, perform the following drive audit:

A. Start vehicle and let idle on a flat surface for three (3) minutes.

B. Verify correct transaxle fluid level and fluid color.

C. Drive 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 coast-down shifts.

D. Verify vehicle has correct reverse engagement and no slippage in reverse range.

E. During drive audit, the driver should not feel any slips and/or bumps in transaxle operation.

If vehicle has normal transaxle operation, proceed to Step 3 and install intermediate servo cover kit, as instructed.

If vehicle does not have normal transaxle operation, replace transaxle with a Hydra-Matic 3T40 SRTA (Servo Replacement Transmission Assembly - J-Cars = 0AYC 8665993 or L-Car = 0LYC 8665994), following instructions and cautions listed in appropriate vehicle Service Manual, Section 7A.

If transaxle is replaced, please reset memory functions for owner, or advise owner that these memory functions were lost due to disconnection of battery.

NOTICE: Cooler flushing MUST be performed; the time allowance for Transaxle Removal and Replacement provides for this.

If transaxle is replaced, do NOT install intermediate servo cover kit.

3. Install Intermediate Servo Cover Kit as follows:

A. Raise vehicle and suitably support (see section 0A in appropriate service manual.

B. Remove fluid pan and gasket.

C. Remove strainer and multi-lip seal. Save both parts for reinstallation.

D. Remove reverse fluid pipe retainers and bolts (Fig. 2, 140-143).

E. Remove intermediate servo cover (Fig. 2, 137) and gasket (Fig. 2, 136).

F. Remove third accumulator exhaust valve (Fig. 2, 126) and exhaust spring (Fig. 2, 125).

G. Remove intermediate servo assembly (Fig. 2, 128-135).

H. Install new seals (Fig. 2, 132 & 134) on new intermediate servo piston (Fig. 2, 133) from kit. Transfer parts (Fig. 2, 128-131 & 135) to new intermediate servo piston to make a new intermediate servo assembly.

I. Install new third accumulator exhaust valve (Fig. 2, 126) and exhaust spring (Fig. 2, 125).

J. Install new intermediate servo cover and new gasket.

K. Reinstall reverse fluid pipe retainers and bolts (Fig. 2, 140-143). Torque bolts to 24 Nm (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 bolts to 11 Nm (96 lb. in.).

N. Adjust fluid level as required.

4. Install 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.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

FAILED PARTS CC-FC LABOR LAB OTH NET REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS AMT -------------------- -- ------- ----- ----- ------ --- --- --- Inspect Transaxle ID Plate Only - No - -- -- SK-00 V6550 0.2 0.1 -- Repair & No Drive Audit Required

Inspect Transaxle ID Plate and Install 1 08681967 ** SK-00 V6551 0.6 0.1 $## Kit (No Drive Audit)

Inspect Transaxle ID Plate, Perform Drive 1 08681967 ** SK-00 V6552 1.1 0.1 $## Audit and Install Kit

Inspect Transaxle ID Plate, Perform Drive Audit and Replace 1 08665993 ** SK-00 V6553 5.0 0.1 $## Transaxle With Hydra-Matic 3T40 SRTA Assy. (No Kit)

* Campaign Administrative Allowance.

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.

*** The $## identified in the "Net Amount" column should represent the cost plus 30% for transaxle fluid used in conjunction with labor operations V6551, V6552 & V6553.

Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim Submission.

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.