4L80 TRANS. TORQUE CONVERTER DAMPNER SPRING FRACTURED. GMC Truck GMC Suburban

GROUP: 7A - AUTOMATIC TRANSMISSION

DATE: SEPTEMBER 1990

SUBJECT: 4L80-E TRANSMISSION TORQUE CONVERTER DAMPER SPRING

MODELS: 1991 R/V 2500 SUBURBANS AND R/V 3500 CREW CABS EQUIPPED WITH AUTOMATIC TRANSMISSIONS MT1 (FLINT ASSEMBLY ONLY)

GENERAL MOTORS HAS DETERMINED THAT ALL 1991 R/V 2500 SUBURBANS AND R/V 3500 CREW CABS SHIPPED FROM FLINT ASSEMBLY PRIOR TO AUGUST 18, 1990, A EQUIPPED WITH 4L80-E AUTOMATIC TRANSMISSIONS HAVE TRANSMISSION TORQUE CONVERTERS WHICH HAVE DAMPER SPRINGS WHICH COULD FRACTURE, RESULTING I NOISE AND POSSIBLE TRANSMISSION FAILURE.

TO PREVENT THE TRANSMISSION FROM FAILING, IT WILL BE NECESSARY TO INSTALL A NEW TORQUE CONVERTER.

VEHICLES INVOLVED

INVOLVED ARE 1991 R/V 2500 SUBURBANS AND R/V 3500 CREW CAB MODEL TRUCK EQUIPPED WITH THE 4L80-E AUTOMATIC TRANSMISSION RPO MT1 BUILT AT FLINT ASSEMBLY WITHIN THE FOLLOWING VIN BREAKPOINTS:

MODEL MODEL YEAR PLANT FROM THROUGH

R/V 2500 1991 FLINT MF500086 MF502109 SUBURBAN

R/V 3500 1991 FLINT MF700003 MF700085 CREW CAB

THERE ARE A TOTAL OF 144 VEHICLES INVOLVED.

THE SPECIFIC VEHICLES INVOLVED IN THIS CAMPAIGN HAVE BEEN IDENTIFIED B VEHICLE IDENTIFICATION NUMBER COMPUTER LISTINGS. THESE LISTINGS ARE FURNISHED TO ALL INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN.

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 NEW AND USED VEHICLE STOCK PRIOR TO THEIR SALE.

WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN IS TAKEN INTO YOUR NEW OR USED VEHICLE INVENTORY, OR IT IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, YOU SHOULD TAKE THE STEPS NECESSARY TO ENSURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE RESELLING OR RELEASING THE VEHICLE.

OWNERS OF VEHICLES RECENTLY SOLD FROM YOUR NEW VEHICLE INVENTORY ARE T BE CONTACTED BY THE DEALER AND ARRANGEMENTS MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO INSTRUCTIONS CONTAINED IN THIS BULLETIN.

IF THE NAME AND ADDRESS OF THE OWNER OF AN INVOLVED VEHICLE WAS UNAVAILABLE TO GMC TRUCK DIVISION AT THE TIME OF CAMPAIGN INITIATION, THE DEALER MUST DETERMINE THE OWNER'S NAME AND ADDRESS FROM THE DEALERSHIP SALES RECORDS. PLEASE PROVIDE THIS INFORMATION DIRECTLY ON THE SECOND COPY OF THE LISTING NEXT TO THE APPLICABLE VIN SO THAT OUR RECORDS MAY BE UPDATED AND THE APPROPRIATE NOTIFICATION MAILED TO THE OWNER. THIS SECOND COPY SHOULD THEN BE SUBMITTED TO THE ADDRESS LISTE BELOW IN THE PREVIOUSLY SUPPLIED YELLOW CAMPAIGN ENVELOPES.

GMC TRUCK DIVISION GENERAL MOTORS CORPORATION 101 UNION STREET PLYMOUTH, MICHIGAN 48170

OWNER NOTIFICATION

OWNERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY GMC TRUC DIVISION (SEE COPY OF OWNER LETTER INCLUDED WITH THIS BULLETIN). A LISTING OF OWNER NAMES AND ADDRESSES HAS BEEN FURNISHED TO THE INVOLVE DEALERS TO ENABLE DEALERS TO FOLLOW UP WITH OWNERS INVOLVED IN THIS CAMPAIGN. THIS LISTING MAY CONTAIN OWNER NAMES AND ADDRESSES OBTAINED FROM STATE MOTOR VEHICLE REGISTRATION RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF LAW SEVERAL STATES. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THIS CAMPAIGN.

