Exchange Program - Service Parts Restriction Program for Allison Series 1000 Automatic Transmission. GMC Truck GMC K Sierra

Subject:

Service Parts Restriction Program for Allison® Series 1000 Automatic Transmission

Models:

2001-2002 Chevrolet and GMC C/K 2500/3500 Series Pickup Models

With Allison® Series 1000 Automatic Transmission (RPO M74)

This bulletin is being revised to add model years as well as additional information. Please discard Corporate Bulletin Number 00-07-30-017A (Section 07 -- Transmission/Transaxle).

Important: "IPC" dealers are not authorized to utilize this service bulletin.

In order to gain helpful product feedback, certain Allison® Series 1000 automatic transmissions and parts are being placed on a restriction program effective February 1, 2002 through July 1, 2002. Effective with this bulletin, dealers MUST contact Technical Assistance (TAC) prior to replacing or ordering the following parts through Service Parts Operations (SPO):

•	Transmission Assembly

•	Transmission Control Module (TCM)

We recommend you review this bulletin in its entirety and become familiar with the documentation of diagnostic requirements. Only the parts/assembly mentioned above are included in this restriction program.

The following information explains the requirements regarding diagnosis, replacement procedure, warranty claims processing procedures and shipping instructions.

Your cooperation in adhering to these procedures will assist General Motors in making continuous improvements to our products.

Diagnosis Procedure

Important: The Allison® Series 1000 Automatic transmission MUST be repaired by a technician that has SUCCESSFULLY COMPLETED ALL of the following training courses:

USA

•	Allison LCT 1000 Automatic Transmission #17340.10B (Part 1)

•	Allison LCT 1000 Automatic Transmission #17340.11B (Part 2)

•	Allison LCT 1000 Automatic Transmission Diagnostic Issues & Procedures #17340.12D

•	Allison LCT 1000 Automatic Transmission Diagnostic Close-Up #17340.13D

Canada

•	Allison LCT 1000 Automatic Transmission CPT course #57030.00 (Part 1)

•	Allison LCT 1000 Automatic Transmission CTP course #57031.00 (Part 2)

•	Allison LCT 1000 Automatic Transmission HIDL course #17030.01

All repairs must be completed in accordance to the instructions provided in these training courses, current Service Bulletins and the Technical Assistance Center (TAC).

The enclosed diagnostic worksheets (Allison® Series 1000 Diagnostic Worksheet/Allison® Series 1000 TCM Diagnostic Worksheet) and a Tech 2 snapshot MUST BE COMPLETED prior to contacting TAC. When repairs are completed, copies of these documents MUST BE attached to the parts/assembly returned to the Warranty Parts Center. The original copy of these worksheets must be attached to the shop copy of the repair order. This procedure will assure that the proper diagnosis has been performed and the most expeditious repair has been done for the customer, thus avoiding the potential for warranty chargeback due to an incorrect repair. (Refer to the forms at the end of this bulletin.)

The diagnosis of oil leaks MUST be done with the "black light" method. Refer to Allison® LCT 1000 Automatic Transmission Course #17340.11B booklet, part 2 (in Canada, course #57031.00, part 2), pages 1 through 5 and Corporate Bulletin Number 01-07-30-041, dated December, 2001. All transmissions returned for oil leaks WILL BE TESTED with the "black light" method. Should the transmission have an oil leak in the case or one you are unable to repair, the location MUST be indicated by circling the area of lubricant leakage on the Leak Identification Chart found at the end of this bulletin (reproduce locally). Using a permanent marker, also circle the leak area on the transmission.

Restricted Serviceable Components

•	Transmission Assembly -- 2001 Part Numbers

-	29537662 - 2WD Gas Engine

-	29537669 - 2WD Diesel Engine

-	29537663 - 4WD Gas Engine

-	29537661 - 4WD Diesel Engine

•	Transmission Assembly -- 2002 Part Numbers

-	29538988 - 2WD Gas Engine

-	29538990 - 2WD Diesel Engine

-	29538989 - 4WD Gas Engine

-	29538987 - 4WD Diesel Engine

•	Transmission Control Module - P/N 29537441

Replacement Procedure

Once the diagnosis is made and replacement of one of the restricted part/assembly is deemed necessary, contact the Technical Assistance Center. Be prepared to provide TAC with the information recorded on the appropriate worksheets (Allison® Series 1000 Diagnostic Worksheet, Allison® TCM Diagnostic Worksheet, Tech 2 snapshot).

In the USA, if is in agreement with your diagnosis, they will provide your dealership with a TAC case number, which is to be recorded on the repair order, and arrange to ship the restricted parts to your dealership. In Canada, if TAC is in agreement with your diagnosis, they will provide your dealership with a TAC case number, which is to be recorded on the repair order and is required by SPO when you order parts.

In the USA, the restricted parts/assembly will not be available from GMSPO for vehicles repairs without TAC approval. During the period of this restriction, TAC will order the parts/assembly for the dealer and the parts/assembly will be shipped and billed to the dealer account by GMSPO. This process includes warrantable and non-warrantable repairs.

The removed part/assembly must be returned complete, as removed from the vehicle without examination other than what is required to perform proper diagnosis. Dealerships returning units that have been disassembled beyond what is required will be considered as violating this procedure and will be subject to being billed for all materials and labor.

Warranty Claims Processing

Upon completion of the repair, a warranty claim is to be submitted for the following information:

Labor Operation	Labor Time	Part Allowance	Administrative Allowance
K7000 Trans. Assy, 2WD - R&R	4.2 hrs	40%	0.2 hr
K7000 Trans. Assy, 4WD - R&R	5.3 hrs	40%	0.2 hr
ADD: Trans. Diagnosis	1.3 hrs	N/A	N/A
K5365 Transmission Control Module - R	0.6 hr	40%	0.2 hr
ADD: Trans. Diagnosis	1.3 hrs	N/A	N/A

All parts/assemblies ordered and shipped to dealers as a result of this bulletin will be billed to the dealer's SPO account, including the core charge for the transmission assembly. Any questions you may have with regard to the order status of parts/assemblies should be directed to SPAC at GMTRACS, 1-800-433-6961 and in Canada to SPAC at GMTRACS, 1-866-275-5832. Further inquiries as to parts/assembly status should be directed to your Field Area Parts Manager.

When the part/assembly has a core charge and the dealer has been requested to return the part/assembly to the WPC, the dealer is to submit for the core credit through the warranty claims system. Refer to the appropriate section of the Policy & Procedures Manual/Claim Processing Manual. Further questions should be directed to your Area Service Manager.

Important: ALL PARTS/ASSEMBLIES IN THIS RESTRICTION ARE TO BE RETURNED TO THE WARRANTY PARTS CENTER (WPC). DO NOT RETURN THE PART/ASSEMBLY UNTIL YOU RECEIVE THE REQUEST NUMBER FROM THE WPC. QUESTIONS WITH REGARD TO WPC RETURNS SHOULD BE DIRECTED TO THE WPC HELP DESK AT 1-248-371-9901.

As part of continuous improvement to GM products, the Warranty Parts Center (WPC) will request all of the parts in this restriction program to be returned per normal WPC procedures outlined in Corporate Bulletin Number 99-00-89-019B, dated January 2002 (dealers in Canada should refer to Home Office Letter 99-201). To increase the effectiveness of this program, submit the warranty claim as soon as possible in order for the WPC to process the necessary return request.

Preparation for Shipping

When returning these parts to the WPC, ALL OF THE DOCUMENTS LISTED BELOW MUST be enclosed in the waterproof envelope with your shipment. When returning a transmission, wire the envelope securely to a bell housing bolt hole of the removed unit.

•	Copy of repair order (all repairs)

•	Leak Identification Chart (if the transmission is replaced due to leaks)

•	Completed Allison® Series 1000 Diagnostic Worksheet (all transmission replacements)

•	Completed Allison® TCM Diagnostic Worksheet (all TCM replacements)

•	Paper copy of Tech 2 snapshot which best demonstrates the concern (all repairs)

Using a permanent marker, write the TAC case number of the top of the returned transmission.

