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Makes 🢒 GMC_Truck 🢒 1991 🢒 GMC G Van 🢒 Bulletins 🢒 CAMPAIGN: 4L60 SOFT TURBINE SHAFT, BREAKAGE/NO DRIVE POWER

CAMPAIGN: 4L60 SOFT TURBINE SHAFT, BREAKAGE/NO DRIVE POWER

SUBJECT: 4L60 TRANSMISSION SOFT TURBINE SHAFT

MODELS: 1991 C/K PICKUP TRUCKS AND G-VANS EQUIPPED WITH 4L60 AUTOMATIC TRANSMISSIONS (MD8)

FOLLOWING INFORMATION SENT VIA DCS MESSAGE TO INVOLVED SELLING DEALERS ON JUNE 21, 1991.

General Motors has determined that a small number of 1991 C/K pickup trucks and G-Vans, equipped with 4L60 automatic transmissions (MD8), may have been built with a transmission turbine shaft that may be at less than specified hardness. This is likely to cause a failure of the turbine shaft in the first 2,000 miles of vehicle usage, resulting in total loss of drive power in forward and/or reverse.

To prevent this condition from occurring, it is necessary to replace the transmission with a new transmission assembly.

VEHICLES INVOLVED

Involved are certain 1991 C/K pickup trucks and G-Vans equipped with 4L60 automatic transmissions (MD8) built between 5/31/91 and 6/4/91. Dealer codes and vehicles involved are listed on next page.

DEALER CAMPAIGN RESPONSIBILITY

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. Dealers are to correct all affected vehicles in new vehicle stock prior to their sale.

Should vehicles be sold inadvertently from your new vehicle inventory, prior to repair, owners are to be contacted by the dealer and arrangements made to make the required correction according to instructions contained in this bulletin.

SELLING SHIP TO DEALER DEALER CODE CODE VIN (Selling Dealer Code Order) -------- -------- ----------------- 48-06075 48-06075 2GTFC29K1M1544647 48-06128 48-54988 2GDEG25KXM4514370 48-06128 48-54988 2GDEG25K9M4514375 48-06128 48-63297 2GDEG25K2M4514377 48-06128 48-54988 2GDEG25K8M4514397 48-06128 48-54988 2GDEG25K8M4514416 48-06128 48-54988 2GDEG25K2M4514427 48-06267 48-06267 2GTFK29K0M1544884 48-10300 48-10300 2GTEK19K5M1544692 48-10471 48-10471 2GTEK19K6M1544801 48-18003 48-18003 2GTFK29K1M1544800 48-18046 48-18046 2GTEK19K3M1544805 48-21049 48-21049 2GTEK19K9M1544789 48-21057 48-21057 2GTFC29KXM1544680 48-21322 48-21322 1GKEG25K8M7514817 48-21334 48-21334 2GTEC19K1M1544654 48-21524 48-21524 1GTDC14H7MZ531194 48-21648 48-21648 2GTEC19K4M1544681 48-21998 48-21998 2GTEC19KXM1544717 48-30083 48-30083 2GTEC19K0M1544676 48-30135 48-30135 2GTEK19K5M1544787 48-30317 48-30317 2GTEC19KXM1544779 48-30437 48-30437 2GTEC19K9M1544661 48-30553 48-30553 2GTFC29K7M1544698 48-30641 48-62553 2GDEG25K6M4514379 48-30641 48-62553 2GDEG25K6M4514401 48-40001 48-40001 2GTFK29KXM1544830 48-40001 48-40001 2GTEK19K9M1544890 48-40035 48-40035 1GTEG25H9M7514762 48-40050 48-40050 2GTFC29K7M1544829 48-40075 48-40075 2GTFK29K6M1544713 48-40092 48-40092 2GTEK19K4M1544764 48-40116 48-40116 1GTDC14K4MZ531195 48-40155 48-40155 2GTFK29K9M1544785 48-40162 48-40162 2GTFK29K6M1544887 48-40203 48-40203 2GTFC29K4M1544724 48-40220 48-40220 2GTFK29K9M1544821 48-40998 48-40998 2GTEC19K9M1544756 48-42004 48-42004 2GTEK19K5M1544837 48-42022 48-42022 2GTEC19K4M1544728 48-42022 48-42022 2GTFC29K9M1544749 48-42022 48-42022 2GTEC19K3M1544784 48-42044 48-42044 2GTEC19K9M1544921 48-42067 48-42067 2GTEC19K6M1544732 48-42078 48-42078 2GTEC19K0M1544757 48-44618 48-44618 2GTEK19K8M1544797 48-44629 48-44629 2GTEK19K2M1544777 48-47035 48-47035 1GDDC14K3MZ531197

