MUNCIE 5-SP. TRANSAXLE PROGRAM DIAGNOSIS - P/N'S FOR REPAIRS

MODEL AND YEAR: 1987 CELEBRITY, CAVALIER, CORSICA, AND BERETTA

To gain needed product feedback on the above transaxles, and to minimize vehicle downtime, a transaxle exchange program is now in effect and will continue until further notice.

The exchange program will be administered by Hydramatic Division and all requests for exchange units will be handled through Chevrolet Technical Assistance Network.

The following information thoroughly explains all requirements regarding Diagnosis, Serviceable and Non-serviceable items, Serviceable Part Numbers, Warranty Claims Processing procedures and shipping instructions.

In the event your dealership receives a complaint on an MG282 follow the procedure listed below. Your cooperation will greatly improve the effectiveness of the program.

NOTE: ---- o Numbers in brackets refer to item numbers on disassembled views, Figures 1 and 2.

o A Serviceable Parts Item Number/GM Part Number Cross Reference is provided for your convenience, Fig. 3.

A. Preliminary Diagnostic Procedure o Refer to Diagnosis chart. o Insure correct oil level. o Insure that the shift linkage is properly adjusted. o Insure that the clutch linkage is properly adjusted. o Insure that all engine and transmission mounts are tight.

B. On-car service (without exchange)

Oil leaks at the following locations may be repaired without exchanging transmissions.

ITEM DESCRIPTION SPEC TOOLS/SPECIFICATIONS ---- ----------- ------------------------- 23 Axle Seals Install using J26938 & J8092 140 Shift Shaft Cover No special tool required 208 Shift Shaft Seal Install using J35823 164 Clutch Fork Seal No special tool required 85-90 End Plate to case leaks Bolt Torque 21NM (15 lb.ft.) B Back up light switch Bolt Torque 23NM (24 lb.ft.) C Speedometer driven gear Bolt Torque 5.5NM (4 lb.ft.) 79-80 Transaxle drain plug/washer Drain plug 24NM (15 lb.ft.) 100-101 Fluid level indicator/washer Fully seated, not stripped 82-83 Fill plug and washer Fill plug torque 24 NM (15 lb. ft) 204 Plug, Shift rail No special tool required.

C. Out-Of-Vehicle repairs (without exchange)

ITEM DESCRIPTION

174 Oil leak at detent cover 163-177 Clutch fork bushing replacement 165 Clutch fork replacement 22 Clutch release bearing service/replacement

Any clutch repair/replacement Special tool requirement: - Bushing (163), Using J36037 (remove/install) Bushing (177), Using J36032 & J23907 to remove/install using J36033 and J36190. - Clutch Fork (165), Using J36037 to remove/install bushing (163).

D. Out-Of-Vehicle repairs (with exchange)

o Any repair which necessitates splitting the clutch housing and the transaxle case (Item 20 & 85).

E. Exchange Procedure

o Call the Chevrolet Technical Assistance Network for authorization. Ask for a transmission specialist.

NATIONAL 1-800-227-3175 ALASKA ONLY 1-800-227-3173

o Provide Technical Assistance with the necessary information. It would be a good idea to fill out the MG1/MG2 reporting form (attached) prior to calling.

o Technical Assistance will arrange to ship an exchange unit to your dealership.

o Technical Assistance will provide dealership with an authorized "case number". This number must be written on the unit (clutch housing) as well as the shipping container used to return the unit to Hydramatic-Muncie.

o Once the exchange unit is received, the complaint unit is to be returned to Hydramatic-Muncie plant, 1200 West Eighth Street, Muncie, Indiana 47302.

o The exchange unit will have an envelope attached to it. This envelope will contain: -- Return shipping label -- Administrative Procedures -- MG1/MG2 Reporting Form -- Return shipping carrier information -- Identification tag

o The complaint unit must be returned within 5-7 days after receipt of the exchange unit.

F. Preparation for shipping

o Drain the oil and replace the drain plug.

o Remove plastic shipping plugs from the exchange unit and install them into the complaint unit.

o Fold the reporting form, staple it to the identification tag and secure the tag to the clutch housing of the complaint unit.

o Write the Technical Assistance "Case Number" on clutch housing and shipping container.

o Repack the complaint unit into original shipping container.

o Place the shipping label on the original shipping container.

G. Warranty Claims Processing Procedure

o Upon completion of the repair, a warranty claim is to be submitted to Chevrolet for only the labor for the R and R and transmission fluid.

DIAGNOSIS CHART

CONDITION PROBABLE CAUSE --------- -------------- A knock at low speeds a. Worn drive axle CV or TRI-POT joints. b. Worn side gear hub counterbore. ------------------------------------------------------------------------------ Noise most pronounced on turns. Differential gear noise. ------------------------------------------------------------------------------ Clunk on acceleration or a. Loose engine mounts. deceleration. b. Worn drive axle inboard TRI-POT joints. c. Worn differential pinion shaft in case. d. Side gear hub counterbore in case worn oversize. ------------------------------------------------------------------------------ Clicking noise in turns. Worn outboard CV joint. ------------------------------------------------------------------------------ Vibration a. Rough wheel bearing. b. Bent drive axle shaft. c. Out of round tires. d. Tire unbalance. e. Worn CV joint in drive axle shaft. f. Incorrect drive axle angle. (Trim Height) ------------------------------------------------------------------------------ Noisy in Neutral with Engine a. Worn input gear bearings. Running b. Worn clutch release bearing. ------------------------------------------------------------------------------ Noisy in First Only a. Chipped, scored, or worn first-speed constant-mesh gears. b. Worn 1-2 synchronizer. ------------------------------------------------------------------------------ Noisy in Second Only a. Chipped, scored, or worn second-speed constant-mesh gears. b. Worn 1-2 synchronizer. ------------------------------------------------------------------------------ Noisy in Third Only a. Chipped, scored, or worn third gear constant-mesh gears. b. Worn 3-4 synchronizer. ------------------------------------------------------------------------------ Noisy in Fourth Only a. Worn 3-4 gear synchronizer. b. Chipped, scored, or worn fourth-gear or output gear. ------------------------------------------------------------------------------ Noisy in Fifth Gear Only a. Worn 5th gear synchronizer. b. Chipped, scored, or worn fifth-speed gear or output gear. ------------------------------------------------------------------------------ Noisy in Reverse Only a. Chipped, scored, or worn reverse idler gear, idler gear bushing, input or output gear. ------------------------------------------------------------------------------ Noisy in All Gears a. Insufficient lubricant. b. Worn bearings. c. Chipped, scored, or worn input gear (shaft) and/or output gear (shaft). ------------------------------------------------------------------------------ Slips out of Gear a. Worn or improperly adjusted linkage. b. Shift linkage does not work freely; binds. c. Bent of worn cables. d. Input gear bearing retainer broken or loose. e. Worn or bent shift fork. ------------------------------------------------------------------------------ Leaks Lubricant a. Fluid level indicator not seated in fill port, causing fluid leakage at vent plug. b. Worn axle shaft seals. c. Excessive amount of lubricant in transaxle. d. Loose or broken input gear (shaft) bearing retainer. e. Worn input gear bearing and/or lip seal damaged. f. Worn shift lever seal leaks. g. Lack of sealant between case and clutch cover or loose clutch cover. ------------------------------------------------------------------------------

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.