UNDER NO CIRCUMSTANCES MAY THE PARTS/ASSEMBLIES IN THIS RESTRICTION PROGRAM BE RETAINED OR PURCHASED BY THE DEALER.

Allison® LCT 1000 Diagnostic Worksheet
ALL INFORMATION BELOW MUST BE PROVIDED TO TAC SPECIALIST AT TIME OF TAC CALL.
Date:	TAC Case #:
Dlr Code:	Telephone #:
Technician's Name:
VIN:		Mileage:
Transmission Serial No:
Transmission Part No:
Vehicle Application (Wrecker, Flat Bed, Van Body, Etc.):
Primary Use (City, Highway, Etc.):
Is the Service Engine Soon Light on? (circle one) Yes No
Oil Level: Where on dipstick, +/- from ADD mark?
Oil - Hot or Cold? (circle one) Oil Color:
Does the transmission oil have a burnt odor? (circle one) Yes No Oil Leaks? (circle one) Yes No
If yes, location:
List all codes found: Active:
History:
Circle ranges that are obtainable: P R N 5 4 3 2 1 (Technician to attempt to drive truck and verify all 5 forward ranges attained or verify by using clutch test mode in Tech 2.) Does the range inhibit light, which is incorporated into the PRNDL on the dash, come on? (circle one) Yes No Can the torque converter clutch be achieved? (circle one) Yes No Is the "limp-home" (fail mode) achievable? (circle one) Yes No
Check and record the main line pressure @ idle:
Check and record the main line pressure @ 1200 RPM:
What is the voltage to TCM at the J1 connector?
Is the battery properly charged? (circle one) Yes No Battery voltage__________________________Tech 2 Check the battery-direct fuse. Is it OK? (circle one) Yes No
Are the following connections properly made? (circle one) J1 Connector: Yes No J2 Connector: Yes No Main Transmission Connector: Yes No Speed Sensor: Front: Yes No Speed Sensor: Middle: Yes No Speed Sensor: Rear: Yes No NBSU Switch: 4 Pin Connector: Yes No NBSU Switch: 7 Pin Connector: Yes No NBSU Switch linkage properly adjusted? Yes No
Tech Diagnosis (Why does the transmission need replacement? Please be specific.):__________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
THIS FORM MUST BE ATTACHED TO THE R.O. WHEN RETURNING THE TRANSMISSION TO THE WARRANTY PARTS CENTER.

TCM Diagnostic Worksheet for Allison® 1000 Series Transmission
THIS FORM MUST BE ATTACHED TO THE REPAIR ORDER AND TO THE TCM. All entries in this first section are REQUIRED. The TCM will be returned without credit if the form is incomplete. At least ONE section of the Troubleshooting Summary must be completed.
Dlr Name:
Dlr Code:	TAC Case #:
R.O. No:
VIN:		Mileage:
Technician's Name:
Technician's SS#:
Installation Information:
Transmission Serial Number:
TCM Serial Number - Original: TCM Serial Number - New (when installed):
Describe problem:



Explain why TCM must be replaced:



Conditions when problem occurs:


Tech 2 Data: Calibration P/N:
Codes (CIRCLE ACTIVE CODES):

Troubleshooting Summary
Fill in at least ONE of the following seven sections.
If the problem is a P1760, P0880, P0562, P0563, P0602, P0606, were the following checked? Any previous re-calibrations? Yes No Explain: TCM direct power to battery? Pin C1-3 Yes No TCM ignition power to battery? Pin C1-2 and Pin C1-4 Yes No TCM grounds to battery? Pin C1-1 and Pin C1-5 Yes No
If the problem is speed sensor codes, were the following checked? Speed sensor connectors inspected? Yes No Continuity checked on speed sensor wires? Yes No Are the sensor wires twisted pair wires? Yes No
If the problem is a code P0705, P0706, P0708, NSBU-related, were the following checked? Was the manual selector linkage properly adjusted? Yes No Were the PRNDL positions OK on the diagnostic tool? Yes No Opens/shorts in harness (circle appropriate one)? Yes No
If the problem is solenoid codes, were the following checked? Solenoid resistance? Yes No Opens/shorts in wiring harnesses (circle appropriate one)? Yes No Loose terminals in connectors? Yes No Shorts to transmission case? Yes No Power and return voltage at the CJ-1 connector? Yes No
If the problem is the pressure switch code, were the following checked? Proper switch open and closed states on the diagnostic tool? Yes No Loose terminals in connectors? Yes No Opens/shorts in wiring harnesses (circle appropriate one)? Yes No Shorts to transmission case? Yes No
If the problem was a code U2105, U2104, were the following checked? Proper connections at C2-29? Yes No Proper connections at C2-31? Yes No Proper connections at C2-32? Yes No
If the problem is related to input or output function, were the following checked? Continuity on wiring at pins C1-9? Yes No Continuity on wiring at pins C1-10? Yes No Continuity on wiring at pins C1-11? Yes No Continuity on wiring at pins C1-12? Yes No Continuity on wiring at pins C1-13? Yes No Continuity on wiring at pins C1-14? Yes No Status of functions at the diagnostic tool (function on when commanded)? Yes No
Additional Comments:


