Hybrid Two-Mode 2ML70 Automatic Transmission Exchange Program

This bulletin is being revised to update information under WPC Request. Please discard Corporate Bulletin Number 07-07-30-028A (Section 07 -- Transmission/Transaxle).

This bulletin will explain the Hybrid Two-Mode transmission exchange program for the 2008 and 2009 models listed above. This program has been extended to December 31, 2008 to get important feedback on this new hybrid transmission. This bulletin will be revised to announce the end of the exchange program at a later date.

Product teams continually seek valuable information for engineering improvements. To assist in this effort, a transmission exchange program will be used for this product. As additional learnings are developed, more on-vehicle service parts and procedures will be released.

The 2008-2009 model year Hybrid Two-Mode exchange program will be administered by the GM Technical Assistance Center (TAC). The servicing technician must provide detailed customer comments, conditions, diagnostic trouble codes (DTCs) and other useful information. To request an exchange, dealerships are required to call Technical Assistance (TAC). Prior to calling TAC, please make sure to complete the OEM Transmission Exchange worksheet referenced at the end of this bulletin. Use of this worksheet will minimize the time spent on the telephone and avoid the need of a second call to the TAC. Guidelines for honoring exchange requests under this program are being strictly enforced.

Components that may be removed and serviced without exchange of the transmission are identified in the list below. Any repairs involving transmission components not identified in the table below may require a transmission exchange. Please note that this list is subject to change as the program progresses. You will be notified by the TAC consultant if additional transmission items are considered serviceable.

All other components of the transmission require assembly replacement at this time.

Important: Transmission repairs or failures that are caused by components external to the transmission DO NOT fall under the exchange program. TAC will assist in an assessment of these situations. Also, transmissions needed for insurance repairs have to be obtained from GMSPO. The exchange program is created as a way to identify and correct internal concerns. External components causing a failure do not provide any useful information in improving a transmission. The transmission received from GMSPO will be a new transmission. As normal process, all warranty claims for transmission replacement must be approved through TAC.

Caution: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

•	Identify how to disable high voltage.

•	Identify how to test for the presence of high voltage.

•	Identify conditions under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Important: : If vehicle damage does not allow access to the high voltage manual disconnect, disconnect the 12V battery and remove the damaged portion of the vehicle until such time as the HV manual disconnect can be removed and the High Voltage Disabling procedure can be completed.

1. Perform the high voltage disable procedure at the drive motor generator control module assembly or cable connections. Refer to High Voltage Disabling in SI.
2. Perform the high voltage enable procedure when the transmission is installed and ready to be test driven.

1. A thorough diagnosis must be performed in order to prevent unnecessary component replacements. Refer to Diagnostic System Check Vehicle in SI to identify the correct procedure for diagnosing the system.
2. If DTCs are present and the procedure gives direction to remove internal components; stop, capture snapshot stored data, and, if possible, test drive the vehicle with the Tech2 installed and capture a snap shot of the transmission data when the condition occurs. See Service Bulletin #07-07-30-010 for correct snap shot data collection. Call TAC once the data has been captured. TAC will request that you e-mail the snapshot to them.
3. If DTCs are not present, refer to Symptoms Automatic Transmission in SI.
4. If any diagnostic procedure gives direction to remove internal components, stop and call TAC. The oil must be drained from the transmission before shipping, but internal components should not be removed.
5. Prior to calling TAC, complete the OEM Transmission Exchange worksheet referenced at the end of this bulletin.
6. Contact TAC to verify that proper diagnosis has been performed. Upon review of the diagnosis, TAC will establish a case reference number and make arrangements for shipping an exchange unit to your dealership if necessary. DO NOT SHIP A TRANSMISSION TO THE WARRANTY PARTS CENTER (WPC) WITHOUT AN OFFICIAL WPC REQUEST.
7. The exchange transmission will come with three-phase high voltage cables attached. The high voltage cables that come with the exchange unit should be installed in the vehicle. The old high voltage cables will need to be returned in the original packaging. During the exchange period, a supplemental method of transmission R&R may be considered to supplement the procedures in SI. After following the proper high voltage disabling procedure outlined is SI, follow procedures for transmission removal.
8. Removal of the engine intake manifold per SI Document ID# 2035638 will allow the transmission to be removed and reinstalled with the high voltage cables still attached to the transmission.
9. Disconnect the transmission 3-phase high voltage cables from the TPIM and place EL 48569 Terminal Covers over the cable ends to prevent damage on both removal and reassembly.
10. Perform TCM reprogramming as well as check and reprogram all hybrid control modules with the latest calibrations.

Important::  Failure to return the replaced transmission by the due date will result in the dealership being debited the entire warranty claim (parts and labor). The removed unit must be returned complete in the shipping container. For effective engineering analysis, please do not remove or disassemble any components. Dealerships returning transmissions that have been even partially disassembled will be judged as violating this procedure and, as such, will be billed for all materials furnished.

Notice: 

The WPC will fax a Special Part Request to your dealership requesting return of the transmission. DO NOT wait for the warranty claim to be paid before returning the transmission. The Special Request will provide a request number that must be labeled on the outside of the shipping container. Failure to label the container with the request number may delay the processing of your return. Return the transmission following WPC procedures outlined in Bulletin #99-00-89-019E. If you do not receive the WPC Special Part Request, contact Annette Quince at 1-248-371-9939 (French-speaking dealerships in Canada should call the PQC at 1-866-654-7654) to obtain the proper paperwork to return the transmission. Failure to return the transmission may result in a debit. Do not ship a transmission to the WPC without an official WPC request.

1. Remove the drain plug and drain the transmission fluid. Reinstall the drain plug.
2. Remove the transmission from the vehicle as outlined in Transmission Replacement in SI.
3. Tighten any fasteners that were loosened or removed during transmission removal to the original torque specification.
4. Remove the torque dampener holding strap and any plastic shipping plugs or covers from the new unit and install them on the transmission to be returned.
5. If the transmission leaks, mark the leak area directly on the transmission with a permanent marker.
6. Write the TAC case reference number on the repair order.
7. Write the TAC case reference number on the transmission in a visible location.
8. Place the transmission core into the shipping container and attach the completed return shipping tag to the transmission.

1. Place a copy of the WPC request, repair order with technician comments and the completed OEM Transmission Exchange worksheet into the plastic envelope. The bill of lading and customs papers (for cross border shipments) should also be inserted into the plastic envelope. Remove the original shipping label and attach the plastic envelope with the return shipping label on it to the container.
2. Label the outside of the shipping container with the WPC request number and the TAC case reference number. Refer to Corporate Bulletin Number 99-00-89-019E for detailed shipping information.
3. Contact Annette Quince at 1-248-371-9939 (French-speaking dealerships in Canada should call the PQC at 1-866-654-7654) if questions arise about shipping.
4. Have the driver sign the bill of lading. Retain a copy of the signed bill of lading and attach your copy to the original repair order. This will be your proof of returning the transmission.
5. Ship the transmission with appropriate paperwork to: Third Party Freight Collect, GM Warranty Parts Center, 45 Northpointe Drive, Orion, MI 48359.

Refer to Product Quality Center for Engine and Transmission Assembly and Transfer Case Replacement and Corporate Bulletin Number 02-07-30-029F for the worksheet. A copy of this worksheet is included below for your reference.

For DEXRON®-VI part numbers, refer to Corporate Bulletin Number 04-07-30-037A.

For vehicles repaired under warranty, use: