CAMPAIGN: 5 SPEED MANUAL TRANS. MAIN SHAFT SEIZURE
Subject: PRODUCT SAFETY CAMPAIGN 96-C-20 - 5-SPEED MANUAL TRANSMISSION MAIN SHAFT SEIZURE
Model and Year: 1996 2-WHEEL DRIVE PICKUPS WITH 2.2L ENGINE AND 5-SPEED MANUAL TRANSMISSION (LN2 & MW2)
To: All Chevrolet Dealers
IMPORTANT!!
ALL STOCK VEHICLES INVOLVED IN THIS CAMPAIGN WERE PLACED ON STOP SALE/DELIVERY STATUS ON 2/9/96. AFTER THIS SERVICE PROCEDURE IS COMPLETED, THE INVOLVED UNITS CAN BE RELEASED FOR DELIVERY.
The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to repair within sixty (60) days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time.
If the condition is not adequately repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation.
To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter that is being sent to owners, the owners are being instructed to contact the Chevrolet Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.
DEFECT INVOLVED
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 1996 S model 2-wheel drive pickup trucks equipped with 2.2L engines and 5-speed manual transmissions. Some of these trucks have been built with a transmission containing parts not machined to specification. Transmissions built with mismachined parts could seize and lock the rear wheels while the truck is being operated. This could cause a loss of vehicle control and possibly a vehicle crash without prior warning.
To correct this condition, dealers will inspect the transmission main shaft output torque using a special tool. If the output torque does not meet the inspection criteria, the transmission will be replaced.
VEHICLES INVOLVED
Involved are certain 1996 S model 2-wheel drive pickup trucks equipped with 2.2L engines and 5-speed manual transmissions and built within the following VIN breakpoints:
PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ----- ---- ------- 1996 S Truck Linden "K" TK100134 TK159462 1996 S Truck Shreveport "8" T8100116 T8133112
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.
PARTS INFORMATION
Transmissions must be obtained through New Venture Gear (NVG) DO NOT ORDER TRANSMISSIONS FROM GMSPO. Contact NVG at 1-800-417-9556 to order or ship a, transmission. This phone number will be answered from 8:00 a.m. through 7:00 p.m. EST, Monday through Friday, and 8:00 a.m. through 2:00 p.m. EST, Saturday. Unsold units will receive a new transmission, sold units will receive a remanufactured transmission.
Obtaining A Transmission
1. Once you have tested the transmission with the special tool provided, call NVG at 1-800-417-9556 to order a transmission.
2. NVG will obtain dealership name and shipping information as well as the VIN. The replacement transmission will be shipped to arrive within 48 hours.
Replacement transmissions will be marked with the last eight digits of the vehicle VIN. Transmissions will also be marked with a color dot to indicate if they are new or remanufactured. New transmissions will be marked with a green dot, remanufactured transmissions will be marked with a yellow dot.
Returning A Transmission
IMPORTANT: Removed transmissions must be shipped to NVG immediately to avoid a charge-back. Failure to return the transmission will result in the dealership being billed $1,000 which is the value of the exchange transmission.
1. All oil must be drained from the transmission being returned. Remove shipping plugs from the replacement transmission and install them on the return transmission.
2. Use a marker to write the last eight digits of the VIN on the removed transmission.
3. The shipping container from the replacement transmission is to be used for return shipments to NVG. A pre-printed shipping label is included with the replacement transmission. This label should be used on the shipping container.
4. After transmission is packaged in the shipping container, call NVG at 1-800-417-9556 to return a transmission. NVG will contact the carrier, schedule pickup, and pay for shipping.
Part Number Description Quantity ----------- ----------- -------- 12377916 Manual Transmission Fluid As Required
Dealers need to order the transmission fluid from GMSPO as required.
If an additional special tool is needed call Helm, Inc. at (313)865-5000 (ext. 3263).
*** DO NOT ORDER SPECIAL TOOL FROM GMSPO ***
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
All unsold new vehicles in dealers, possession and subject to this campaign must be held and inspected/repaired per the service procedure of this campaign bulletin before owners take possession of these vehicles.
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.
Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owners letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.
SERVICE PROCEDURE
Turning torque of the transmission must be measured using special tools supplied to the dealership.
Special Tool Information
The special tool will be pre-shipped to all dealers free of charge. Tools will be shipped by Helm the week of 2/19/96. A replacement tool can be obtained by contacting Helm, Inc. at 313-865-5000 (extension 3263).
Test Procedure
This test procedure must be performed on all involved vehicle transmissions.
1. Raise and support the vehicle with the frame level to the ground.
2. Remove the transmission fluid fill plug and verify that transmission fluid level is full.
3. Measure transmission fluid temperature using thermometer J6742-03 or equivalent. Fluid temperature must be between 50 and 100 degrees F. Temperatures outside this range can produce inaccurate results.
4. Remove the propeller shaft.
5. Install the special tool to the transmission output shaft. Do not bottom the tool on the extension seal as this could produce inaccurate results or damage the seal.
CAUTION:
The special tool can slide out of the transmission and fall to the floor causing possible personal injury. Be sure you hold onto the tool when the clutch pedal is depressed.
** An assistant must be in the truck cab to accomplish the next 7 steps.
6. The assistant should stroke the clutch pedal six (6) times and hold the pedal to the floor for the next 5 steps.
7. The assistant should shift the truck into Reverse and take hand off the shift lever.
8. Rotate the special tool clockwise and counter clockwise six (6) times to, assure that the clutch disc and the synchronizer blocker rings are fully released.
