CAMPAIGN: AUTO TRANS REAR INTERNAL GEAR (REPLACE GEAR)

Subject: PRODUCT CAMPAIGN 92C24 (a) - 4L80-E OR 4L80-EHD ELECTRONIC 4-SPEED AUTOMATIC TRANSMISSION REAR INTERNAL GEAR -SUPPLEMENT-

Model and Year: 1992 C/K TRUCKS, P30 TRUCKS AND G VANS

This supplement revises the PARTS INFORMATION, SERVICE PROCEDURE and CLAIM INFORMATION sections of Chevrolet Product Campaign Bulletin 92C24, dated July, 1992. Specifically, the incorrect Rear Internal Gear Package Part Number was listed for transmission model DNP, Steps 5, 13, 29, 30, 33, 47 & 48 have been revised and labor operation V7496 was repeated for two operations. In addition, V7492 now clarifies Heavy Duty C Trucks as vehicles between 12,000-15,000 lbs. GVW. The corrected PARTS INFORMATION, SERVICE PROCEDURE and CLAIM INFORMATION sections are shown below with revised information shown in bold type and denoted with a # sign.

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 ----------- ----------- --------- * 08687940 Rear Internal Gear Repair Package 4L8O-EHD 1

(For Trans. Models: BMP, BNP, DNP, DPP, DRP, LLP, BYP, BZP)

* 08687939 Rear Internal Gear Repair Package 4L80-E 1

(For Trans. Models: ABP, ACP, AFP, AJP, BAP, BJP, MBP, MKP, MPP, BSP, BUP, MAP, MJP, MLP, MHP, DCP, DLP, HTP, TWP, TSP, LAP, LFP)

08683922 Greased Output Shaft Sleeve & Seal Assembly 1

(For C Trucks And G Vans With Trans. Models AJP, AFP, MJP, MKP, MLP, MPP, HTP and TSP)

12345881 Dexron II-E Automatic Transmission Fluid 7 Quarts

* Denotes Change

Order only one rear internal gear repair package per vehicle based on the transmission model type. Transmission model type is identified by the model code on the transmission as illustrated below.

Note that each rear internal gear repair package (PIN 08687940 or 08687939) consists of two layers of parts. The contents of each layer are listed below.

1st Layer: Center Support, Center Support Bolt, Rear Internal Gear, Pump Assembly Bolts, Filter Assembly, Converter Seal Assembly, 4th Clutch Bolt, Small Package With Oil Fill Tube Multi-Lip Seal, Manual Shift Shaft Seal Assembly & Force Motor Feed Filter Assembly.

2nd Layer: (Under Cardboard Insert) Center Support Seal Rings, Pump Gasket, Pump Seal, Rear Servo Cover Gasket, And Valve- Body-To-Case Gasket.

Notice: The previous center support and rear internal gear must be discarded after the normal warranty retention period. Do not reuse these parts.

Also, some parts in kits 08686940 and 08687939 will not be installed as part of the procedures in this bulletin.

* SERVICE PROCEDURE -----------------

* Notice Regarding Tools Required: -------------------------------- A drift may be used in place of J-23093

* 5. Remove converter assembly (1) after removing torque converter holding strap J-21366.

Notice: Torque converter is extremely heavy (approx. 65 lbs.), personal injury may result

Do not drain fluid from torque converter unit.

13. Remove Valve-body-to-case gasket (48).

* Notice: Do not disassemble valve body and accumulator housing assembly unless it is required.

29. Install new seal rings (639) to new center support (640) using J38735. Reuse piston (636), seals (637 & 638), spring & retainer assembly (635), and snap ring (634) using J-23327 and J-38734 and install to center support.

Notice: Inspect center support for orifice cup plug (530). If plug is not there, order a new center support package (P/N #08680914).

30. Install new rear internal gear (666) to main shaft (662) with snap ring.

* Notice: Inspect the rear internal gear for the gear teeth spline angle. Be sure that new gear has same gear teeth angle.

33. Align center support (640) using J-23093.

a. Locate J-23093 into center support direct clutch passage through case.

b. Apply pressure on J-23093, seating center support splines counterclockwise against case splines (push tool toward rear servo bore).

C. Install new center support bolt (25) and torque to 43 Nm (32 lb. ft.). DO NOT OVER TORQUE.

* Notice: When tightening center support bolt (25), be sure bolt is completely seated to bottom of case.

47. Install check balls (54) in proper location.

* Notice: Do not use a magnet to install check balls. Magnet could cause a check ball to become magnetized and cause metal particles to stick to the ball. The #2 position SHOULD NOT have a check ball installed at that location (if necessary reference Unit Repair Manual 4L80-E-58 Figure 108 for proper locations).

48. Install new valve-body-to-case gasket (48).

* Notice: Check to see if valve-body-to-case gasket (48) is properly lined up with case bolt holes. If not, order a new valve-body-to-case gasket (P/N # 08680593)

* 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 ---------------- -- -------- ------ ----- ----- ---- --- ----

Install New Rear Internal Gear - C Truck - Sleeve & 1 08687939 ** SK-00 V7490 4.4 0.1 $ Seal Assembly Not Required

Install New Rear Internal Gear - C Truck - Sleeve 2 08687939 ** SK-00 V7491 4.6 0.1 $ Seal Assembly Recruired

Install New Rear Internal Gear - 1 08687940 ** SK-00 V7492 4.6 0.1 $ C Truck-Heavy Duty (12000-15000# Gvw)

Install New Rear Internal Gear - 1 08687939 ** SK-00 V7493 5.8 0.1 $ K Truck - Without Skid Plate

Install New Rear Internal Gear - 1 08687939 ** SK-00 V7494 6.1 0.1 $ K Truck - With Skid Plate

Install New Rear Internal Gear - G Van - Sleeve & 1 08687939 ** SK-00 V7495 4.1 0.1 $ Seal Assembly Not Required

Install New Rear Internal Gear - G Van - Sleeve & 2 08687939 ** SK-00 V7496 4.3 0.1 $ Seal Assembly Recruired

Install New Rear Internal Gear - 1 08687939 ** SK-00 V7497 4.6 0.1 $ P Truck

Notice: All labor times include 0.3 hrs. for test driving vehicle after campaign repair is performed.

* 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 $ shown in the "Net Amount" column represents 7 quarts of transmission fluid used to perform the required campaign repairs.

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.