Exchange Program - ZF 6-Speed Manual Transmission Exchange Program (RPO ML6)

This bulletin is being revised to add warranty claim information and add text under the Exchange Procedure section. Please discard Corporate Bulletin Number 00-07-29-002 (Section 07 -- Transmission/Transaxle).

Important: 'IPC' Dealers are not authorized to utilize this service bulletin.

In order to gain product feedback on the new ZF 6-speed manual transmission (RPO ML6), an exchange program is in effect from start of production until September 30, 2001.

The following information explains all the requirements regarding diagnosis, serviceable and non-serviceable items, warranty claims processing procedures and shipping information. File this information in the Special Exchange Policy Procedures manual.

In the event your dealership receives a concern on the ZF 6-speed manual transmission (RPO ML6), follow the procedures listed below. Your cooperation in adhering to these procedures will greatly improve the program effectiveness.

Direct all requests for exchange to the U.S. Technical Assistance Center (TAC) at 1-877-446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). THE DIAGNOSTIC WORKSHEET AND ALL DIAGNOSIS MUST BE COMPLETED BEFORE ANY REQUEST FOR AN EXCHANGE TRANSMISSION IS ACCEPTED.

Preliminary Diagnosis Procedure

Important: The ZF 6-speed manual transmission must NOT be disassembled or repaired unless indicated by the Dealer Serviceable Components section in this exchange bulletin.

Refer to the Diagnostic Worksheet in this bulletin. Misdiagnosis results not only in a dissatisfied customer, but also a repeat repair for the dealership.

Dealer Serviceable Components

The following parts may be replaced without exchanging the transmission:

For exchange units that are leaking, indicate by circling the location(s) of transmission fluid leakage on the Leak Identification Locator sheet at the end of this bulletin. Using a permanent marker, also circle the leak area on the transmission case.

Diagnostic Worksheet

Below are some common symptoms that are transmission related. Also listed below are some common concerns that are not transmission related. If additional information is required concerning the clutch and transmission diagnosis, contact U.S. TAC at 1-877-446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). Before calling, have all the necessary information available per the Diagnostic Worksheets below in order to help further diagnose your customers concern.

Use the diagnostic symptom tables and the repair procedures in the 2001 C/K Silverado and Sierra Service Manual to diagnose the customer's concern. The list of diagnostic symptom tables for diagnosing the transmission can be found in Symptom-Manual Transmission procedure located in the Transmission/Transaxle section in the Manual Transmission-ZF S6-650 subsection. The list of diagnostic symptom tables for diagnosing the clutch can be found in the Symptom-Clutch System procedure in the Transmission/Transaxle section in the Clutch subsection.

The clutch diagnostic symptom tables include the following conditions:

The transmission diagnostic symptom tables include the following conditions:

After using the tables to properly diagnose the customers concern, and the table indicates the transmission is faulty, complete the following diagnostic worksheets provided. The worksheets must be completed before calling TAC.

Diagnostic Worksheets

To complete the worksheets, select the appropriate symptom and specify Yes or No. For the conditions, refer to the appropriate Symptom - Manual Transmission, Symptom - Clutch procedures in the appropriate Service Manual.

Exchange Procedure

A thorough diagnosis must be performed on the condition in order to prevent unnecessary component replacements. When the above preliminary diagnosis/repairs are completed, and an exchange unit is still necessary, contact U.S. TAC at 1-877-446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French) to verify that proper diagnosis has been performed. TAC will establish a case reference number and make arrangements for shipping an exchange unit, normally within 24 hours, to your dealership. In order to increase the effectiveness of the program, the Warranty Parts Center (WPC) will request the return of the unit removed only upon submission of a warranty reimbursement claim. Therefore the dealer is strongly encouraged to submit these claims as quickly as possible in order to facilitate the WPC request. DO NOT SHIP A TRANSMISSION TO THE WPC WITHOUT AN OFFICIAL WPC REQUEST.

Be prepared to provide the necessary information by completing the Diagnostic Worksheet prior to calling.

Important: The exchange transmission will be shipped with new synthetic lubricant, GM P/N 12378515 (In Canada use P/N 88900701). With the fluid fill plug removed, verify that the fluid is level with the bottom of the fill hole when the truck is level. Should lubricant be needed, use ONLY GM P/N 12378515 (In Canada use P/N 88900701).

UNDER NO CIRCUMSTANCES MAY THE REMOVED TRANSMISSION BE RETAINED OR PURCHASED BY THE DEALER.

The removed transmission must be returned complete, as removed from the vehicle, without disassembling. Failure to return a transmission, or returning a transmission that has been partially disassembled, will be considered as violating this procedure and will be subject to being billed for all materials and labor.

Included with the exchange unit will be return shipping instructions, including a return shipping label and partially completed Bill of Lading.

Shipping Preparation

1. Securely attach the following items to a wired tag and secure the tag to a top bell housing bolt hole of the removed unit.

•	Diagnostic Worksheet

•	Copy of WPC request message

•	Copy of repair order (R.O.) (front and reverse side)

•	Leak Identification Locator sheet, if needed

•	Two ounce transmission lubricant sample (bottle in plastic bag provided)

2. Using a permanent marker, write the TAC case number on the top portion of the case of the removed transmission.
3. Repack the removed transmission into the original shipping container.

Shipping Instructions

In order to minimize the dealerships' workload, the removed transmission will be returned per the normal WPC procedures outlined in Corporate Bulletin Number 99-00-89-019, dated October, 1999 (Dealers in Canada should refer to Home Office Letter 99-201). Please reference these bulletins for shipping instructions.

Warranty Information

The ZF 6-speed manual transmission is not available from General Motors Service Parts Operations (GMSPO) for vehicles repaired under warranty. Any purchases through GMSPO without prior authorization from TAC may be disallowed on the warranty claim. For vehicles not repaired under warranty, contact TAC for an authorization (case) number before ordering from GMSPO. Upon completion of the repair, submit a warranty claim using:

*Dealers are provided a part allowance. This amount represents 40% of the dealer net price of the difference between the current GMSPO Dealer Net Price less the component return credit (core allowance) for parts that were furnished free-of-charge by General Motors through their suppliers. This amount is to be placed in the Total Parts amount field of the warranty claim.

Dealer Serviceable Components, listed at the beginning of this bulletin, shall be claimed per normal warranty procedure.