INFORMATION ON HYDRA-MATIC 4T40 - E - TRANSAXLE

SUBJECT: INFORMATION ON HYDRA-MATIC 4T40-E TRANSAXLE

MODELS: 1995 CHEVROLET CAVALIER 1995 PONTIAC SUNFIRE WITH 2.3L ENGINE (VIN D - RPO LD2) AND HYDRA-MATIC 4T40-E TRANSAXLE (RPO MN4)

HYDRA-MATIC 4T40-E TRANSAXLE PRODUCT INTRODUCTION

THE HYDRA-MATIC 4T40-E TRANSAXLE IS A NEW FOUR SPEED, FRONT WHEEL DRIVE, ELECTRONICALLY CONTROLLED TRANSAXLE USED IN THE 1995 CHEVROLET CAVALIER AND PONTIAC SUNFIRE WITH THE 2.3L DOHC (LD2) ENGINE.

THIS BULLETIN CONTAINS THE FOLLOWING INFORMATION REGARDING THE HYDRA- MATIC 4T40-E TRANSAXLE:

HYDRA-MATIC 4T40-E SERVICE POLICY

GOODWRENCH SERVICE REPLACEMENT TRANSMISSION ASSEMBLY (SRTA) PROGRAM INFORMATION AND TRANSAXLE CORE RETURN POLICY

SERVICE PARTS INFORMATION

HYDRA-MATIC 4T40-E TRAINING INFORMATION

GENERAL SERVICE GUIDELINES AND UNIQUE 4T40-E TRANSAXLE FEATURES

SERVICE POLICY

THE HYDRA-MATIC 4T40-E TRANSAXLE SERVICE POLICY IS DESIGNED TO PROVIDE VALUABLE PRODUCT INFORMATION TO GENERAL MOTORS POWERTRAIN DIVISION. THE SERVICE POLICY INCLUDES THREE DISTINCT TIME PERIODS WITH DIFFERENT SERVICE STRATEGIES. THESE DIFFERENCES ARE AS FOLLOWS:

START OF PRODUCTION (S.O.P.) THROUGH JULY 31, 1995: TRANSAXLE REPLACEMENT ONLY HYDRA-MATIC 4T40-E TRANSAXLES CAN ONLY BE SERVICED THROUGH THE GOODWRENCH SRTA PROGRAM. ON-VEHICLE SERVICE AND BENCH REPAIR OF THE TRANSAXLE ARE NOT ALLOWED BEFORE AUGUST 1, 1995.

AUGUST 1, 1995 TO JULY 31, 1996: LIMITED ON-VEHICLE SERVICE BEGINNING AUGUST 1, 1995, LIMITED ON-VEHICLE SERVICE WILL BE PERMITTED FOR HYDRA-MATIC 4T40-E TRANSAXLES. THE COMPONENTS INCLUDED FOR LIMITED ON-VEHICLE SERVICE ARE SHOWN IN FIGURE 2. ALL REPAIRS WHICH CANNOT BE CORRECTED WITH THE COMPONENTS SHOWN IN FIGURE 2 MUST USE A GOODWRENCH SRTA TRANSMISSION FOR THE REPAIR.

AUGUST 1, 1996: COMPLETE TRANSAXLE SERVICE BEGINNING AUGUST 1, 1996 THE HYDRA-MATIC 4T40-E TRANSAXLE CAN BE SERVICED COMPLETELY WITH REPLACEMENT COMPONENTS. HOWEVER, THE GOODWRENCH SRTA PROGRAM WILL CONTINUE TO BE AVAILABLE FOR REPAIRS THAT WARRANT A COMPLETE TRANSAXLE REPLACEMENT.

GOODWRENCH SRTA PROGRAM TRANSAXLE RETURNS

GOODWRENCH SRTA PROGRAM

GOODWRENCH SRTA TRANSMISSIONS ARE THE PRODUCT OF A HIGHLY SUCCESSFUL, CUSTOMER SATISFACTION DRIVEN PROGRAM THAT PARALLELS THE EXISTING HYDRA-MATIC 3T40, 4T60, 4T60-E, 4L60, 4L60-E, 4L80-E AND 4T80-E PROGRAMS.

