Product Safety Recall - Transmission Transfer Case-Replace

THIS CAMPAIGN BULLETIN IS BEING SENT TO INVOLVED DEALERS VIA DCS MESSAGE ONLY. PLEASE RETAIN THIS COPY AS NO PRINTED BULLETIN WILL BE MAILED TO DEALERS. AN ELECTRONIC COPY WILL BE AVAILABLE ON THE GM SERVICE INFORMATION SYSTEM (SI2000) IN THE NEAR FUTURE. ON AUGUST 27, 2001 VEHICLES INVOLVED IN THIS CAMPAIGN WERE PLACED ON STOP DELIVERY VIA ADMINISTRATIVE MESSAGE WIS20010049 - WIS20010051. COMPLETION OF THIS CAMPAIGN WILL RELEASE THE VEHICLE FROM THE STOP DELIVERY.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy vehicles. Some of these vehicles were built with a range shift collar in the transmission transfer case that contains cracks. This condition could result in a complete fracture of the range shift collar and subsequent loss of vehicle forward and reverse gears; and the inability to maintain "park" position. This increases the risk of a vehicle crash resulting from unintended movement of a parked vehicle.

To prevent the possibility of this condition occurring, dealers are to replace the transmission transfer case and update the transfer case control module calibration.

Involved are certain 2002 Chevrolet TrailBlazer and GMC Envoy model vehicles equipped with a transmission transfer case and built within the following VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC Only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number and were included in the division specific administrative messages WIS20010049, WIS20010050 and WIS20010051, dated August 27, 2001.

Important: An initial supply of transfer cases and gaskets (100% of involved vehicles) required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of September 4, 2001. Parts received for a recently transferred vehicle should be forwarded by the original dealer (with a phone call) to the dealer that received the transferred vehicle. Pre-shipped parts will be charged to dealer's open parts account.

Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

(U.S., IPC) The updated calibration for the transfer case control module is included in TIS 2000 version 9.5, which will be broadcast to dealers via GM Access on August 31, 2001; and on TIS 2000 #10 CD-ROM release of September 19, 2001. The following table shows the calibration information.

(Canada) Call Technical Assistance Center for instructions on recalibration information. This is mandatory before the vehicle can be released to the customer.

Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information.

Transfer Case Replacement w/Reprogram

Caution: Please use the parking brake when the vehicle is parked or left unattended as described in the owner's manual.

Removal Procedure

1. Raise the vehicle.
2. Remove the fuel tank shield retaining bolts.
3. Remove the fuel tank shield.
4. Remove the rear propeller shaft.

4.1.	Reference mark the propeller shaft to the rear axle pinion yoke.

4.2.	Remove the bolts and the yoke retainers from the rear axle pinion yoke.

4.3.	Disconnect the propeller shaft from the rear axle pinion yoke.

4.4.	Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer case.

5. Drain the transfer case.

5.1.	Remove the drain plug and drain the fluid into a suitable container.

5.2.	Install the drain plug.

Tighten
Tighten the drain plug to 34 N·m (25 lb ft).

6. Remove the front propeller shaft.

6.1.	Reference mark the propeller shaft to the front axle pinion yoke.

6.2.	Remove the bolts and the yoke retainers from the front axle pinion yoke.

6.3.	Disconnect the propeller shaft from the front axle pinion yoke.

6.4.	Remove the propeller shaft from the transfer case.

7. Remove the fuel lines from the retainer.
8. Remove the electrical harness from the retainers.
9. Remove the electrical connector from the speed sensors.
10. Remove the motor/encoder electrical connector.
11. Remove the transfer case wiring harness.
12. Remove the vent hose.
13. Install a transmission jack for the transfer case.
14. Remove the transfer case mounting nuts.
15. Remove the transfer case from the vehicle.
16. Remove the transfer case gasket.

Installation Procedure

Notice: To avoid part damage, verify that transfer case fluid is present. If required, add or fill transfer case fluid. Refer to SI for fluid specifications and fill instructions.

Important: DO NOT use silicone sealant in place or with the transfer case gasket.

1. Replace the transfer case gasket.
2. Install the transfer case in the vehicle.
3. Install the transfer case mounting nuts.

