1980-81 CITATIONS EQUIPPED WITH AUTOMATIC TRANSMISSIONS

THIS BULLETIN SUPERSEDES C.D.S.T.B. 81-T-78.

NOTICE: A DRIVE AXLE SEAL REPAIR PACKAGE, P/N 8643931, HAS BEEN RELEASED THROUGH WDDGM FOR CORRECTION OF A RIGHT AXLE SEAL LEAK CAUSED BY DIFFERENTIAL CARRIER WEAR. DIFFERENTIAL CARRIER AND SIDE GEARS ARE NOT TO BE REPLACED FOR THIS CONDITION AS WAS INSTRUCTED IN BULLETIN 81-T-78. THIS NEW REPAIR PACKAGE IS TO BE USED IN THEIR PLACE.

SOME 1980 CITATIONS AND EARLY PRODUCTION 1981 CITATIONS WITH THM 125 TRANSMISSIONS HAVE A CONDITION OF PREMATURE WEAR OF THE FINAL DRIVE DIFFERENTIAL CARRIER. THIS CAN RESULT IN A TRANSMISSION OIL LEAK AT THE RIGHT DIRVE AXLE SEAL.

A SPECIAL POLICY ON SUBJECT VEHICLES CONCERNING THIS LEAK CONDITION WAS COVERED IN DEALER SERVICE TECHNICAL BULLETIN 81-T-78, DATED, MAY, 1982 AND DEALER LETTER DATED MAY 4, 1982 GM-85. THIS BULLETIN PROVIDES DIAGNOSIS INFORMATION AND THE RECOMMENDED REPAIR PROCEDURES FOR CORRECTION OF THE RIGHT DRIVE AXLE SEAL LEAK. THE REPAIRS ARE TO BE PERFOMED AT NO CHARGE TO THE OWNERS AS COVERED UNDER THE SPECIAL POLICY.

PARTS INFORMATION

DRIVE AXLE SEAL REPAIR PACKAGE, P/N 8643931, CONTAINS THE FOLLOWING PARTS:

1 - BEARING AND SEAL HOUSING ASSEMBLY 1 - HOUSING RETAINER 1 - DRIVE AXLE SLEEVE 1 - BALL JOINT RETAINING BOLT 1 - MAGNET 2 - HOUSING RETAINER BOLTS - USED ONLY ON V6 ENGINE VEHICLE 2 - HOUSING RETAINER SPACERS - USED ONLY ON V6 ENGINE VEHICLE 1 - INSTRUCTION SHEET 1 - TUBE OF ADHESIVE (LOCTITE 271)

SPECIAL TOOL AND MATERIAL INFORMATION

TOOL J-33411 IS REQUIRED FOR INSTALLATION OF THE DRIVE AXLE SLEEVE. THE TOOL HAS BEEN SHIPPED TO ALL DEALERS FROM KENT MOORE TOOL DIVISION.

SERVICE PROCEDURE

PART I - DIAGNOSIS OF LEAK

1. INSPECT TRANSMISSION IN AREA OF RIGHT DRIVE AXLE SEAL.

2. IF AXLE SEAL IS LEAKING, PORTIONS OF THE TRANSMISSION CASE FROM THE SEAL TO THE OIL PAN RAIL WILL BE WET "TO THE FEEL" WITH RED TRANSMISSION OIL. OIL STAINS ON THE CASE ARE NOT SIGNS OF A CURRENT LEAK, BUT INDICATION OF A PREVIOUS LEAK.

IF WET TRANSMISSION OIL IS EVIDENT, BE SURE SOURCE IS NOT FROM SOME OTHER AREA, SUCH AS SPEEDOMETER DRIVEN GEAR SLEEVE "O" RING.

PROCEED WITH PART II OF THIS PROCEDURE ONLY IF RIGHT AXLE SEAL IS LEAKING

PART II - INSPECTION OF DIFFERENTIAL CARRIER BORE

THIS INSPECTION IS TO DETERMINE IF ONLY DRIVE AXLE SEAL SHOULD BE REPLACED, OR IF REPAIR PACKAGE NUMBER 8643931 SHOULD BE INSTALLED.

1. RAISE THE CAR ON A HOIST THAT DOES NOT USE THE FRONT WHEELS OR CONTROL ARMS FOR SUPPORT (FRAME HOIST, ETC.). LEAVE THE STEERING WHEEL UNLOCK- ED SO FRONT WHEELS CAN BE TURNED.

2. REMOVE RIGHT FRONT WHEEL AND TIRE ASSEMBLY.

3. REMOVE SPLASH SHIELD AND RETAINING SCREWS FOR BOTH BRAKE LINE AND HOSE BRACKETS AT CROSSMEMBER SIDE RAIL. REFER TO FIGURE 1.

4. INSTALL TOOL J-28712 AXLE BOOT SEAL PROTECTORS AS SHOWN IN FIGURE 2.

5. REMOVE THE BALL JOINT RETAINING BOLT AND NUT. DO NOT REUSE BOLT. REFER TO FIGURE 3.

6. INSERT A PRY BAR BETWEEN ENGINE CRADLE SIDE MEMBER AND THE RIGHT LOWER CONTROL ARM. PRY DOWNWARD UNTIL THE HUB AND BEARING ASSEMBLY ARE DIS- ENGAGED FROM THE BALL JOINT STUD. REFER TO FIGURE 4.

7. USING TOOL J-28468, AXLE SHAFT REMOVE, DISENGAGE THE AXLE FROM THE TRANSMISSION. REFER TO FIGURE 2.

8. MOVE THE FRONT WHEELS TO A FULL LEFT TURN POSITION.

9. PUSH THE HUB AND BEARING ASSEMBLY TO THE REAR OF THE WHEEL WELL AND PULL THE DRIVE AXLE OUT OF THE TRANSMISSION, SWING THE END PAST THE ENGINE CRADLE SIDE MEMBER UNTIL IT IS FREE TO HANG DOWN FROM THE WHEEL HUB.

10. REMOVE THE RIGHT AXLE OIL SEAL FROM THE TRANSMISSION CASE, BEING CAREFUL NOT TO DAMAGE THE TRANSMISSION CASE BORE.

11. INSPECT DIFFERENTIAL CARRIER AXLE SHAFT BORE FOR STEP WEAR. REFER TO FIGURE 5.

A. IF THERE IS A SLIGHT EVEN STEP 360 DEG.AROUND BORE, REPLACE ONLY AXLE SHAFT SEAL, P/N 8631156, PART III OF THIS PROCEDURE.

B. IF THERE IS A LARGER STEP IN BORE IN THE DIRECTION OF THE DIFFERENTIAL PIN, AS SHOWN IN FIGURE 5, INSTALL REPAIR PACKAGE NUMBER 8643931, PART IV OF THIS PROCEDURE.

NOTICE: DO NOT INSTALL PACKAGE UNLESS CARRIER WEAR IS EVIDENT IN STEP B, AS THIS MAY RESULT IN DIFFICULT REINSTALLATION OF DRIVE AXLE CARRIER.

PART III - INSTALLATION OF DRIVEAXLE SHAFT OIL SEAL - P/N 8643931

1. CLEAN SEAL BORE AND INSTALL NEW AXLE OIL SEAL USING J-26938. BE CAREFUL NOT TO DAMAGE SEAL DURING INSTALLATION.

2. REINSTALL DRIVE AXLE FOLLOWING THE STEPS 10 THROUGH 13 AND 18, 19, 21 AND 22 IN PART IV OF THIS PROCEDURE. IT IS NOT NECESSARY TO CHANGE OIL AND STRAINER.

