TRANSFER CASE DIAGNOSTIC AND EXCHANGE PROCEDURE. Chevrolet Chevy K Pickup

REVISION 02/01/90

THIS BULLETIN CANCELS AND REPLACES BULLETIN NUMBER 867401R TO INCLUDE THE 1990 MODEL YEAR AND THE 4470 TRANSFER CASE.

REVISION 09/10/93

THIS BULLETIN IS BEING REVISED TO CANCEL THE EXCHANGE PROGRAM. THIS BULLETIN WILL NOT BE PUBLISHED. ----------------------------------------------------------------------

SUBJECT: TRANSFER CASE DIAGNOSTIC AND EXCHANGE PROCEDURE

MODELS: 1989-90 K3 TRUCKS EQUIPPED WITH BORG-WARNER 1370 OR 4470 TRANSFER CASE

********************************************************************** * ALL COPIES OF THE FOLLOWING BULLETINS SHOULD BE DESTROYED: *

* DIVISION BULLETIN # PUBLISHED DATE * * * * GMC TRUCK 93-7D-34 FEBRUARY 1990 * * CHEVROLET 90-193-7D JUNE 1990 * * GM OF CANADA 90-7-103 MARCH 1990 * **********************************************************************

EFFECTIVE JUNE 1, 1993 THE EXCHANGE PROGRAMS FOR BORG-WARNER 1370, 4401, 4470, AND 4472 ENDED. DEALERSHIPS WILL ASSUME RESPONSIBILITY FOR REQUIRED SERVICE ON THE TRANSFER CASES AFTER JUNE 1, 1993.

SERVICE ACTION

1. GENERAL MOTORS SERVICE TRAINING: ALL WHEEL DRIVE / FOUR WHEEL DRIVE SYSTEMS - COURSE NUMBER 14003.04 (2 DAY CLASS) AVAILABLE AT YOUR LOCAL TRAINING CENTER.

2. ESSENTIAL SERVICE TOOLS: ALL ESSENTIAL TOOLS ARE IN DEALERSHIPS.

3. SERVICE PARTS: ALL SERVICE PARTS ARE AVAILABLE THROUGH GMSPO.

4. LABOR TIME GUIDE: THE LABOR TIME GUIDE INCLUDING INFORMATION FOR BORG-WARNER TRANSFER CASES IS COMPLETE AND IN DEALERSHIPS.

5. SERVICE MANUALS: ON-VEHICLE SERVICE INFORMATION IS AVAILABLE IN THE APPROPRIATE YEAR SERVICE MANUAL. TRANSFER CASE OVERHAUL INFORMATION IS AVAILABLE IN THE APPROPRIATE YEAR LIGHT DUTY TRUCK UNIT REPAIR MANUAL OR SERVICE MANUAL.

FIGURES: 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.

THIS BULLETIN COVERS:

* PRELIMINARY DIAGNOSIS AND EXCHANGE PROCEDURE FOR THE 1370 AND 447 TRANSFER CASES.

* IN ORDER TO GIVE NEEDED PRODUCT FEEDBACK ANY 1370 OR 4470 TRANSFE CASE NEEDING WARRANTY REPAIR WILL BE EXCHANGED FOR A REPLACEMENT UNIT.

IMPORTANT: CUSTOMER PAY UNITS REQUIRING REPAIR CAN CONTINUE TO BE SERVICED USING INDIVIDUAL PARTS AVAILABLE THROUGH GMSP

SERVICE INFORMATION:

* PRELIMINARY DIAGNOSIS PROCEDURE:

- INSURE THAT THE CLUTCH COIL RELAY (MOUNTED TO THE COWL, UNDE THE HOOD) IS PRESENT AND PROPERLY MOUNTED. REFER TO SECTION 7D OF SERVICE MANUAL X-9031.

- REFER TO SERVICE MANUAL X-9031 DIAGNOSTIC CHARTS.

- INSURE CORRECT OIL FILL.

- INSURE THE TRANSFER CASE SHIFT LINKAGE IS PROPERLY ADJUSTED.

- INSURE THE SHIFT LINKAGE IS FREE AND NOT BLOCKED BY THE WIRING CABLE.

- INSURE ALL WIRING CONNECTIONS ARE MAKING GOOD CONTACT AND AR PROPERLY SEATED.

- INSURE ALL ENGINE AND TRANSMISSION MOUNTS ARE TIGHT.

- CHECK FOR PROPER TIRE INFLATION.

EXCHANGE PROCEDURE:

1. REFERENCE FIGURES NO. 1, 2 AND 3, AND HAVE INFORMATION AVAILABLE BEFORE CALLING. IF THE VEHICLE HAS AN OIL LEAK, DETERMINE WHERE THE LEAK IS BY USING THE OIL LEAK IDENTIFICATION CHART. THE NOISE AND SHIFTING CHARTS CAN BE FILLED OUT BY USING CHECK MARKS IT IS NECESSARY TO RECORD THIS INFORMATION AS IT WILL BE NEEDED TO FILL OUT THE FORM ON THE TRANSFER CASE BEING RETURNED. (BLANK FORMS WILL BE SHIPPED WITH EXCHANGE UNIT.) RECORD THE GM PART NUMBER, THE BORG-WARNER PART NUMBER, AND THE UNIT SERIAL NUMBER FROM THE I.D. TAG LOCATED AT THE REAR OF THE TRANSFER CASE.

