1980-81 CITATION 4-SPEED MANUAL TRANSAXLE INSPECTION

THIS BULLETIN IS BEING REISSUED TO CORRECT THE DIFFERENTIAL CASE NUMBER AS SHOWN ON PAGE 2. THE PROPER DIFFERENTIAL CASE SERVICE PART NUMBER IS 463058.

WHEN REPAIRING 1980 OR 1981 CITATION MANUAL TRANSAXLES FOR EITHER SHIFT FORK WEAR OR AXLE SHAFT SEAL LEAKS DUE TO SIDE GEAR/CASE WEAR, AN INSPECTION SHOULD BE MADE FOR BOTH CONDITIONS TO DETERMINE WHAT THE EXTENT OF REPAIR SHOULD BE.

THE FOLLOWING PROCEDURES SHOULD BE ADHERED TO WHEN MAKING SUCH REPAIRS.

SHIFT FORK WEAR

CONDITIONS OF WORN 76MM TRANSAXLE SHIFT FORKS (BOTH 1-2 AND 3-4) HAVE BEEN FOUND TO BE CAUSED BY THE SHIFT FORK GROOVE SURFACE FINISH IN THE SYNCHRONIZER ASSEMBLY. TO CORRECT A WORN SHIFT FORK CONDITION, REPLACEMENT OF THE 1-2 SYNCHRONIZER ASSEMBLY WITH NEW P/N 14062629 OR 3-4 SYNCHRONIZER ASSEMBLY WITH NEW P/N 14062631, TOGETHER WITH THE SHIFT FORK, IS MANDATORY.

WHILE THE OLD SYNCHRONIZER ASSEMBLY MIGHT APPEAR TO BE REUSEABLE, THE SHIFT FORK GROOVE IN THE SYNCHRONIZER ASSEMBLY WILL CONTAIN MICROSCOPIC BURRS FROM RUNNING METAL-TO-METAL WITH THE FORK AND WILL CAUSE CONDITION TO RECUR.

THE NEW SYNCHRONIZER ASSEMBLIES INCORPORATE A SMOOTHER SURFACE IN THE SHIFT FORK GROOVE.

SERVICE OF THE SYNCHRONIZER ASSEMBLY REQUIRES THE REMOVAL OF THE SPEED GEARS FROM THE INPUT OR OUTPUT SHAFTS AS OUTLINED IN THE SERVICE MANUAL.

AXLE SHAFT SEAL LEAKS

CONDITIONS OF DRIVE AXLE SEAL LUBE LEAKAGE CAN BE THE RESULT OF THE SIDE GEAR BEING LOOSE IN THE DIFFERENTIAL CASE. THIS CAN RESULT IN AXLE SHAFT MOVEMENT EXCEEDING THE SEAL LIMIT THEREBY ALLOWING A LEAK.

IF EXAMINATION OF THE SEAL REVEALS NO DISCREPANCIES SUCH AS WEAR, CUTS, SPLITS OR IMPROPER INSTALLATION, AND IF THE AXLE SHAFT CAN BE MOVED BY HAND ENOUGH TO PRODUCE AN OIL LEAK, IT IS LIKELY THAT THE SIDE GEAR HAS WORN THE DIFFERENTIAL CASE. TO REPAIR, THE DIFFERENTIAL CASE MUST BE REPLACED ALONG WITH THE DIFFERENTIAL SIDE GEARS.

INSTALL NEW DIFFERENTIAL CASE, P/N 463058, SIDE GEARS, P/N 14040530, WHICH AHVE IMPROVED FINISH AND NEW THRUST WASHERS, P/N 14040531, WITH FINE GRAIN PHOSPHATE COATING TO CORRECT THE CONDITION.

SHIFT FORK/SYNCHRONIZER LABOR OPERATION: T0093 LABOR TIEM - 1980 MODELS : 4.0 HOURS LABOR TIME - 1981 MODELS : 4.5 HOURS

DIFFERENTIAL ASSEMBLY LABOR OPERATION: T0094 LABOR TIME - 1980 MODELS : 3.2 HOURS LABOR TIME - 1981 MODELS : 3.7 HOURS

BOTH SHIFT FORK AND DIFFERENTIAL ASSEMBLY LABOR OPERATION : T0095 LABOR TIME - 1980 MODELS : 4.4 HOURS LABOR TIME - 1981 MODELS : 4.9 HOURS

PRIOR TO INSTALLATION OF THE DRIVE AXLE SHAFT, THE FOLLOWING SHOULD BE PERFORMED:

A. CHECK THE AXLE BEARING JOURNAL - MICRO FINISH - FOR DAMAGE. USE CROCUS CLOTH TO POLISH THE FOURNAL, IF NECESSARY.

B. USE EMERY CLOTH TO REMOVE ANY BURRS OR SHARP EDGES FROM DRIVE AXLE SPLINES. APPLY LUBE TO AXLE SPLINES AND SEAL. CAREFULLY INSTALL DRIVE AXLE IN TRANSMISSION. USE EXTREME CARE TO PREVENT AXLE SHAFT FROM DAMAGING SEAL DURING INSTALLATION.

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.