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CAMPAIGN:UNDERTORQUED TRANSMISSION TO ENGINE

SUBJECT: UNDER TORQUED TRANSMISSION TO ENGINE AND/OR TRANSMISSION TO CLUTCH HOUSING BOLTS

MODELS: 1994 GMC SONOMA PICKUPS PRODUCED AT THE LINDEN, NEW JERSEY ASSEMBLY PLANT (VIN CODE "K") EQUIPPED WITH 2.2L (RPO LN2) ENGINE AND EITHER THE 4L60E (RPO M30) 4 SPEED AUTOMATIC OR BORG WARNER (RPO MW1) 5 SPEED MANUAL TRANSMISSION.

CERTAIN 1994 S/T Trucks built at Linden Assembly and equipped with 2.2L engines (LN2) may have transmission-to-engine bolts tightened below the specified torque. On vehicles equipped with an automatic transmission (M30), any of the six bolts that attach the transmission to the engine may be affected. On vehicles equipped with a manual transmission (MW1), any of the six bolts that attach the bell housing to the engine, as well as the four bolts that attach the transmission to the bell housing, may be affected. This "low torque" condition could cause very noticeable driveline disturbance. If the operator failed to heed this warning, further damage could occur, including transmission case fracture and possible fluid leaks, transmission torque converter, pump, or clutch damage, loss of drive, or the inability to disengage the clutch.

To correct this condition, dealers are to properly torque the transmission to engine and/or transmission to clutch housing bolts.

VEHICLES INVOLVED

Involved are CERTAIN S/T pickup trucks produced at Linden assembly (VIN code "K") and built within the following VIN breakpoints:

Year Model From Through

1994 S/T Truck SOP RK516988

The specific vehicles involved in this campaign have been identified by Vehicle Identification Number Computer Listings. These listings are furnished to all involved dealers with the campaign bulletin. Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) or SERVICENET prior to beginning campaign repairs.

DEALER CAMPAIGN RESPONSIBILITY

All unsold vehicles in dealers'possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE owners take possession of these vehicles.

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.

Owners of vehicles recently sold from your vehicle inventory are to be contacted by the dealer and arrangements made to make the required correction according to instructions contained in this bulletin.

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.

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 listed 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 Truck Division (see copy of owner letter included with this bulletin) and customers will personally be contacted by phone. A listing of owner names and addresses has been furnished to the involved 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 in several states. Accordingly, you are urged to limit the use of this listing to this campaign.

SERVICE PROCEDURE

For vehicles equipped with the 2.2L engine and 4L60E (RPO M30 Figure 1, Item 1) automatic transmission, perform the following procedure:

1. Move gear selector to LOW "1."

2. Raise vehicle.

3. Disconnect exhaust hangers (2 or 3 depending on wheelbase) and lower exhaust system.

4. Remove fuel line bracket at cross member (1 bolt).

5. Remove transmission control lever (Figure 3, Item 3) from transmission shift lever (1 cotter pin) (Figure 3, Item 5).

6. Position transmission j ack under transmission.

7. Remove 3 left side transmission crossmember bolts.

8. Remove 4 right side transmission crossmember bolts.

9. Remove transmission mount nut and crossmember from vehicle.

10. Lower transmission (Figure 1, Item 1) as required to access transmission attaching bolts.

11. Torque 5 transmission to engine bolts (Figure 1, Item 2) using a 28" extension, to 90 Nm (66 lb. ft.).

12. Torque nut (Figure 1, Item 5) on lower right side transmission to engine bolt (Figure 1, Item 3) to 90 Nm (66 lb. ft.).

13. Raise transmission to the proper installation position.

14. Install crossmember and torque 3 left side and 4 right side bolts to 54 Nm (40 lb. ft.).

15. Torque transmission mount nut to 45 Nm (33 lb. ft.)

16. Remove transmission jack.

17. Install transmission control lever (Figure 3, Item 3) to transmission shift lever (Figure 3, Item 5) and fasten (1 cotter pin).

18. Install fuel line bracket at transmission crossmember and torque to 17 Nm (13 lb. ft.).

19. Reconnect exhaust hangers and torque fasteners to 25 Nm (18 lb. ft.)

20. Adjust linkage using the following procedure:

Adjustment procedure applies to vehicles w/4L60E transmission.

A. Linkage adjustment must be performed at the transmission prior to any "PRNDL" indicator adjustment at the steering column.

B. Full weight of vehicle must be on wheels (curb height). Do not use a frame hoist to raise the vehicle for this procedure. Mandatory that vehicle be raised on a twin post hoist or utilize an alignment rack.

C. Position the steering column shift lever in the neutral gate notch. (Do not use the indicator to find neutral).

D. Loosen the bolt (Figure 3, Item 2) in the swivel (Figure 3, Item 4) that clamps the shift rod (Figure 3, Item 1) to the transmission equalizer lever (Figure 3, Item 3). Make sure that the shift rod moves freely in the swivel.