GMSPO PARTS DISTRIBUTION CENTERS ARE COMMITTED TO A 48 HOUR MAXIMUM DELIVERY TIME FOR ALL GOODWRENCH SRTA MODELS WITH NO VIP CHARGES. (NINETY-SIX (96) HOURS FOR GM OF CANADA DEALERS.)

THE GOODWRENCH SRTA TRANSAXLE CONTAINS AN INFORMATION PACKET THAT INCLUDES LIMITED WARRANTY INFORMATION, TRANSAXLE CORE EXCHANGE RETURN PROCEDURE INFORMATION, AND A PRE-ADDRESSED RETURN MAILING ENVELOPE (FIGURE 3).

IT IS IMPORTANT THAT THE PRODUCT FEEDBACK FORM (FIGURE 4) BE PROPERLY COMPLETED BY THE TECHNICIAN OR SERVICE MANAGER AND INCLUDE ALL DIAGNOSTIC INFORMATION. THIS INFORMATION IS ESSENTIAL FOR PROPER ROOT CAUSE ANALYSIS. INSERT THE WHITE COPY OF THE COMPLETED FORM AND A COPY OF THE REPAIR ORDER INTO THE GOODWRENCH SRTA INFORMATION PACKET ENVELOPE, SEAL THE ENVELOPE AND WIRE TAG IT TO THE BELL HOUSING OF THE UNIT BEING RETURNED FOR TRANSAXLE CORE EXCHANGE. RETURN THE YELLOW COPY OF THE COMPLETED PRODUCT FEEDBACK FORM, USING THE POSTAGE PAID ENVELOPE, TO GM POWERTRAIN DIVISION.

TRANSAXLE CORE RETURN PROCESS DEALERS SHOULD EXPEDITE SHIPMENT OF THE TRANSAXLE CORE TO THE APPROPRIATE GMSPO PARTS DISTRIBUTION CENTER. A SPECIAL RETURN STICKER WILL BE ATTACHED TO THE TRANSAXLE CORE CONTAINER. THE DEALER MUST ADD THE APPROPRIATE DEALER CODE INFORMATION TO THE STICKER TO EXPEDITE THE CORE RETURN FOR ROOT CAUSE ANALYSIS AT GM POWERTRAIN.

SERVICE PARTS INFORMATION

GOODWRENCH SRTA MODEL REPLACEMENT CHART

SRTA PART NUMBER MODEL DESCRIPTION

24203573 5WLR 2.3L LD2 J-CAR

PARTS ARE CURRENTLY AVAILABLE FROM GMSPO.

PART NUMBERS ARE ACCURATE AT THE TIME OF PRINTING AND ARE SUBJECT TO CHANGE. REFER TO THE LATEST GMSPO PARTS CATALOG FOR PART NUMBERS OF GOODWRENCH SRTA TRANSAXLES AND SERVICE PARTS.

PARTS INFORMATION REGARDING THE LIMITED SERVICE COMPONENTS SHOWN IN FIGURE 2 WILL BE AVAILABLE PRIOR TO AUGUST 1, 1995.

HYDRA-MATIC 4T40-E TRAINING INFORMATION

TECHNICIAN'S ARE REQUIRED TO COMPLETE THE HYDRA-MATIC 4T40-E CERTIFIED PLUS TRAINING (CPT) TRAINING COURSE. CPT IS AN IN- DEALERSHIP PRODUCT TRAINING PROGRAM ON VIDEOTAPE PRODUCED BY THE GM SERVICE TECHNOLOGY GROUP. THE CPT PROGRAM IS AN EXTENSION OF GM TRAINING CENTER CLASSROOM TRAINING.

CPT KITS INCLUDE A VIDEOTAPE, COURSEBOOK AND TEST ANSWER SHEETS. CPT KITS ARE SENT DIRECTLY TO THE DEALERSHIP'S SERVICE MANAGER, MAKING THE PROGRAM EASILY ACCESSIBLE.

GENERAL SERVICE GUIDELINES AND UNIQUE TRANSAXLE FEATURES

COOLER FLUSHING TRANSAXLE OIL COOLER FLUSHING MUST BE PERFORMED WHENEVER A TRANSAXLE IS REMOVED FROM THE VEHICLE FOR SERVICE OR IF FLUID CONTAMINATION IS SUSPECTED. USE KENT-MOORE TOOL J 35944-A AND SOLVENT J 35944-22 TO FLUSH THE COOLER. INSTRUCTIONS FOR USING THE COOLER FLUSHING TOOL ARE PUBLISHED IN THE TRANSAXLE ON-VEHICLE SERVICE SECTION OF EACH SERVICE MANUAL.

FLUID LEVEL SERVICE PROCEDURE (FIGURE 6) THE HYDRA-MATIC 4T40-E TRANSAXLE DOES NOT HAVE A FLUID LEVEL INDICATOR. THE TRANSAXLE FLUID LEVEL IS CHECKED BY REMOVING THE OIL LEVEL CONTROL PLUG IN THE TRANSAXLE CASE. FIGURE 6 PROVIDES A DETAILED PROCEDURE FOR CHECKING OR SETTING THE TRANSAXLE FLUID LEVEL.

THE HYDRA-MATIC 4T40-E TRANSAXLE IS FILLED WITH DEXRON(R) III AUTOMATIC TRANSMISSION FLUID. IT IS IMPORTANT THAT ONLY DEXRON(R) III TRANSMISSION FLUID BE USED WITH THE HYDRA-MATIC 4T40-E TO MAINTAIN THE APPROPRIATE TRANSAXLE SHIFT CHARACTERISTICS.

FASTENERS THE HYDRA-MATIC 4T40-E TRANSAXLE IS ASSEMBLED WITH SELF-THREADING FASTENERS. DURING TRANSAXLE SERVICE IT IS IMPORTANT TO FOLLOW THE SERVICE GUIDELINES LISTED BELOW:

IMPORTANT: THE 1995 4T40-E SERVICE MANUAL SECTION STATES THAT STANDARD FASTENERS WOULD BE AVAILABLE FOR SERVICE. THIS INFORMATION IS INCORRECT. SELF-THREADING FASTENERS WILL BE AVAILABLE FOR SERVICE. THE SERVICE MANUAL SHOULD BE CORRECTED TO REFLECT THIS CHANGE.

INSPECT THE FASTENERS AND FASTENER HOLE THREADS FOR DAMAGE AND REPAIR OR REPLACE COMPONENTS AS NECESSARY.

NOTICE: ALWAYS HAND START FASTENERS TO PREVENT CROSS-THREADING.

NOTICE: DO NOT USE AIR TOOLS TO INSTALL ANY FASTENERS. THIS IS PARTICULARLY IMPORTANT WITH SELF-THREADING FASTENERS THAT WILL DAMAGE COMPONENTS IF THEY ARE CROSS-THREADED OR NOT TIGHTENED PROPERLY.

NOTICE: DO NOT USE AIR TOOLS TO REMOVE ANY FASTENERS. USING AIR TOOLS MAY DAMAGE THE THREADED HOLE.

THOROUGHLY CLEAN THE FASTENERS AND FASTENER HOLES OF ANY DEBRIS THAT MAY HAVE BEEN CREATED BY THE THREAD FORMING PROCESS.

AXLE SEALING SYSTEM (FIGURE 7) THE HYDRA-MATIC 4T40-E TRANSAXLE HAS A UNIQUE TWO PIECE AXLE SEALING SYSTEM. THIS DESIGN INCLUDES BOTH AN AXLE SEAL PRESSED INTO THE TRANSAXLE CASE AT EACH END AND A SLEEVE PRESSED ONTO EACH OF THE TWO OUTPUT SHAFTS. THE LEFT HAND SHAFT IS REFERRED TO AS THE OUTPUT SHAFT AND THE RIGHT HAND SHAFT IS REFERRED TO AS THE STUB SHAFT.

THE AXLE SEAL IS SIMILAR TO OTHER AXLE SEAL DESIGNS. HOWEVER, THE TRANSAXLE IS SEALED BY THE OUTPUT AND STUB SHAFT SLEEVES RIDING AGAINST THE AXLE SEALS. A TRANSAXLE FLUID LEAK WILL DEVELOP IF EITHER AN AXLE SEAL OR SHAFT SLEEVE IS DAMAGED.

FIGURES: 7 ATTACHMENTS: 0

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.

COPYRIGHT 1995 GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.