PART IV - INSTALLATION OF SEAL REPAIR PACKAGE NUMBER 8643931

1. REMOVE THE TWO (2) BOLTS FROM THE TRANSMISSION EXTENSION TO ENGINE BRACKET. REFER TO FIGURE 7.

2. L4 ENGINE ONLY, PRY THE EXHAUST BRACKET OUTWARD WITH SCREWDRIVER TO ~ROVIDE CLEARANCE FOR RETAINER. REFER TO FIGURE 8.

3. CLEAN THE SEAL TO CASE BORE WITH A TRICHLOROETHANE SOLVENT MAKING SURE THAT ALL OF THE OLD SEAL MATERIAL IS REMOVED FROM THE CASE. THIS CLEANING IS IMPORTANT SINCE THIS SURFACE MATES TO THE NEW SEAL HOUSING ASSEMBLY "O" RING.

4. LIGHTLY LUBRICATE THE "O" RING, AND PUSH THE NEW SEAL HOUSING ASSEMBLY IN TO THE CASE BORE BY HAND. POSITION KEY WAY AT 12 O'CLOCK. REFER TO FIGURE 9.

5. INSTALL THE HOUSING RETAINER AS FOLLOWS: RETAINER KEY MUST GO INTO SEAL HOUSING KEY WAY. REFER TO FIGURE 9. TORQUE RETAINING BOLTS TO 50 N.M (37 FT. LBS.)

A. VEHICLES EQUIPPED WITH L4 ENGINES

PLACE RETAINER BETWEEN ENGINE BRACKET AND EXHAUST PIPE BRACKET.

USE ORIGINAL BOLTS.

TIGHTEN EXHAUST PIPE HANGER BOLTS (MAY HAVE LOOSENED WHEN BRACKET BENT). B. VEHICLES EQUIPPED WITH V6 ENGINES

USE THE LONGER BOLTS AND THE SPACERS FURNISHED IN THE KIT. SPACERS GO BETWEEN THE ENGINE BRACKET AND THE BEARING RETAINER.

6. REMOVE THE CV JOINT AIR BLEED SHIELD IF THE SHAFT IS SO EQUIPPED. REFER TO FIGURE 10.

7. USE EMERY CLOTH TO LIGHTLY REMOVE ANY CORROSION AT THE BASE OF THE INNER AXLE SHAFT END. THOROUGHLY CLEAN THIS AREA. ALSO CLEAN I.D. OF SLEEVE FURNISHED IN KIT.

8. SPREAD LOCTITE 271 FURNISHED IN KIT TO THE INNER DIAMETER OF THE BEARING SLEEVE AND TO THE OUTSIDE DIAMETER OF THE DRIVE AXLE. REFER TO FIGURE 11 THREE (3) TO FOUR (4) DROPS OF LOCTITE IS SUFFICIENT FOR SLEEVE AND AXLE SURFACES. BE SURE VENT HOLE IS OPEN BY CHECKING WITH WIRE.

NOTICE: ONLY APPLY SEVERAL DROPS OF LOCTITE TO BOTH MATING SURFACES OF PARTS. PROPER RETENTION AND SEALING OF SLEEVE TO SHAFT REQUIRES ONLY A FINE FILM OF ADHESIVE ON MATING SURFACES.

9. USE INSTALLATION TOOL J-33411 TO POSITION THE SLEEVE ON SHAFT. THE THIN WALL SECTION OF THE SLEEVE MUST GO TOWARD THE CV JOINT. REFER TO FIGURE 12. WHEN INSTALLING THE SLEEVE, DRIVE THE SLEEVE UNTIL INSTALLER TOOL BOTTOMS OUT ON END OF SHAFT. ALLOW LOCTITE TO CURE FOR APPROXIMATELY 15 MINUTES AFTER SLEEVE IS INSTALLED ON SHAFT.

10. 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.

11. WITH FRONT WHEELS STRAIGHT AHEAD, INSTALL THE BALLJOINT STUD TO THE HUB AND WHEEL BEARING ASSEMBLY. INSTALL THE NEW BALL JOINT RETAINING BOLT. INSTALL NUT AND TORQUE TO 50 N.M (40 FT. LBS.) REFER TO FIGURE 3.

