Product Safety - Transmission Oil Cooler Line Degradation

DUE TO PARTS AVAILABILITY, THIS CAMPAIGN WILL BE ADMINISTERED IN TWO PHASES. THE FIRST PHASE WILL CONSIST OF 1999 VEHICLES. THE SECOND PHASE WILL CONSIST OF 2000 VEHICLES. ENCLOSED IN THE DEALER LISTING FOR THE FIRST PHASE. A NEW DEALER LISTING WITH THE INVOLVED VEHICLES FOR THE SECOND PHASE WILL BE MAILED TO YOU WHEN PARTS BECOME AVAILABLE. ANY DEALER NOT RECEIVING A DEALER LISTING HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1999-2000 Chevrolet and GMC B7 and C6/7 series medium duty vehicles. Some of these vehicles exhibit a condition in which transmission fluid may leak from a heat degraded transmission fluid cooler hose onto the exhaust system on the passenger's side of the vehicle. If this were to occur, a fire could result.

Dealers are to install a new transmission fluid cooler inlet hose and outlet hose designed with a heat sleeve and ensure adequate clearance to the exhaust system take-down pipe. Dealers are to also inspect the right-hand exhaust manifold seal for leakage, and replace if necessary.

Involved are certain 1999-2000 Chevrolet and GMC B7 and C6/7 series medium duty vehicles built within these VIN breakpoints:

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

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

Parts required to complete this campaign 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.

1. Raise the vehicle.
2. Remove the bolt that attaches the line clips to the side member bracket.



3. Remove the bolt that attaches the line clips to the engine bracket.



4. Remove the bolt that attaches the line clips to the transmission.
5. Disconnect the inlet and the outlet cooler lines from the fittings on the transmission.
6. Disconnect the outlet cooler line from the oil filter adapter.



7. Disconnect the inlet cooler line from the radiator.
8. Remove the inlet and the outlet cooler lines from the vehicle.
9. Transfer the line clips to the new cooler lines.
10. Install the inlet and the outlet cooler lines to the vehicle.
11. Connect the inlet cooler line to the radiator.

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

12. Connect the outlet cooler line to the oil filter adapter.

Tighten
Tighten the nut fitting to 30 N·m (22 lb ft).

13. Connect the inlet and the outlet cooler lines to the fittings on the transmission.

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

14. Position the line clips and install the bolt that attaches the clips to the transmission.
15. Position the line clips and install the bolt that attaches the clips to the engine bracket.
16. Position the line clips and loosely install the bolt that attaches the clips to the side member bracket.



17. Adjust the line position by rotating the clips on the bracket so that there is a minimum of 51 mm (2 in) clearance between the cooler hoses and the exhaust take-down pipe.
18. Hold the position of the lines and tighten the bolt that attaches the clips to the side member bracket.
19. Lower the vehicle.
20. Replenish the transmission fluid as necessary.
21. Raise the vehicle with the engine running. Check the cooler lines and the connections for leaks.
22. Inspect the right side exhaust manifold seal for leaks. An exhaust leak may be identified by the following:

-	Stains at the area of the leak

-	Felt by holding a hand close to the suspect area

-	Popping or hissing sound

23. Lower the vehicle and turn off the engine.

•	If the exhaust manifold seal does not leak, no further action is required. Install the GM Campaign Identification Label.

•	If the exhaust manifold seal does have a leak, replace the right exhaust manifold seal. Proceed to Step 24.

24. Raise the vehicle.



25. Remove the nuts that attach the exhaust pipe to the manifold. Discard the nuts.
26. Lower the exhaust pipe.
27. Remove the exhaust manifold seal. Discard the seal.
28. Inspect the exhaust manifold studs and thread for damage. Replace if necessary.
29. Install the new exhaust manifold seal.
30. Install the new nuts that attach the exhaust pipe to the manifold.

Tighten
Tighten the nuts to 65 N·m (48 lb ft).

31. Lower the vehicle.
32. Install the GM Campaign Identification Label.

FOR US

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. 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.

Put the Campaign 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 Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels for US dealers can be obtained from Dealer Support Material by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

FOR CANADA

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. 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.

Put the Campaign 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 Campaign 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 Campaign Claim with the information indicated below:

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

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

FOR US

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall campaign 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 campaign notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the campaign is not completed within a reasonable time.

FOR ALL

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 customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign 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 inventory, and for which there is no customer information indicated on the dealer listing, 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. Campaign 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 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.

Dear Chevrolet/GMC 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 1999-2000 Chevrolet and GMC B7 and C6/7 series medium duty vehicles. Some of these vehicles exhibit a condition in which transmission fluid may leak from a heat degraded transmission fluid cooler hose onto the exhaust system on the passenger's side of the vehicle. If this were to occur, a fire could result.

Your dealer will install a new transmission fluid cooler inlet hose and outlet hose designed with a heat sleeve and ensure adequate clearance to the exhaust system take-down pipe. Your dealer will also inspect the right-hand exhaust manifold seal for leakage, and replace the seal if necessary. This service will be performed for you at no charge .

The length of time required to perform this service correction is approximately 30 minutes, however, if the exhaust seal is replaced, another 15 minutes will be required. 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 Chevrolet/GMC 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 Chevrolet/GMC 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/Relations 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 1-800-424-9393 (Washington, DC residents use 202-366-0123).

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.

Chevrolet/Pontiac-GMC Division

General Motors Corporation

Enclosure