E. Set trans lever (Figure 3, Item 5) in neutral detent. Obtain neutral detent by indexing trans lever all the way clockwise to "PARK", then counter-clockwise two detents to "NEUTRAL".

(Alternate procedure is rotate trans lever counter-clockwise all the way to "L1", then rotating it clockwise four detents.

F. Make sure that trans control lever (Figure 3, Item 3) is fully seated in trans lever (Figure 3, Item 5). Hold the rod (Figure 3, Item 1) tightly in the swivel (Figure 3, Item 4). Tighten clamp screw (Figure 3, Item 2) against rod (Figure 3, Item 1) to 25 Nm. (18 Lbs. ft.). Make sure the rod does not move in the swivel while tightening the screw.

G. Verify proper adjustment:

0 When moving the transmission shift lever in either direction, all detent positions will be attainable without a binding condition present.

0 With the key on and the shift lever in "Reverse", the key will not be removable and the steering column will not be locked.

0 With the key in the lock position and the shift lever in the "Park" position, the key will be removable, the steering wheel will be locked, and the shift lever will not disengage "Park". In addition, verify that the vehicle is held stationary in "Park".

0 The engine must start in the "Neutral" or "Park" positions only. Adjust neutral safety switch as required.

0 Verify that shift indicator position matches actual transmission range. Adjust "PRNDL" switch as required.

21. Lower vehicle.

22. Return gear selector to "PARK."

23. Apply the campaign identification label.

24. Wash customer's vehicle.

For vehicles equipped with the 2.2L engine and 5 speed (RPO MW1 Figure 2, Item 1) manual transmission, perform the following procedure:

1. Place shift lever in neutral.

2. Raise vehicle.

3. Disconnect exhaust hangers (2 or 3 depending on wheelbase) and lower exhaust system.

4. Position transmission jack under transmission.

5. Remove 3 left side transmission crossmember bolts.

6. Remove 4 right side transmission crossmember bolts.

7. Remove transmission mount nut and transmission crossmember.

8. Lower transmission until top of extension housing (at rear) is no more than 6" from floorpan.

9. Torque 5 clutch housing to engine bolts (Figure 2, item 2) using a 28", extension, to 90 Nm (66 lb. ft. ft.).

10. Torque nut (Figure 2, Item 4) on lower right side clutch housing to engine bolt (Figure 2, Item 5) to 90 Nm (66 lb. ft.).

11. Torque 4 transmission to clutch housing bolts (Figure 2, Item 3) to 75 Nm (55 lb. ft.). A "crowsfoot" wrench may need to be used to access these bolts.

12. Raise transmission to proper installation position.

13. Install transmission crossmember and torque 3 left side and 4 right side bolts to 54 Nm (40 lb. ft.).

14. Torque transmission mount nut to 45 Nm (33 lb. ft.).

16. Remove transmission jack.

17. Reconnect exhaust hangers and torque fasteners to 25 Nm (18 lb. ft.).

18. Lower vehicle.

19. Install campaign identification label.

20. Wash customer's vehicle.

PARTS INFORMATION

Parts are not required to complete this campaign.

WARRANTY INFORMATION

Dealers should submit a warranty claim on each vehicle completed under this campaign.

Labor Operation *Time Net Trouble Number Description Allowance Amount Code ------------------------------------------------------------------------- V 9060 Torque bolts 1.0 - - 96 (Automatic/Manual Trans.) T 501 Customer Vehicle Wash 0.0 $6.00 96

* 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 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 "GMC Truck Warranty Claims Processing Manual" #P9119.

Dear GMC Truck Owner:

As a valued customer, your complete satisfaction with your GMC truck is our goal. In keeping with this goal, we want to let you know that we have discovered a condition that could affect your vehicle and we want to take care of it at no charge to you.

Certain 1994 Sonoma pickups with 2.2L engines may have transmission-to-engine or transmission-to-clutch housing bolts tightened below the specified torque. This condition effects vehicles with either an automatic or manual transmission and could result in a very noticeable driveline disturbance. If left uncorrected, further damage could occur to the transmission.

To correct this condition, dealers are to properly torque the transmission-to-engine and/or transmission-to-clutch bolts on all involved vehicles.

Instructions for performing this service have been sent to your GMC Truck dealer, and parts are available. Please contact you GMC dealer to arrange a service date as soon as possible. This procedure will take about one hour to complete, but you should ask how much additional time your dealer will need to schedule and process 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. If you have sold or traded your vehicle, please furnish us the complete name and address of the person you sold or traded your vehicle to and return 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 product.

GMC TRUCK DIVISION GENERAL MOTORS CORPORATION


Object Number: 81105  Size: FS


Object Number: 81104  Size: FS


Object Number: 84044  Size: FS

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.