12. REMOVE TOOL J-28712 AXLE SHAFT BOOT SEAL PROTECTORS.

13. INSTALL THE RIGHT SIDE FRONT BRAKE PIPE AND HOSES BRACKETS AND SPLASH SHIELD.

NOTICE: USING SUITABLE SOLVENT, CLEAN ANY DIRT OR GREASE FROM ROTOR BRAKING SURFACE.

14. DRAIN TRANSMISSION OIL, REMOVE OIL PAN, OIL STRAINER AND "O" RING. REMOVE ANY METALLIC PARTICLES AND DEGREASE THE OIL PAN BEFORE REIN- STALLATION.

15. INSTALL NEW TRANSMISSION OIL STRAINER, "O" RING AND STRAINER (P/N 8631951).

16. PLACE MAGNET FURNISHED IN KIT INSIDE OIL PAN SO THAT IT WILL BE POSITION ED IN AREA OF DIFFERNTIAL CARRIER WHEN PAN REINSTALLED.

17. CLEAN GASKET SURFACE OF TRANSMISSION CASE. REINSTALL OIL PAN WITH A NEW BASKET, TORQUING RETAINING BOLTS TO 17 N.M (12 FT. LBS.).

18. REINSTALL THE RIGHT WHEEL AND TIRE ASSEMBLY, TORQUING RETAINING NUTS TO 140 N.M (103 FT. LBS.)

19. LOWER THE CAR.

20. IF PAN WAS REMOVED, FILL TRANSMISSION WITH FIVE (5) QUARTS OF DEXRON II AUTOMATIC TRANSMISSION FLUID.

22. CHECK TRANSMISSION FLUID LEVEL AND ADD AS REQURIED.

A. PLACE TRANSMISSION IN "PARK" AND LEAVE IN "PARK". APPLY PARKING BRAKE AND BLOCK WHEELS START ENGINE AND LET IDLE (CARBURETOR OFF FAST IDLE STEP). DO NOT RACE ENGINE. MOVE THE LEVER THROUGH THE RANGES.

B. VEHICLE ON LEVEL SURFACE.

C. CHECK OIL LEVEL ON DIPSTICK.

THE OIL LEVEL AT TOOM TEMPERATURE OF APPROXIMATELY 70 DEG F (21 DEG C) SHOULD BE 13 MM (1/2") ABOVE THE "FULL" MARK, OR BETWEEN THE TWO DIMPLES ON THE DIPSTICK. (THIS IS DUE TO A HIGHER THAN NORMAL OIL LEVEL IN PAN AS THE THERMO-ELEMENT DOES NOT OPEN UNTIL OIL WARMS UP). THE OIL LEVEL WILL DROP TO BETWEEN THE "ADD" AND "FULL" MARKS AS TRANSMISSION WARMS UP TO NORMAL OPERATING TEMPERATURE.

TO NOT OVERFILL TRANSMISSION AS THIS MAY CAUSE FOAMING AND LOSS OF OIL THROUGH THE VENT.

22. INSPECT TRANSMISSION OIL PAN AND NEW AXLE SEAL FOR ANY LEAKS. CORRECT AS REQUIRED

WARRANTY INFORMATION

WHEN PERFORMING THE REPAIRS OUTLINED IN THE SERVICE PROCEDURE OF THIS BULLETIN, SUBMIT CLAIM FOR CREDIT AS FOLLOWS:

INSPECT CARRIER BORE AND REPLACE RIGHT DRIVE AXLE SEAL USE LABOR OPERATION T0090 FOR .8 HOURS.

INSPECT CARRIER BORE AND INSTALL DRIVE AXLE SEAL REPAIR PACKAGE - USE OPERATION NUMBER T0089 FOR 1.1 HOURS.

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.