SERVICE PROCEDURE

REMOVE

TOOL REQUIRED:

J-21366 CONVERTER HOLDING STRAP

1. BATTERY (-) NEGATIVE CABLE. - RAISE THE VEHICLE.

2. TRANSMISSION FLUID.

3. SHIFT LINKAGE.

4. PROPELLER SHAFT(S), REFER TO PROPELLER SHAFT (SECTION 4A).

5. SUPPORT BRACKET AT THE CATALYTIC CONVERTER. - ANY OTHER COMPONENTS AS NEEDED FOR CLEARANCE. - SUPPORT THE TRANSMISSION, AND THE TRANSFER CASE IF USED, WITH A TRANSMISSION JACK.

6. TRANSMISSION CROSSMEMBER.

IMPORTANT: DO NOT STRETCH OR DAMAGE ANY WIRES OR OTHER COMPONENTS WHEN LOWERING THE TRANSMISSION.

7. TRANSMISSION FAR ENOUGH FOR CLEARANCE TO REACH OTHER COMPONENTS.

8. DIPSTICK TUBE AND THE SEAL. - COVER THE OPENING IN THE TRANSMISSION.

9. ELECTRICAL CONNECTORS FROM THE TRANSMISSION.

IMPORTANT: USE CARE NOT TO BEND OR DAMAGE THE CONNECTOR PINS.

10. COOLER LINES. - CAP ALL OPENINGS IN THE TRANSMISSION AND THE LINES.

11. TRANSFER CASE SHIFTER (IF USED) AND MOVE IT ASIDE, REFER TO TRANS (SECTION 7D).

12. TRANSMISSION SUPPORT BRACES. - NOTE THE LOCATION OF THE BRACES, THEY MUST BE INSTALLED IN THE SAME POSITIONS.

13. CONVERTER HOUSING COVER.

14. TORQUE CONVERTER TO FLEXPLATE BOLTS.

IMPORTANT: SUPPORT THE ENGINE WITH A JACK OR HOIST BEFORE DISCONNECTING THE TRANSMISSION.

15. TRANSMISSION TO ENGINE BOLTS. - NOTE THE LOCATION OF ANY BRACKETS OR CLIPS AND MOVE THEM ASIDE. - SLIDE THE TRANSMISSION STRAIGHT BACK OFF THE LOCATING PINS AND INSTALL J-21366 CONVERTER HOLDING STRAP.

16. TRANSMISSION FROM THE VEHICLE.

17. HOLDING STRAP J-21366 AND CONVERTER.

CAUTION:

CONVERTER IS EXTREMELY HEAVY (65 LBS.) WHEN FULL OF FLUID. MAKE SURE YOU HAVE A GOOD CLEAN GRIP, THIS WILL HELP PREVENT PERSONAL INJURY.

18. TURBINE SHAFT O-RING SEAL.

INSTALL

TOOL REQUIRED:

J-21366 CONVERTER HOLDING STRAP

1. NEW TURBINE SHAFT O-RING SEAL.

2. NEW TORQUE CONVERTER ASSEMBLY. - WITH TRANSMISSION IN HORIZONTAL POSITION PUSH TORQUE CONVERTER UNTIL THE HUB IS INTO THE CONVERTER SEAL. - ROTATE THE TRANSMISSION TO A VERTICAL POSITION (BELL HOUSING FACING UP). - ROTATE THE CONVERTER ASSEMBLY UNTIL IT DROPS INTO POSITION.

3. TRANSMISSION ASSEMBLY. - ATTACH J-21366 HOLDING STRAP TO THE CONVERTER ASSEMBLY. - RAISE THE TRANSMISSION INTO PLACE AND REMOVE J-21366.

IMPORTANT: DO NOT PINCH OR DAMAGE ANY WIRES OR OTHER COMPONEN WHEN RAISING THE TRANSMISSION.

- SLIDE THE TRANSMISSION STRAIGHT ONTO THE LOCATING PINS WHILE LINING UP THE TORQUE CONVERTER AND FLEX PLATE.

IMPORTANT: THE TORQUE CONVERTER MUST BE FLUSH ONTO THE FLYWHE AND ROTATE FREELY BY HAND.

4. TRANSMISSION TO ENGINE BOLTS. - ALL BRACKETS, CLIPS AND HARNESSES MUST BE POSITIONED AS THEY WE WHEN REMOVED. - DO NOT INSTALL THE DIPSTICK TUBE OR TRANSMISSION SUPPORT BRACE BOLTS. - TORQUE BOLTS TO 44 N.M (33 LBS. FT.).

5. TORQUE CONVERTER TO FLEX PLATE BOLTS. - TORQUE BOLTS TO 44 N.M (33 LBS. FT.). - REMOVE TRANSMISSION JACK.

6. CONVERTER HOUSING COVER. - HOOK THE PAN UNDER THE LIP OF THE ENGINE OIL PAN. - TORQUE BOLTS TO 7 N.M (60 LBS. IN.)

7. TRANSMISSION SUPPORT BRACES. - THE BRACES MUST BE INSTALLED IN THE SAME POSITIONS FROM WHICH THEY WERE REMOVED. - TORQUE BOLTS TO 90 N.M (66 LBS. FT.).