SELLING SHIP TO DEALER DEALER CODE CODE VIN (Selling Dealer Code Order) -------- -------- ----------------- 48-47085 48-47085 2GTEC19KXM1544748 48-47090 48-47090 2GTEC19K3M1544655 48-47302 48-64163 2GDEG25Z1M4514366 48-47302 48-47302 2GTEC19K6M1544679 48-47302 48-47302 2GTEC19KXM1544684 48-47332 48-47332 2GTEC19K4M1544745 48-47351 48-47351 2GTEC19K6M1544682 48-50090 48-50090 2GTEC19K1M1544721 48-50141 48-50141 1GTDC14HXMZ531206 48-50409 48-50409 2GTEC19K0M1544760 48-51085 48-51085 1GTDC14Z0MZ531174 48-51085 48-51085 1GTDC14Z8MZ531200 48-51191 48-51191 1GTDC14K7MZ531207 48-51191 48-51191 2GTEC19K7M1544710 48-51246 48-51246 2GTEC19K9M1544689 48-51264 48-51264 2GTEC19K1M1544668 48-53032 48-62863 2GDEG25Z5M4514404 48-53057 48-53057 2GTEC19K0M1544693 48-53395 48-53395 1GTDC14K5MZ531240 48-53512 48-53512 1GTDC14Z5MZ531221 48-56111 48-56111 2GDEG25K0M4514359 48-56111 48-56111 2GDEG25K9M4514425 48-56112 48-56112 1GDEG25K5M7514829 48-56115 48-56115 2GDEG25K9M4514361 48-56117 48-56117 2GDEG25K4M4514364 48-56117 48-56117 2GDEG25K4M4514395 48-56117 48-56117 2GDEG25K2M4514430 48-56120 48-56120 1GDEG25K6M7514760 48-56120 48-56120 1GDEG25K6M7514774 48-56120 48-56120 1GDEG25K9M7514803 48-56120 48-56120 1GDEG25K4M7514806 48-56120 48-56120 1GDEG25K1M7514827 48-56120 48-56120 1GDEG25K4M7514840 48-56120 48-56120 1GDEG25K6M7514855 48-56120 48-56120 1GDEG25KXM7514857 48-56120 48-56120 1GDEG25K4M7514868 48-56120 48-56120 1GDEG25K8M7514873 48-56120 48-56120 1GDEG25KXM7514874 48-56150 48-56150 1GDDC14K2MZ531224 48-56790 48-56790 2GTFK29K4M1544774 48-56886 48-56886 2GDEG25K9M4514411 48-56886 48-56886 2GDEG25K2M4514444

* VIN no longer involved.

OWNER NOTIFICATION

There will be no owner letter sent out with this campaign. Due to the stop sale issued prior to vehicle sale, it is anticipated the vehicles should still be in your new vehicle inventory and should be repaired prior to retail sale. If a unit has been retailed, in order to maintain customer satisfaction, contact the owner immediately and arrange to correct this condition on his/her vehicle.

SERVICE PROCEDURE

Remove Tool Required: J 21366 Convertor Holding Strap

1. Negative (-) battery cable.

2. TV cable from the throttle linkage.

3. Fuel lines at the TBI. - Relieve fuel pressure, refer to the 1991 Light Duty Fuel and Emissions Manual, 4-17.

-Raise the vehicle.

4. Transmission fluid. -Transfer case fluid (K model). -Transfer case skid plate, if equipped (K model).

5. Shift linkage.

6. Propeller shaft, refer to PROPELLER SHAFT (SEC. 4A). -Front propeller shaft from the transfer case (K model).

7. Electrical connector and transfer case vent tube (K model).

8. Transfer case shift linkage (K model). Refer to TRANSFER CASE (SEC. 7D).

9. Transfer case to adaptor mounting bolts (K model).

10. Transfer case (K model). -Clean transfer case gasket mating surfaces.

11. Support bracket at the catalytic convertor. -Any other components as needed for clearance.

12. Exhaust crossover at the manifolds.

13. Transmission mount and crossmember. -Support the transmission with a transmission jack.

IMPORTANT: Do not stretch or damage any cables, wires or other components when lowering the transmission.

14. Transmission far enough for clearance to reach other components.

15. Transmission fill tube and the seal.

16. Speedometer harness connector.

17. Electrical connectors from the transmission.

18. Transmission cooler lines. -Cap all openings in the transmission and the lines.

19. Transmission to engine support braces. -Note the location of the braces, they must be installed in the same positions.

20. Convertor housing cover.

21. Torque convertor to flywheel bolts.

IMPORTANT: Support the engine with a jack or hoist before disconnecting the transmission.

22. Transmission to engine bolts. - Note the location of any brackets or clips and move them aside.

- Slide the transmission straight back off of the locating pins and install J 21366.

23. Transmission from the vehicle. -TV cable from transmission. -Transfer case adaptor from transmission (K model).

Install Tool Required: J 21366 Convertor Holding Strap

1. New transmission. - TV cable to transmission. - Transfer case adapter to transmission (K model). - Tighten transmission to transfer case adapter bolts to 33 N.m (24 lbs. ft.) (K model). - Be sure the torque convertor is seated properly and that J 21366 is in place. - Support the transmission with a transmission jack. Raise the transmission into place and remove J 21366. - Slide the transmission straight onto the locating pins while lining up the flywheel to torque convertor bolt holes.

