MUNCIE 5-SP. TRANSAXLE PROGRAM DIAGNOSIS - P/N'S FOR REPAIRS. Buick Skyhawk 1987

For 1990-2009 cars

# MUNCIE 5-SP. TRANSAXLE PROGRAM DIAGNOSIS - P/N'S FOR REPAIRS

#### MODELS AFFECTED: 1987 SKYHAWKS WITH 2.OL TURBO ENGINES (VIN CODE M) AND 5-SPEED MANUAL (GETRAG MG1) TRANSAXLES

To gain needed product feedback on the above transaxles, and to minimize vehicle downtime, a transaxle exchange program is now in effect and will continue until further notice.

The exchange program will be administered by Detroit Diesel Allison Division and all requests for exchange units will be handled through the Buick Technical Assistance Center.

The following information from DDA Muncie Division thoroughly explains all requirements regarding diagnosis, serviceable and non-serviceable items, serviceable part numbers, warranty claims processing procedures and shipping instructions.

In the event your Buick dealership receives a complaint on an MG1 unit, follow the procedure listed below. Your cooperation will greatly improve the effectiveness of the program.

#### NOTE: o Serial number tag location is Item (A), Figure 1. o Numbers in brackets refer to item numbers on disassembled views, Figures 1 and 2. o A serviceable parts item number/GN part number cross reference is provided for your convenience, Figure 3.

A. Preliminary Diagnostic Procedure -------------------------------- o Refer to Diagnosis Chart. o Insure correct oil level. o Insure that the shift linkage is properly adjusted. o Insure that the clutch linkage is properly adjusted. o Insure that all engine and transmission mounts are tight.

B. On-Car Service (Without Exchange) -------------- Special Tool Requirements and Oil Leaks at: Torque Specifications

- Axle Seals (23) - Install using J-26938 & J8092 - Shift Shaft Cover (140) - No special tool required - Shift Shaft Seal (208) - Install using J-35823 - Clutch Fork Seal (164) - No special tool required - End Plate-to-Case Leaks (85/90) - Bolt torque 21 N.m (15 lb. ft.) - Back-up Light Switch (B) - Bolt torque 33 N.m (24 lb. ft.) - Speedometer Driven Gear (C) - Bolt torque 5.5 N.m (4 lb. ft.) - Transaxle Drain Plug/Washer (79/80) - Drain plug torque 94 N.m (18 lb. ft) - Fluid Level Indicator/Washer - Fully seated, not stripped (100/101) - Fill Plug and Washer (80/83) - Fill plug torque 24 N.m (18 lb. ft.) - Plug, Shift Rail (204) - No special ool required

C. Out-of-Vehicle Repairs (Without Exchange) ---------------------- o Oil Leak at Detent Cover (174) o Clutch Fork Bushing Replacement (163/177) o Clutch Fork Replacement (165) o Clutch Release Bearing Service/Replacement (LO2) o Any Clutch Repair/Replacement o Special Tool Requirement: - Bushing (163), using J-36037 (remove/install). Bushing (177), using J-36032 and J-23907 to remove/install using J-36033 and J-36190. - Clutch fork (165), using J-36037 to remove/install bushing (163).

D. Out-of-Vehicle Repairs (With Exchange) ---------------------- Any repair which necessitates splitting the clutch housing and the transaxle case.

E. Exchange Procedure ------------------ 1. Call your Technical Assistance Center, for authorization.

2. Provide Technical Assistance with the necessary information. It would be a good idea to fill out the MGI/MG2 Reporting Form (attached) prior to calling.

3. Technical Assistance will arrange to ship an exchange unit to your dealership.

4. Technical Assistance will provide dealership with an authorized "Request Number". This number must be written on the unit (clutch housing) as well as the shipping container used to return the unit to DDA-Muncie.

5. Once the exchange unit is received, the complaint unit is to be returned to DDA-Muncie, 1200 West Eighth Street, Muncie, IN 47302.

6. The exchange unit will have an envelope attached to it. This envelope will contain:

Return Shipping Label Administrative Procedures MG1/MG2 Reporting Form Return Shipping Carrier Information Identification Tag

7. The complaint unit MUST be returned within 5-7 days after receipt of the exchange unit.

F. Preparation For Shipping ------------------------ o Drain the oil and replace the drain plug. o Remove plastic shipping plugs from the exchange unit and install them into the complaint unit. o Fold the Reporting Form, staple it to the Identification Tag and secure the tag to the clutch housing of the complaint unit. o Repack the complaint unit into the original shipping container. o Place the shipping label on the original shipping container.

