4L80 TRANS. TORQUE CONVERTER DAMPNER SPRING FRACTURED
Subject: PRODUCT CAMPAIGN 91C02 TORQUE CONVERTER DAMPER SPRING
Model and Year: 1991 R/V 2500 SUBURBANS AND R/V 3500 CREW CABS EQUIPPED WITH ELECTRONIC AUTOMATIC TRANSMISSIONS (FLINT ASSEMBLY PLANT ONLY)
TO: ALL CHEVROLET DEALERS
General Motors has determined that all 1991 R/V 2500 Suburbans and R/V 3500 Crew Cabs shipped prior to August 18, 1990 from the Flint Assembly Plant and equipped with electronic automatic transmissions have torque converters with suspect damper springs. These damper springs may fracture near the tip end resulting in noise and possible transmission failure.
To prevent these transmissions from failing, it will be necessary to install a new torque converter.
VEHICLES INVOLVED
Involved are all 1991 R/V 2500 Suburbans and R/V 3500 Crew Cabs shipped prior to August 18, 1990 from the Flint Assembly Plant and equipped with electronic automatic transmissions within the following VIN breakpoints:
YEAR MODEL PLANT FROM THROUGH
1991 R/V 2500 Flint MF101270 MF104800 Suburban
1991 R/V 3500 Flint MF300005 MF300226 Crew Cab
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 correc- tion 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 --------- ------------------ -------- 08674193 Torque Converter - 1 5.7L or 6.2L Engines
08674194 Torque Converter 1 7.4L Engine
08661760 Turbine Shaft 0-ring Seal 1
01259475 Dipstick Tube Seal 1
01051855 Transmission Fluid As Required
SERVICE PROCEDURE - Note: 1991 R/V Model Service Manuals should begin arriving in dealerships around September 14.
Tool Required: J-21366 Converter Holding Strap
1. Remove negative battery cable.
2. Raise vehicle.
3. Drain transmission fluid (transmission pan seal is reusable).
4. Remove shift linkage.
5. Remove Propeller Shaft(s). Refer to "Propeller Shaft", Section 4A, 1991 R/V Model Service Manual.
6. Remove support bracket at catalytic converter and any other components as needed for clearance. Support transmission, and transfer case if equipped, with a transmission jack.
7. Remove transmission cross member.
8. Lower transmission far enough for clearance to reach other components.
NOTICE: Do not stretch or damage any wires or other components when lowering transmission.
9. Remove transmission dipstick tube and seal. Cover opening in trans- mission.
10. Disconnect electrical connectors from the transmission.
NOTICE: Do not bend or damage connector pins.
11. Remove cooler lines. Cap openings in transmission and lines.
12. Disconnect transfer case shifter (if equipped) and move aside. Refer to "Transfer Casell, Section 7D, 1991 R/V Model Service Manual.
13. Remove Transmission support brace. Be sure to note location of braces as they must be reinstalled in same positions.
14. Remove converter housing cover.
15. Remove torque converter to flexplate bolts.
NOTICE: Support engine with jack or hoist before disconnecting transmission.
16. Remove transmission to engine bolts. Note location of any brackets or braces and move aside. Slide transmission straight back off locating pins and install J-21366 Converter Holding Strap.
17. Remove Transmission from vehicle.
18. Remove holding strap and converter.
NOTICE: Converter is extremely heavy (65 lbs.) when full of fluid. Make sure you have a good, clean grip to help prevent personal injury.
19. Remove turbine shaft 0-ring seal.
20. Install new turbine shaft 0-ring seal.
21. Install new converter assembly as follows:
a. With transmission in horizontal position, push new converter in until the hub is into converter seal.
NOTICE: Take care not to cut seal when installing converter.
b. Rotate transmission to a vertical position (Bell housing facing up).
c. Rotate converter until it drops into position.
22. Install transmission assembly as follows:
a. Attach J-21366 converter holding strap to converter assembly.
b. Raise transmission into place and remove J-21366.
NOTICE:- Do not pinch or damage any wires or other components when raising transmission.
c. Slide transmission straight onto locating pins while lining up torque converter and flexplate.
NOTICE: Torque converter must be flush onto flywheel and rotate freely by hand.
23. Install Transmission to engine bolts. Torque to 44 Nm. (33 lbs. ft.).
24. Position all brackets, clips and harnesses as when removed. Do not re- install transmission dipstick tube or transmission support brace bolts.
25. Install torque converter to flexplate bolts. Torque to 44 Nm (33 lbs. ft.).
26. Remove engine support.
27. Install converter housing cover. Hook pan under lip of engine oil pan. Torque bolts to 7 Nm. (60 lbs. in.).
28. Install transmission support braces. Braces must be installed in same positions as when removed. Torque bolts to 90 Nm. 66 lbs. ft. .
29. Install transfer case shifter (if equipped). Refer to "Transfer Case", Section 7D, 1991 R/V Model Service Manual.
30. Uncover transmission and cooler line openings, and install cooler lines. Do not bend or twist lines. Torque fittings to 38 Nm. (28 lbs. ft.).
31. Reconnect electrical connectors to transmission.
NOTICE: Do not bend or damage connector pins.
32. Uncover dipstick tube opening and install new seal.
33. Install dipstick tube with retainer bolt. Torque bolt to 44 Nm. (33 lbs. ft.).
34. Install transmission cross member, transmission mount, and any other components which were removed for clearance. Torque cross member and transmission mount bolts to 44 Nm. (33 lbs. ft.). Remove transmission jack.
35. Install support bracket at catalytic converter.
36. Install propeller shaft(s). Refer to "Propeller Shaft", Section 4A, 1991 R/V Model Service Manual.
37. Reinstall shift linkage.
38. Add new transmission fluid.
39. Install negative battery cable.
40. 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 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:
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FAILED PARTS CC-FC LABOR LAB OTH NET REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS AMT
Remove & Replace 3 08674193 ** SK-00 V6350 3.0 0.1 $#.## Torque Converter 2WDI
Remove & Replace 3 08674193 ** SK-00 V6351 3.9 0.1 $#.## Torque Converter 4WDI
*Campaign Administrative Allowance of 0.1 hrs. Add 0.2 hrs. for vehicles equipped with skid plates as needed after obtaining Wholesale Authorization "E".
**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 "Net Amount" column should represent transmission fluid used in conjunction with the above labor operations.
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.
Chevrolet bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer." They are written to inform these 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 has that condition. See your Chevrolet dealer for information on whether your vehicle may benefit from that information.
Dear Chevrolet Owner:
This notice is sent to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.
REASON FOR THIS RECALL
General Motors has determined that 1991 R/V 2500 Series Suburbans and R/V 3500 Series Crew Cabs shipped prior to August 18, 1990 from the Flint Assembly Plant and equipped with electronic automatic transmissions have torque converters with suspect damper springs. These damper springs may fracture near the tip end resulting in noise and possible transmission failure. WHAT WE WILL DO
To prevent these transmissions from failing, it will be necessary to install a new torque converter. This service will be performed for you at no charge.
WHAT YOU SHOULD DO
Please contact your Chevrolet dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle.
The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.
