CAMPAIGN: 5 SPEED MANUAL TRANSAXLE REPLACEMENT. Chevrolet Corsica 1989

For 1990-2009 cars

# CAMPAIGN: 5 SPEED MANUAL TRANSAXLE REPLACEMENT

#### Model and Year: 1989 CHEVROLET "J" & "L" CARS

General Motors has determined that certain 1989 Chevrolet Cavalier & Corsica/Beretta models produced with 5-speed manual transaxles may have gears with a high carbon content in the tooth surface. These gears could, as mileage accumulates, damage the softer gears to which they mate. The first notice to a driver would be gear noise resulting from spalling (pitting) of gear surfaces. If the transaxle is left unserviced, internal damage may occur, leading to vibration or the shifter "popping out of gear", and finally to a loss of drive in one or more gears.

Up to ten different gears in each of the involved transaxles may have excess carbide, hence the involved transaxle assemblies are to be exchanged to prevent the above condition from recurring on the same vehicles as mileage accumulates.

#### VEHICLES INVOLVED

Involved are certain 1989 Chevrolet Cavalier & Corsica/Beretta models produced within the following breakpoints:

#### MODEL/YEAR PLANT FROM THROUGH ---------- ----- ---- -------

J 1989 Janesville KJ294024 KJ294694

" " Lordstown K7151467 K7238379

L " Linden KE291166 KE296730

" " Wilmington KY192036 KY291216

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 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 Chevrolet Motor 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 mileage, age 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 dealership 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 contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin.

#### NOTICE: DEALERS ARE TO CONTACT ALL OWNERS ON THEIR INITIATION LIST TO VERIFY LOCATION/AVAILABILITY OF VEHICLE. ONCE IT IS DETERMINED THAT THE VEHICLE CAN BE MADE AVAILABLE TO YOUR DEALERSHIP LOCATION, ORDER TRANSAXLE ASSEMBLY AS INDICATED IN "PARTS INFORMATION SECTION".

#### PARTS INFORMATION

Transaxles for this Campaign are to be ordered directly from Hydra-Matic Division by calling 1-317-747-2026, between 6:00 A.M. and 2:30 P.M., CENTRAL TIME. COLLECT PHONE CHARGES WILL BE ACCEPTED thru December 22, 1989. After this date, transaxles for this campaign are to be ordered directly from Hydra-Matic Division by calling 1-317-747-2132, between 6:00 A.M. and 2:30 P.M., CENTRAL TIME.

Quantity/ Part Number Description Vehicle ----------- ----------- ------- 12345349 Manual Transaxle Fluid 3 qts.

Information for transaxle order which the dealer will be required to provide during the telephone order:

1) Dealer Name. 2) Dealer Code. 3) Parts Shipping Address. 4) Contact Person. 5) Telephone Number (Dealer). 6) Vehicle VIN. 7) Mileage On Vehicle. 8) Vehicle Status: A. Dealer Inventory. B. Sold But Not Delivered. C. Customer Vehicle. D. Customer Vehicle Down For Transaxle Problem.

Vehicle Model Transaxle Model Code Part Number ------------- -------------------- ----------- JC 9XBX 8672341 JF 9XBX 8672341 LV 9XNX 8672024 LW 9XNX 8672024

Do not order this part from General Motors Service Parts operations (GMSPO)

#### SERVICE PROCEDURE

1. Phone Hydra-Matic (use applicable phone number from "Parts Information" section) and provide them the Bar Code Number (see illustration above) from transaxle to be replaced. Hydra-Matic will then confirm that the transaxle involved requires replacement.

2. Once the Bar Code number is confirmed in Step 1, the transaxle in each involved vehicle is to be replaced, using the procedures listed in the Cavalier or Corsica/Beretta Service Manual, including observing the CAUTIONS, and making the transmission, clutch and other misc. adjustments required.

3. Install Campaign Identification Label.

#### RETURN SHIPPING INSTRUCTIONS

The shipping container will include return shipping instructions and label for the removed unit along with a form to record the data given during the telephone order.

The replaced transaxle is to be shipped in the new transaxle's original container to Hydra-Matic within 10 days after the new one is installed.

The freight charges, both ways, will be prepaid by Hydra-Matic (subject to Hydra-Matic instructions and choice of shipper).

DEALERS WILL BE CHARGED $750.00 IF THE REPLACED TRANSAXLE IS NOT RETURNED TO HYDRA-MATIC WITHIN 10 DAYS.

Information to be declared on the Bill-of-Lading description for returning the replaced transaxle:

Description: "Transmissions or clutches or parts thereof NOI NMFC 100-I, Item 19940, Class 85."

Weight of container and transaxle: 111 pounds

#### Routing Instructions:

Carrier: (as specified by Hydra-Matic) Consign Return To:

Hydra-Matic Division Muncie Transmission Plant 1200 West 8th Street Muncie, IN 47307

Hydra-Matic Muncie Plant will ONLY be financially responsible for freight charges which would result from the carrier specified by Hydra-Matic. Do not use air freight unless Hydra-matic specifically requests the RETURN of the transaxle by AIR.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this bulletin will require a "Campaign Identification Label". Each label provides a space to include the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a 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.

#### CLAIM INFORMATION

Submit a Product Campaign claim with the information indicated below: * ** FAILED PARTS CC-FC LABOR LAB OTH NET REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS AMT ---------------- -- -------- ----- ----- -- --- --- --- Reptace Transaxte SK-00 V5570 3.6 0.1 $220.831 Assembly

*Campaign Administrative Allowance

** The $220.83 identified in the "Net Amount" column represents 30% of dealer cost for all transmission parts plus 3 quarts of transaxle fluid required for the repair. Transaxles will be ordered directly from Hydra-Matic on a no charge basis.

Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim Submission.

This notice is sent to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.

REASON FOR THIS RECALL

General Motors has determined that certain 1989 Chevrolet Cavalier and Corsica/Beretta models produced with 5-speed manual transaxles may have gears with a high carbon content in the tooth surface. These gears could, as mileage accumulates, damage the gears to which they mate. The first notice to a driver would be gear noise resulting from pitting of gear surfaces. If the transaxle is left unserviced, internal damage may occur, leading to vibration or the shifter "popping out of gear", and finally to a loss of drive in one or more gears. WHAT WE WILL DO

To prevent the possibility of this condition occurring, your Chevrolet Dealer will install a new transaxle. This service will be performed at no charge to you.

WHAT YOU SHOULD DO

Please contact your Chevrolet dealer as soon as possible so he may order the necessary parts and arrange a service date. Instructions for making this correction have been sent to 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 owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it 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.

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.