CAMPAIGN: FLYWHEEL TO CRANKSHAFT BOLTS
PRODUCT CAMPAIGN 88-C-01 CLUTCH COVER-TO-FLYWHEEL BOLTS AND FLYWHEEL-TO-CRANKSHAFT BOLTS
VEHICLES AFFECTED: Certain 1988 Grand Am Models Equipped with Quad 4 (LD2) Engines And HM-282 Manual 5-Speed Transaxles (MG2)
TO: ALL PONTIAC DEALERS
General Motors has determined that certain 1988 Grand Am models equipped with Quad 4 (LD2) Engines and HM-282 Manual 5-Speed (MG2) Transaxles may have been produced with inadequately tightened flywheel-to-crankshaft bolts, and/or clutch cover-to-flywheel bolts, which could result in one or more of the following conditions: slipping, noisy, "knocking sound", or inoperative clutch.
Dealers are to inspect, tighten bolts, and, if required, replace damaged parts as directed in the Service Procedure of this product campaign bulletin.
VEHICLES INVOLVED
Involved are certain 1988 Grand Am models equipped with Quad 4 (LD2) Engines and HM-282 Manual 5-Speed (MG2) Transaxles with the following VIN breakpoints:
Year Plant Beginning Up to and Including ---- ----- --------- -------------------
1988 Lansing Start of Production JC662081
Involved vehicles have been identified by Vehicle Identification Number computer listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to the involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow up with owners involved in this campaign.
These listings 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 the follow up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.
OWNER NOTIFICATION
Owners will be notified of this campaign on their vehicles by Pontiac Division (see copy of Owner Letter included with this bulletin).
DEALER CAMPAIGN RESPONSIBILITY
Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of vehicle, or ownership from this time forward.
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 be sure the campaign correction has been made before reselling or releasing the vehicle.
Owners of vehicles recently sold from your new vehicle inventory are to be modification according to instructions contained in this bulletin.
PARTS INFORMATION
Any parts that may be required to complete this campaign are to be obtained from General Motors Service Parts Operation (GMSPO). To insure that these order with no special instruction code, but on advise code (2).
Description Part Number Quantity Per Vehicle ----------- ----------- --------------------
Clutch Fork Shaft 23047092 1 - As Required
As of the printing of this bulletin, the clutch fork shaft assembly was listed in the GMSPO parts catalog incorrectly as part number: 14092026, the correct part number is: 23047092.
SERVICE PROCEDURE
1. Remove transaxle form vehicle following the procedure listed on pages: 7B3-1 through 7B3-4 of the 1988 Grand Am Product Service Manual.
In Step 14. of the above procedure, drain the manual transmission fluid into a clean container and save to reinstall later.
2. Remove the clutch cover from the flywheel, taking note of any loose bolts.
3. Remove the flywheel from the crankshaft, again noting any loose bolts.
4. If bolts were found loose in Steps 2 and 3, inspect the flywheel, crankshaft, clutch parts and the bolts themselves for damage.
If galling or metal transfer is found between the flywheel and crankshaft flange mating surfaces, replace the flywheel. Check for high spots on the crankshaft flange (Figure 1.). If high spots are found, clean the flange surface with a flat file taking off the high spots only. The new flywheel should fit flat against the crankshaft flange.
If the bolt holes, or threads in the crankshaft are damaged, replace the crankshaft.
Replace damaged bolts, clutch cover-to-flywheel or flywheel-to- crankshaft.
Replace other clutch parts as necessary.
5. Before installing bolts, flywheel-to-crankshaft, the original thread adhesive must be removed from the threads of the bolts with a wire brush and from the threads in the crankshaft flange with a M10 x 1.00 - 4H thread tap.
Apply thread locking compound part number 12345493, Loctite 272, or equivalent, to all flywheel-to-crankshaft bolts; then install flywheel and bolts using the torque angle tightening procedure and tools listed on pages: 6A7-33 and 6A7-34 of the 1988 Grand Am New Product Service Manual. The torque specification listed for these bolts is 30 N.m (22 lbs. ft.) plus rotate bolt 45 degrees.
6. The clutch parts are to be installed and bolts torqued in the following sequence:
FAILURE TO FOLLOW THIS BOLT TORQUING SEQUENCE WILL RESULT IN BOLTS WHICH ARE INADEQUATELY TIGHTENED.
A. Install clutch cover and clutch disc assembly with the bolts loose and align with tool No. J 29074. Be sure "light side" identification mark on clutch cover is aligned with "X" on flywheel (see Figure 2.).
B. Tighten the 3 bolts at holes stamped "L" to 10 N.m (88 lbs. in.).
C. Tighten the remaining bolts to 10 N.m (88 lbs. in.).
D. Tighten the 3 bolts at holes stamped "L" to 26 N.m (18 lbs. ft.).
E. Tighten the remaining bolts to 26 N.m (19 lbs. ft.).
7. Reinstall transaxle using the procedure on pages: 7B3-1 through 7B3-4.
8. Reinstall transmission fluid, check fluid level, and top off if required, with Manual Transmission Fluid, GM Part Number: 12345349, or equivalent.
9. Install Campaign Identification Label.
CAMPAIGN IDENTIFICATION LABEL
Each vehicle modified 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, the five (5) digit dealer code of the dealer performing the campaign service, and the date the vehicle was campaigned. This information may be inserted with a typewriter or ball point pen. Install the label only on a clean, dry surface of the radiator baffle where it is readily visible. (Additional campaign labels are availableon stationery order as Form 7901-709.
CLAIM INFORMATION
A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.
DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:
Other * Failure Labor Labor Labor Operation Code Operation Hours Hours --------- ------- --------- ------ -------
Inspect, tighten bolts, and replace damaged parts as required 96 V4430 3.3 .1
* In addition dealerships will receive 0.1 hours credit for dealer administrative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed for credit. This entry will not require authorization.
FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.
Parts required are to be listed in your warranty claim in the normal manner. Parts will be credited at dealer net plus 30% dealer handling allowance.
Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the labor operation as outlined.
RECORDING COMPLETION
Repairs submitted for vehicles not involved in the campaign will not be paid.
Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS." Owners are being asked to present the owner reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.
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.