IMPORTANT: The torque convertor must be flush onto the flywheel and rotate freely by hand.

2. Transmission to engine bolts. - All brackets, clips and harnesses must be positioned as they were when removed. - Remove the engine hoist or jack. - Do not install the transmission fill tube or the transmission support braces at this time.

3. Torque convertor to flywheel bolts. -Tighten bolts finger tight to ensure proper convertor seating. -Torque bolts to 63 N.m (46 lbs. ft.).

4. Convertor housing cover. -Hook the cover under the lip of the engine oil pan.

5. Transmission to engine support braces. -The braces must be installed in the positions from which they were removed.

6. Transmission Cooler lines -Do not twist or bend the lines.

7. Electrical connectors to the transmission.

8. Speedometer harness connector.

9. Transmission fill tube and seal.

10. Transmission mount to transmission. -Tighten bolts to

11. Transmission crossmember. -Tighten frame bolts to 77 N.m (56 lbs. ft.). -Tighten mount bolt to 52 N.m (38 lbs. ft.). -Remove transmission jack.

12. Exhaust crossover at the manifolds.

13. Support bracket at the catalytic convertor. -Any other components removed for clearance.

14. Transfer case (K model). -Install new adaptor gasket. -Tighten transfer case to adapter bolts to 33 N.m (24 lbs. ft.)

15. Transfer case shift lever (K model).

16. Electrical connector and transfer case vent tube (K model).

17. Propeller shaft. -Front propeller shaft to transfer case (K model).

18. Shift linkage.

19. Transmission fluid. -Transfer case fluid (K model). -Transfer case skid plate, if equipped (K model).

20. Fuel lines at the TBI.

21. TV cable at the throttle linkage.

22. Negative (-) battery cable.

23. Install "Campaign Identification Label".

PARTS INFORMATION

A new transmission for each vehicle involved will be shipped to involved dealers by GM Powertrain Division (Hydra-Matic) on a no charge basis. The replaced unit is to be returned to GM Powertrain Division (Hydra-Matic) immediately to avoid a chargeback.

Transmission Return Procedure:

New transmissions will be shipped in a reusable plastic shipping container. This container should be used to return the replaced transmission. Return shipping instructions as well as a return shipping label will be included with the new transmission.

1. Drain as much oil from the replaced transmission as possible. Remove all plastic shipping plugs from the new unit and install them in the replaced transmission.

2. Remove shipping support from new transmission and install it on the replaced transmission. This support will secure the converter to prevent movement and transmission damage.

3. Put replaced transmission in plastic shipping container, attach the shipping label provided and return collect to GM Powertrain via ground transportation (not air).

GM Powertrain 1455 West Alexis Rd. Toledo, OH 43612

DO NOT ORDER A TRANSMISSION ASSEMBLY FROM GENERAL MOTORS SERVICE PARTS OPERATION (GMSPO). IF PROBLEMS ARE INCURRED IN RECEIVING A TRANSMISSION ASSEMBLY CONTACT:

John Keller GM Powertrain (419) 470-5070

The following parts are to be obtained from General Motors Service Parts Operation (GMSPO). To ensure that the parts will be obtained as soon as possible, they should be ordered from GMSPO on a C.I.O. order with no special instruction code but order under an advise code (2).

PART MODEL NUMBER DESCRIPTION QUANTITY ----- ------- ----------------- -------- C, G 1051855 Fluid, Automatic 5 qts. Transmission

K 1051855 Fluid, Automatic 7 qts. Transmission & Transfer Case

K 15642510 Gasket, Transfer 1 Case Adaptor

K 1358899 Seal, Transfer 1 Case Adapter

Parts are currently available from GMSPO.

WARRANTY INFORMATION

Dealers should submit an accurately filled out Warranty Repair Order on each vehicle completed under this campaign.

LABOR OPERATION *TIME **PARTS TROUBLE NUMBER DESCRIPTION ALLOWANCE ALLOWANCE CODE

V-6820 Transmission Assy, 2.8 hrs. $ 57.56 96 Replace C Truck

V-6821 Transmission Assy, 4.2 hrs. $ 57.56 96 Replace K Truck

V-6822 Transmission Assy, 2.6 hrs. $ 57.56 96 Replace G Van

Add: If Equipped With 0.2 hr. Skid Plate

* For dealers to receive Administrative Time Allowance associated with the campaign, add 0.1 hour to the Labor Operation Time Allowance.

** In the interest of customer satisfaction, GMC Truck has decided to replace, rather than repair the transmission. The $57.56 amount identified in the "Parts Allowance" column above represents 30% of dealer net for the parts (input clutch housing, transmission gasket kit and snap ring kit) that would be required to repair these transmissions. This amount is to be placed in the Net Item Amount column of the claim and use type Code "M".

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 five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or 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.

Apply "Campaign Identification Label" only on a clean, dry surface.

ADMINISTRATIVE PROCEDURE

Procedures covering this campaign are outlined in Section V of your dealership's "GM Truck Claims Processing Manual" #P9119.

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.