G. Warranty Claims Processing Procedure ------------------------------------- Upon completion of the repair, a warranty claim is to be submitted to Buick for only the labor for the R& R and transmission fluid. A special labor operation is provided for this situation and is the only labor operation to be used in the event an exchange unit is used.

Labor Operation: T3158 Labor Time: 5.6 Hrs. Trouble Code: 92

#### DIAGNOSIS CHART

CONDITION PROBABLE CAUSE --------- -------------- A Knock At Low Speeds a. Worn drive axle CV or TRI-POT joints. b. Worn side gear hub counterbore.

Noise Most Pronounced On Turns a. Differential gear noise.

Clunk On Acceleration Or Deceleration a. Loose engine mounts. b. Worn drive axle inboard TRI-POT joints. c. Worn differential pinion shaft in case. d. Side gear hub counterbore in case worn oversize.

Clicking Noise In Turns a. Worn outboard CV joint.

Vibration a. Rough wheel bearing. b. Bent drive axle shaft. c. Out of round tires. d. Tire unbalance. e. Worn CV joint in drive axle shaft. f. Incorrect drive axle angle. (Trim Height).

Noisy In Neutral With Engine Running. a. Worn input gear bearings. b. Worn clutch release bearing.

Noisy In First Only a. Chipped, scored, or worn first-speed constant-mesh gears. b. Worn 1-2 synchronizer.

Noisy In Second Only a. Chipped, scored, or worn second-speed constant-mesh gears. b. Worn 1-2 synchronizer.

Noisy In Third Only a. Chipped, scored, or worn third-gear constant-mesh gears. b. Worn 3-4 synchronizer.

Noisy In Fourth Only a. Worn 3-4 gear synchronizer b. Chipped, scored, or worn fourth-speed gear or output gear.

Noisy In Fifth Only a. Worn 5th gear synchronizer. b. Chipped, scored, or worn fifth-speed gear or output gear.

Noisy In Reverse Only a. Chipped, scored, or worn reverse idler gear, idler gear bushing, input or output gear.

Noisy In All Gears a. Insufficient lubricant. b. Worn bearings. c. Chipped, scored, or worn input gear (shaft) and/or output gear (shaft).

Slips Out Of Gear a. Worn or improperly adjusted linkage. b. Shift linkage does not work freely. c. Bent or worn cables. d. Input gear bearing retainer broken or loose. e. Worn or bent shift fork.

Leaks Lubricant a. Fluid level indicator not seated in fill port, causing fluid leakage at vent plug. b. Worn axle shaft seals. c. Excessive amount of lubricant in transaxle. d. Loose or broken input gear (shaft) bearing retainer. e. Worn input gear bearing and/or lip seal damaged. f. Lack of sealant between case and clutch cover or loose clutch cover.

#### PARTS TO BE RELEASED THROUGH GMWDD

ITEM NUMBER NAME PART NUMBER ------ ---- ----------- 22 Bearing, Clutch Release 14080591 23 Seal, Axle 8631156 79 Plug, Oil Drain 14056604 80 Washer 476755 81 Bolt (Case to CL Housing) 11500822 82 Washer 14080243 83 Plug, Fill 476753 89 Washer, Oil Slinger 14092033 90 End Plate, Transmission Case 10051657 91 Bolt (End Plate to Case) 10051637 loo Washer 10051663 101 Dipstick (Oil Level Indicator) 10051636 120 Retainer, Selector Pin 10040797 121 Retainer, Selector Lever 10038871 122 Pin, Selector Lever Pivot 10040796 123 Bolt 14060613 124 Lever, Selector 10038872 125 Collar, Shift Shaft 14091789 126 Pin 11513384 127 Lever, Shift 10038869 128 Washer 14091790 129 Nut 11507027 130 Retainer, Selector Lever 14091785 130 Retainer, Selector Lever 14091794 131 Pin, Selector Lever Pivot 14091786 132 Bolt 14091792 132 Bolt 14091793 133 Lever, Selector 14091781 134 Collar, Shift Shaft 11513884 135 Lever, Shift 14091787 135 Washer 14091790 137 Nut 11507027 138 Pin 11513384 139 Ring, Snap 14080596 140 Cover, Shift Shaft 14080595 163 Bushing, Upper Clutch Fork 14092055 164 Seal, Clutch Fork 14092820 165 Shaft, Clutch Fork 14092026 174 Cover, Detent 14082039 177 Bushing, Lower Clutch Fork 14092054 204 Plug, Shift Rail 14080573 208 Seal, Shift Shaft 14080587

Figure 3 - Serviceable Parts Item Number/GM Part Number Cross Reference.

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.