Tighten
Tighten the nuts to 47 N·m (35 lb ft).

4. Remove the transmission jack stand.
5. Install the transfer case speed sensors electrical connectors.
6. Install the vent hose.
7. Install the motor/encoder electrical connector.
8. Install the transfer case harness to the transfer case.
9. Install the transfer case wiring harness to the retainers.
10. Install the fuel lines to the retainer.
11. Install the rear propeller shaft.

11.1.

Install the propeller shaft into the transfer case.

11.2.

Install the propeller shaft to the rear axle pinion yoke. Align the reference marks made during removal.

11.3.

Install the yoke retainers and the bolts.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).

12. Install the front propeller shaft.

12.1.

Install the propeller shaft to the transfer case.

12.2.

Install the propeller shaft to the front axle pinion yoke. Align the reference marks made during removal.

12.3.

Install the yoke retainers and the bolts.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).

13. Install the fuel tank shield.
14. Install the fuel tank shield retaining bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

15. Lower the vehicle.
16. Reprogram the transfer case control module with calibration P/N 12575794.

16.1.

Connect the scan tool to the vehicle.

16.2.

Power up the scan tool and select the Service Programming feature.

16.3.

Select the appropriate vehicle.

16.4.

Press the Request Info button on the scan tool.

16.5.

Connect the scan tool to the computer station.

16.6.

Follow the menu select items for reprogramming and provide information as to what device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU).

16.7.

Select "vehicle" from the selection menu.

16.8.

Select "ATC Active Transfer Case Module" to program.

16.9.

Select "Normal" for Programming Type.

16.10.

Select the applicable software calibrations.

16.11.

Transfer data file to the scan tool.

16.12.

Position the left side second row seat in order to access the rear fuse block.

16.13.

Remove the No. 6 (Liftgate Module/Driver Seat Module) fuse.

16.14.

Reconnect the scan tool to the vehicle.

16.15.

Turn ON the ignition with the engine OFF.

16.16.

Select the Service Programming feature on the scan tool.

16.17.

Press the Program button on the scan tool.

16.18.

Install fuse and reposition the seat.

17. Install the GM Recall Identification Label.

FOR US AND IPC

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

FOR CANADA

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering.

Submit a Product Recall Claim with the information indicated below:

Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission.

Dealers in possession of vehicles included in the Stop Delivery are eligible for reimbursement of floor plan expense upon completion of this recall. This reimbursement is limited to the number of days from the Stop Delivery message to receipt of the recall parts and/or repair procedures. Floor plan reimbursement beyond these dates is not allowed. The amount of reimbursement should be charged as a net amount expense using the recall labor operation provided.

FOR US

Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter included with this bulletin).

FOR CANADA and IPC

No customer notification by General Motors is necessary because these "stop delivery" vehicles are listed as "unsold."

FOR US AND IPC (US States, Territories, and Possessions)

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty 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 customer 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 remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

FOR ALL

All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle "Stop Delivery" inventory are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2002 4WD Chevrolet TrailBlazer and GMC Envoy vehicles. Some of these vehicles were built with a range shift collar in the transmission transfer case that contain cracks. This condition could result in a complete fracture of the range shift collar and subsequent loss of vehicle forward and reverse gears; and the inability to maintain "park" position. This increases the risk of a vehicle crash resulting from unintended movement of a parked vehicle.

To prevent the possibility of this condition occurring, your dealer will replace the transmission transfer case and update the transfer case control module calibration. This service will be performed for you at no charge .

The length of time required to perform this service correction is approximately two and a half hours. Additional time may be required to schedule and process your vehicle. If you dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed to schedule, process and repair your vehicle.

Please contact your dealer as soon as possible to arrange a service date. Parts are available and instructions for making this correction have been sent to your dealer.

Your dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the number listed below:

If, after contacting the appropriate customer assistance center, 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 SW, Washington, DC 20590 or call 1-888-327-4236.

The attached customer 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 no longer own this vehicle, please let us know by completing the attached and mailing it in the postage paid envelope.

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.

General Motors Corporation

Enclosure