CAMPAIGN: 5-SPEED MANUAL TRANS. MAIN SHAFT SEIZURE
SUBJECT: 5-SPEED MANUAL TRANSMISSION MAIN SHAFT SEIZURE
U. S. Campaign Number Cross Reference: 96-C-2
Models: 1996 Chevrolet S10 and GMC Sonoma 2-Wheel Drive Pickups with 5-Speed Manual Transmission (LN2 & MW2)
TO: ALL GENERAL MOTORS DEALERS
General Motors of Canada Limited has decided that a defect, which relates to motor vehicle safety, exists in CERTAIN 1996 Chevrolet S10 and GMC Sonoma 2-wheel drive Pickup Trucks equipped with 2.2L engines (LN2) and 5-speed manual transmissions (MW2). 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 Chevrolet S1O and GMC Sonoma 2-wheel drive Pickup Trucks equipped with 2.2L engines (LN2) and 5-speed manual transmissions (MW2) built within the following VIN breakpoints:
Year Model Plant Plant Code From Through ---- ----- ----- ---------- ---- --------
1996 GMC'S'Truck Linden K SOP TK512763 1996 GMC'S'Truck Shreveport 8 SOP T8509012 1996 Chevrolet 'S'Truck Linden K SOP TKI59462 1996 Chevrolet 'S' Truck Shreveport 8 SOP T8133112
NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.
All affected vehicles have been identified by the VIN Listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.
DEALER CAMPAIGN RESPONSIBILITY:
All unsold new vehicles in dealer's 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 perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, 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 instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner 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 is taken into your new or used 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.
CAMPAIGN PROCEDURE:
Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.
OWNER NOTIFICATION:
All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors (see copy of owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.
PARTS INFORMATION:
Transmissions must be obtained through New Venture Gear (NVG). DO NOT ORDER TRANSMISSIONS FROM GMSPO. Contact NVG at 1-800417-9556 to order 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
Once you have tested the transmission with the special tool provided:
1. Call NVG at 1-800417-9556 to order a transmission.
2. NVG will obtain dealership name and shipping information as well as 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 colour 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.
NOTE: New transmissions are shipped pre-filled with oil.
Returning A Transmission
IMPORTANT: Removed transmissions must be shipped to the dealer's closest Parts Distribution Centre to avoid a charge-back. Your PDC will ship to Woodstock PDC, who in turn will ship to New Venture Gear.
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 the PDC.
NOTE: A pre-printed New Venture Gear shipping label is included with the replacement transmission. This label should be put in an envelope and scotch taped or glued on the shipping container as Woodstock PDC will need this label to ship transmission back to New Venture Gear.
DO NOT SHIP REPLACEMENT TRANSMISSION TO NEW VENTURE GEAR
Dealers need to order the transmissionn fluid from GMSPO as required.
Part Number Description Quantity/Vehicle ----------- ------------ ----------------
12345349 Manual Transmission Fluid As Required This Transmission Fluid Is To Be Used For Top-Up Purposes Only - Not To Exceed 200 ml. As It May Result In Poor Shift Quality
If an additional special tool is needed due to loss, contact Oshawa by fax 905-644-1563.
DO NOT ORDER SPECIAL TOOL FROM GMSPO.
PARTS AND LABOUR CLAIM INFORMATION:
Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:
Repair Code Description Time Allowance
1A Inspect Transmission Turning Torque - .7 No Further Action Required 2A Inspect and R&R Transmission 2.7 (Includes moving vehicle in and out of stall) T2498 Courtesy Transportation *
Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. An allowance of $500.00 is included in Repair Code 2A for parts handling and also included is $1.20 for the transmission fluid.
Courtesy Transportation only valid with Repair Code 2A, Inspect and R&R.
SERVICE PROCEDURE:
Turning torque of the transmission must be measured using special tool supplied to the dealership. (See Figure 2)
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 February 19, 1996. A replacement tool can be obtained by contacting Oshawa by fax at 905-644-1563.
Test Procedure
This test procedure must be performed on the transmission of all involved vehicles.
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 (See Figure 1). Fluid temperature must be between 10 and 38 degrees C (50 and 100 degrees F). Temperatures outside this range can produce inaccurate results. Reinstall fill plug.
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 dutch 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 five (5) steps.
7. The assistant should shift the truck into Reverse and take his/her hand off the shift lever.
8. Rotate the special tool clockwise and counterclockwise six (6) times to ensure 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 OK. 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 assistants hand is removed from the shift lever.
- If the weight begins to rotate, the transmission is OK. 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 pass 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 N. m (15 lb. ft.) and the centre bearing support bolts to 70 N. m (50 lb. ft.).
13. Verify that the transmission fluid level is full. Install the transmission fluid fill plug. Part Number 12345349 is to be used for top-up purposes only - not to exceed 200 ml.
14. Lower the vehicle.
15. Install Campaign Identification Label.
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 - Vehicle Speed Sensor
IMPORTANT: The exchange transmission will be shipped filled with fluid. If additional fluid is necessary, this transmission may use Manual Transmission Fluid, P/N 12345349 - not to exceed 200 ml as it may result in poor shift quality.
3. Install Campaign Identification Label.
INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL
Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.
Dear General Motors Customer:
General Motors of Canada Limited has decided that a defect, which relates to motor vehicle safety, exists in CERTAIN 1996 Chevrolet SIO and GMC Sonoma 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 loss of vehicle control and result in a vehicle crash without prior warning.
Transmissions with potential to seize generally do so in less than 800 km (500 miles) of use. However, if your vehicle has been driven less than 5,000 km (3200 miles) take it immediately to your General Motors 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 and parts are available. The labour time to perform the inspection is approximately 40 minutes. Labour time to replace your transmission, if required, is approximately 2 1/2 hours. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.
This service will be provided for you at no charge.
Please contact your GM dealer as soon as possible to arrange a service date.
This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.
Customer Support Department General Motors of Canada Limited
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.