9. Position the special tool so that it is stationary at 9 o'clock.
10. Release the special tool and observe whether the weighted end begins to rotate downward.
- If the weight begins to rotate, the transmission is O.K. Proceed to step 11.
- If the weight does NOT begin to rotate, the transmission must be replaced. Proceed to Transmission Replacement Procedure listed below.
IMPORTANT: The weighted end will not rotate to a complete vertical position. Any movement of the weighted end is sufficient to pass inspection. Clutch pedal must be held to the floor.
11. Repeat steps 8, 9 and 10 with the transmission in 1st gear. Be sure the clutch pedal remains depressed to the floor and the assistant's hand is removed from the shift lever.
- If the weight begins to rotate, the transmission is O.K. Proceed to step 12.
- If the weight does NOT begin to rotate, the transmission must be replaced. Proceed to Transmission Replacement Procedure listed below.
IMPORTANT: The weighted end will not rotate to a complete vertical position. Any movement of the weighted end is sufficient to page inspection. Clutch pedal must be held to the floor.
12. Remove the special tool and install the propeller shaft. Torque the pinion flange bolts to 20 Nm (15 lb. ft.) and the center bearing support bolts to 70 Nm (50 lb. ft.).
13. Verify that the transmission fluid level is full. Install the transmission fluid fill plug.
14. Lower the vehicle.
15. Install Campaign Identification Label.
*** After service is procedure is completed, the involved vehicles can be released for delivery.***
Transmission Replacement Procedure
Transmission replacement is required only when the special tool did NOT begin to rotate in either first or reverse.
1. The transmission must be replaced following the transmission replacement procedure as detailed in the 1996 S/T Truck Service Manual, Book 1 of 2 (GMT/96-ST-1). Refer to Manual Transmission Section 7B-6, Transmission Replacement for the proper procedure.
2. Drain the transmission fluid before removing the transmission from the vehicle.
The following components should be removed from the transmission being returned:
- Concentric slave cylinder - Transmission mount
The following components should remain on the transmission being returned:
- Shift housing (shift tower/stub shaft) - Back-up lamp switch - VSS
The exchange transmission will be shipped filled with fluid. If additional fluid is necessary, this transmission MUST use Manual Transmission Fluid, P/N 12377916, because it contains a special friction modifier. Other fluids should not be substituted as they may result in poor shift quality. Fluid capacity is 2.OL (2.2 Qts.).
3. Install Campaign Identification Label.
CAMPAIGN IDENTIFICATION LABEL
Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label". Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted 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. When installing the new Campaign Identification Label, be sure to install the clear protective covering. Additional Campaign Identification Labels can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday-Friday, 8:00 a.m. to 4:30 p.m. EST). Ask for Item Number S-1015 when ordering.
Apply "Campaign Identification Label", only on a clean, dry surface.
CLAIM INFORMATION
Submit a Product Campaign Claim with the information indicated below:
REPAIR PART FAILED PARTS LABOR LABOR NET PERFORMED COUNT PART NO. ALLOW CC-FC OP HOURS* AMOUNT --------- ----- ------- ------ ----- ------ ------ ------ Inspect Transmission Turning Torque -- -- -- MA-96 V9823 0.6 ** No Further Action Required
Inspect & R & R Transmission -- -- -- MA-96 V9824 2.6 *** (Includes Moving vehicle In & Out of Stall)
Courtesy Transportation -- -- -- MA-96 T2498 ---- +
CLAIM INFORMATION
* For Campaign Administrative Allowance, add 0.1 hours to the "Labor Hours'. Add an additional 0.1 hours if transmission is replaced to cover packaging transmission for shipment.
** Net Amount is to include the actual cost of transmission fluid used plus 40% mark-up.
*** Net Item column to include actual cost of transmission fluid used, plus 40% markup; plus $406.20 which is the markup for the transmission furnished for this campaign.
+ Courtesy Transportation "Net Amount" only valid with Labor Op V9824, Inspect and R&R Transmission.
Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submission.
Dear Chevrolet Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
REASON FOR THIS RECALL
General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1996 Chevrolet two wheel drive S-Series pickup trucks, equipped with a 5-speed manual transmission. A small number of these trucks may have been built with a transmission containing parts not machined to specification. Transmissions built with mismachined parts could seize and lock the rear wheels while the truck is being operated. This could cause loss of vehicle control and result in a vehicle crash without prior warning.
WHAT WE WILL DO
Transmissions with potential to seize generally do so in less than 500 miles of use. To correct this condition your dealer will inspect your transmission and replace it if necessary. This service will be performed for you at no charge.
WHAT YOU SHOULD DO
If your vehicle has been driven less than 3200 miles, take it immediately to your Chevrolet dealer for inspection. If the inspection shows your transmission requires replacement and that service cannot be completed that day, a service vehicle will be provided for your use until your transmission is replaced.
Instructions for making this correction have been sent to your dealer. The labor time necessary to perform this service correction is approximately 30 minutes to 2 hours. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process 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.
Your Chevrolet dealer is best equipped to provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within five (5) days, we recommend you contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020.
After contacting your dealer and the Customer Assistance Center, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call 1-800-424-9393 (Washington D.C. residents use 202-366-0123).
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products.
Chevrolet Motor Division GENERAL MOTORS CORPORATION
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.