Resources Used: Was SI2000 used? Yes No Document ID Number:_________________________ Document Date:______________________ Which sections were used?_______________________________ ______________________________________________________ Which other Service Bulletins were used?___________________ ______________________________________________________
_______Check here if comments, explanations or problems are attached to this return sheet.

Troubleshooting Summary

Fill in at least ONE of the following seven sections.

If the problem is a P1760, P0880, P0562, P0563, P0602, P0606, were the following checked?

Any previous re-calibrations? Yes No

Explain:

TCM direct power to battery? Pin C1-3 Yes No

TCM ignition power to battery? Pin C1-2 and Pin C1-4 Yes No

TCM grounds to battery? Pin C1-1 and Pin C1-5 Yes No

If the problem is speed sensor codes, were the following checked?

Speed sensor connectors inspected? Yes No

Continuity checked on speed sensor wires? Yes No

Are the sensor wires twisted pair wires? Yes No

If the problem is a code P0705, P0706, P0708, NSBU-related, were the following checked?

Was the manual selector linkage properly adjusted? Yes No

Were the PRNDL positions OK on the diagnostic tool? Yes No

Opens/shorts in harness (circle appropriate one)? Yes No

If the problem is solenoid codes, were the following checked?

Solenoid resistance? Yes No

Opens/shorts in wiring harnesses (circle appropriate one)? Yes No

Loose terminals in connectors? Yes No

Shorts to transmission case? Yes No

Power and return voltage at the CJ-1 connector? Yes No

If the problem is the pressure switch code, were the following checked?

Proper switch open and closed states on the diagnostic tool? Yes No

Loose terminals in connectors? Yes No

Opens/shorts in wiring harnesses (circle appropriate one)? Yes No

Shorts to transmission case? Yes No

If the problem was a code U2105, U2104, were the following checked?

Proper connections at C2-29? Yes No

Proper connections at C2-31? Yes No

Proper connections at C2-32? Yes No

If the problem is related to input or output function, were the following checked?

Continuity on wiring at pins C1-9? Yes No

Continuity on wiring at pins C1-10? Yes No

Continuity on wiring at pins C1-11? Yes No

Continuity on wiring at pins C1-12? Yes No

Continuity on wiring at pins C1-13? Yes No

Continuity on wiring at pins C1-14? Yes No

Status of functions at the diagnostic tool (function on when commanded)? Yes No

Additional Comments:

Resources Used:

Was SI2000 used? Yes No

Document ID Number:_________________________

Document Date:______________________

Which sections were used?_______________________________

______________________________________________________

Which other Service Bulletins were used?___________________

______________________________________________________

_______Check here if comments, explanations or problems are attached to this return sheet.

Exchange Program - Service Parts Restriction Program for Allison Series 1000 Automatic Transmission

Diagnosis Procedure

USA

Canada

Restricted Serviceable Components

Replacement Procedure

Warranty Claims Processing

Preparation for Shipping

Installation Information:

Tech 2 Data:

Additional Comments:

Resources Used:

Tech 2 Snapshot (Example)

Leak Identification Chart

Transmission Left-Rear (2WD/1K Optional)

Transmission Right-Front View