2. CALL GMC TECHNICAL ASSISTANCE. GMC - TAC WILL ARRANGE WITH BORG-WARNER AUTOMOTIVE TO SHIP AN EXCHANGE UNIT WITHIN ONE WORKING DAY (24 HOURS).

3. DEALERSHIPS WILL BE PROVIDED WITH AN AUTHORIZATION NUMBER BY BOR WARNER. THIS NUMBER MUST BE WRITTEN ON THE TRANSFER CASE IN BLAC MARKER BEFORE ITS RETURN. IF THE CASE IS EXCESSIVELY GREASY, WRITE THE AUTHORIZATION NUMBER ON A TAG AND ATTACH IT TO THE CAS WITH WIRE.

4. ONCE AN EXCHANGE UNIT IS RECEIVED, THE REPLACED UNIT IS TO BE RETURNED TO BORG-WARNER AUTOMOTIVE WITHIN 8-10 DAYS TO AVOID A CHARGEBACK. A RETURN SHIPPING LABEL WILL BE SENT WITH THE EXCHANGE UNIT.

5. THE REPLACED UNIT MUST BE RETURNED COMPLETE AS REMOVED FROM THE VEHICLE WITHOUT ANY DISASSEMBLY OF THE UNIT. DEALERSHIPS RETURNING UNITS EVEN PARTIALLY DISASSEMBLED (EXCLUDING REMOVAL OF SHIFT LEVER LINKAGE DURING REMOVAL OF THE UNIT), WILL BE SUBJECT TO BEING BILLED FOR MATERIALS FURNISHED.

6. THE EXCHANGE UNIT WILL HAVE A PLASTIC BAG ATTACHED TO IT. THIS BAG WILL CONTAIN:

* RETURN SHIPPING LABELS

* REPORTING FORM

* RETURN SHIPPING CARRIER INFORMATION

* IDENTIFICATION TAG

* LEAK IDENTIFICATION CHART

PREPARATION FOR SHIPPING:

1. DRAIN ALL OIL FROM UNIT.

2. REMOVE ALL PLASTIC SHIPPING PLUGS AND COVERS FROM THE REPLACEMENT UNIT AND INSTALL THEM ON THE REPLACED UNIT.

3. PLACE THE REPORT FORM, THE IDENTIFICATION FORMS, AND A COPY OF THE REPAIR ORDER IN THE ENCLOSED PLASTIC BAG. ATTACH THE BAG AN THE IDENTIFICATION TAG TO THE COMPLAINT UNIT WITH ENCLOSED WIRE.

4. WRITE THE AUTHORIZATION NUMBER ON THE CASE COVER OF THE COMPLAIN UNIT.

5. REPACK THE COMPLAINT UNIT INTO THE ORIGINAL SHIPPING CONTAINER.

6. PLACE THE SHIPPING LABEL ON THE ORIGINAL SHIPPING CONTAINER.

IMPORTANT: ALL RETURN SHIPPING IS COD TO BORG-WARNER.

EXCHANGE UNITS ARE COMPLETE LESS SHIFT TOWER AND LINKAGE.

WARRANTY INFORMATION:

FOR REPAIRS PERFORMED UNDER WARRANTY, CLAIMS MAY BE SUBMITTED FOR R&R LABOR, DEXTRON II FLUID, AND MISCELLANEOUS PARTS, IF REQUIRED. REPLACEMENT TRANSFER CASES WILL BE SHIPPED TO THE DEALER ON A NO-CHARGE BASIS.

A COPY OF THE CREDIT MEMO PERTAINING TO THE REPLACEMENT, WITH THE OPERATION HIGHLIGHTED, AS WELL AS THE PROOF OF SHIPMENT TO BORG-WARNE BE SENT TO:

WARRANTY PROCESSING DEPT. GMC TRUCK 16 JUDSON ST. PONTIAC, MI 48058

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OPERATION TIME *PARTS NUMBER DESCRIPTION ALLOWANCE ALLOWANCE ----------- -------------- ------------- -----------

K4410 TRANSFER CASE 1.3 HRS. $129.20 ASSEMBLY REPLACE 1370

K4410 TRANSFER CASE 1.3 HRS. $178.97 ASSEMBLY REPLACE 4470

ADD 0.2 HRS. IF EQUIPPED WITH SKID PLATE.

* THE AMOUNT IDENTIFIED IN THE "PARTS ALLOWANCE" COLUMN ABOVE REPRESENTS 30% OF DEALER NET FOR PARTS THAT WERE FURNISHED BY BORG-WARNER. THIS AMOUNT IS TO BE PLACED IN THE NET ITEM AMOUNT COLUMN OF THE CLAIM AND TYPE CODE "M".