8. TRANSFER CASE SHIFTER (IF USED), REFER TO TRANSFER CASE (SECTION 7D).

9. COOLER LINES. - UNCOVER THE TRANSMISSION AND COOLER LINE OPENINGS. - DO NOT TWIST OR BEND THE LINES. - TORQUE FITTINGS TO 38 N.M (28 LBS. FT.).

10. ELECTRICAL CONNECTORS TO THE TRANSMISSION.

IMPORTANT: USE CARE NOT TO BEND OR DAMAGE THE CONNECTOR PINS.

11. DIPSTICK TUBE AND NEW SEAL. - UNCOVER THE OPENING IN THE TRANSMISSION AND INSTALL THE NEW SEA FIRST. - INSTALL TUBE RETAINER BOLT AND TORQUE TO 44 N.M (33 LBS. FT.).

12. TRANSMISSION CROSSMEMBER AND TRANSMISSION MOUNT. - ANY OTHER COMPONENTS THAT WERE REMOVED FOR CLEARANCE. - REMOVE THE TRANSMISSION JACK. - TORQUE CROSSMEMBER AND TRANSMISSION MOUNT BOLTS TO 44 N.M (33 LBS. FT.).

13. SUPPORT BRACKET AT THE CATALYTIC CONVERTER.

14. PROPELLER SHAFT(S), REFER TO PROPELLER SHAFT (SECTION 4A).

15. SHIFT LINKAGE.

16. NEW TRANSMISSION FLUID.

17. BATTERY (-) NEGATIVE CABLE.

PARTS INFORMATION

PARTS ARE TO BE OBTAINED FROM GENERAL MOTORS SERVICE PARTS OPERATION (GMSPO). TO ENSURE THAT THESE 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 NUMBER DESCRIPTION QUANTITY

8674193 TORQUE CONVERTER 1 5.7L GAS ENGINES AND 6.2L DIESEL ENGINES

8674194 TORQUE CONVERTER 1 7.4L GAS ENGINES

8661760 TURBINE SHAFT O-RING 1 SEAL

1259475 DIPSTICK TUBE SEAL 1

1051855 TRANS. FLUID - DEXRON II AR

WARRANTY INFORMATION

DEALERS SHOULD SUBMIT A WARRANTY CLAIM ON EACH VEHICLE COMPLETED UNDER THIS CAMPAIGN.

LABOR OPERATION *TIME TROUBLE NUMBER DESCRIPTION ALLOWANCE CODE

V6350 R AND R TORQUE 3.0 HRS. 96 CONVERTER 2WD

V6351 R AND R TORQUE 3.9 HRS. 96 CONVERTER 4WD

ADD: 0.2 HR. IF EQUIPPED WITH SKID PLATE

*FOR DEALER TO RECEIVE ADMINISTRATIVE TIME ALLOWANCE ASSOCIATED WITH THIS CAMPAIGN, ADD 0.1 HOUR TO THE LABOR OPERATION TIME ALLOWANCE.

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 AN 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" #P8919. ((

DEAR GMC TRUCK OWNER:

TO PREVENT THE TRANSMISSION FROM FAILING, IT WILL BE NECESSARY TO INSTALL A NEW TORQUE CONVERTER. THIS SERVICE WILL BE COMPLETED FOR YO AT NO CHARGE.

PLEASE CONTACT YOUR GMC TRUCK DEALER AS SOON AS POSSIBLE TO ARRANGE A SERVICE DATE. INSTRUCTIONS FOR MAKING THIS CORRECTION HAVE BEEN SENT YOUR DEALER. PLEASE ASK YOUR DEALER IF YOU WISH TO KNOW HOW MUCH TIME WILL BE NEEDED TO SCHEDULE, PROCESS AND REPAIR YOUR VEHICLE.

THE ENCLOSED POSTAGE PAID OWNER REPLY CARD IDENTIFIES YOUR VEHICLE. PRESENTATION OF THIS CARD TO YOUR DEALER WILL ASSIST IN MAKING THE NECESSARY CORRECTION TO YOUR VEHICLE IN THE SHORTEST POSSIBLE TIME. I YOU HAVE SOLD OR TRADED YOUR VEHICLE, PLEASE FURNISH US COMPLETE NAME AND ADDRESS OF THE PERSON YOU SOLD OR TRADED YOUR VEHICLE TO AND RETUR THE CARD TO US.

WE ARE SORRY TO CAUSE YOU THIS INCONVENIENCE; HOWEVER, WE HAVE TAKEN THIS ACTION IN THE INTEREST OF YOUR CONTINUED SATISFACTION WITH OUR PRODUCTS.

GMC TRUCK DIVISION GENERAL MOTORS CORPORATION

91C02

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.