For 1990-2009 cars

# CAMPAIGN: NEUTRAL START SWITCH DAMAGED

#### SUBJECT: NEUTRAL START SWITCH DAMAGED

#### Models: Certain 1993 Pontiac, Oldsmobile and Buick 'N' Cars

#### TO: ALL GENERAL MOTORS DEALERS

General Motors of Canada Limited has determined that certain 1993 Pontiac Grand Am, Buick Skylark and Oldsmobile Achieva model vehicles contain a neutral start switch that was fractured at installation. Over time, this fracture could result in a no-start condition. A vehicle with this condition may also be started in gear which could cause a vehicle crash without prior warning. To prevent these conditions from occurring, dealers are to replace the neutral start switch on all involved vehicles and inspect/replace the manual shaft assembly as required per the Service Procedure Section of this bulletin.

#### VEHICLES INVOLVED:

The following VIN's are the only vehicles involved in this campaign:

#### BUICK SKYLARK

1G4NM51N2PC298007 1G4NV51N3PC298028

#### OLDSMOBILE ACHIEVA

1G3NL11N6PM036419 1G3NL51N1PM036108 1G3NL51N2PM036392 1G3NL51N5PM036449 1G3NL5130PM036356 1G3NL5132PM036102 1G3NL5132PM036150 1G3NL5132PM036276 1G3NL5132PM036441 1G3NL5133PM036349 1G3NL5135PM036434 1G3NL5135PM036448 1G3NL5137PM036161

#### PONTIAC GRAND AM

1G2NE11NXPM605450 1G2NE11NXPM606016 1G2NE11NXPM606100 1G2NE11N0PM606414 1G2NE11N0PM606574 1G2NE11NOPM606705 1G2NE11N0PM606753 1G2NE11N1PM605966 1G2NE11N1PM605997 1G2NE11N2PM605474 1G2NE11N2PM608648 1G2NE11N3PM606066 1G2NE11N3PM606228 1G2NE11N4PM605427 1G2NE11N4PM606075 1G2NE11N4PM606383 1G2NE11N5PM605310 1G2NE11N5PM606330 1G2NE11N5PM606361 1G2NE11N6PM605493 1G2NE11N6PM606336 1G2NE11N6PM606482 1G2NE11N6PM606577 1G2NE11N7PM606023 1G2NE11N7PM606040 1G2NE11N7PM606054 1G2NE11N7PM606233 1G2NE11N8PM606354 1G2NE11N8PM606399 1G2NE11N9PM606055 1G2NE11N9PM606458 1G2NE51NXPC792122 1G2NE51NXPM605780 1G2NE51NXPM609165 1G2NE51N0PM605531 1G2NE51N0PM606162 1G2NE51N0PM606176 1G2NE51N1PC792414 1G2NE51N1PM605540 1G2NE51N1PM606154 1G2NE51N1PM606199 1G2NE51N1PM606459 1G2NE51N2PM605983 1G2NE51N2PM606423 1G2NE51N3PM606348 1G2NE51N4PC791984 1G2NE51N4PC792018 1G2NE51N4PC792438 1G2NE51N4PM606150 1G2NE51N5PM606531 1G2NE51N6PC792330 1G2NE51N6PM605341 1G2NE51N6PM605436 1G2NE51N6PM605517 1G2NE51N6PM605548 1G2NE51N6PM605971 1G2NE51N6PM606165 1G2NE51N6PM606201 1G2NE51N6PM606439 1G2NE51N7PC792322 1G2NE51N7PM605509 1G2NE51N7PM606191 1G2NE51N7PM606790 1G2NE51N8PC792619 1G2NE51N8PM605535 1G2NE51N8PM606071 1G2NE51N8PM606202 1G2NE51N9PC791740 1G2NE51N9PC792127 1G2NE51N9PM605477 1G2NE51N9PM606032 1G2NE51N9PM606080 1G2NE513XPC792099 1G2NE5131PC791536 1G2NE5132PC792212 1G2NE5134PC792003 1G2NE5139PC792045 1G2NW11NXPC791686 1G2NW11N0PC792300 1G2NW11N0PC792345 1G2NW11N2PC792430 1G2NW11N4PC792428 1G2NW11N6PC792169 1G2NW11N8PC792366 1G2NW11N8PC792397 1G2NW51N3PC791956 1G2NW51N3PC792024 1G2NW51N8PC792309

#### NOTE: PLEASE CHECK DCS SCREEN 45 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

#### DEALER CAMPAIGN RESPONSIBILITY:

All unsold new vehicles in dealer's 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 perform this campaign on all involved vehicles at no charge to owners, regardless of kilometers traveled, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner letter accompanying this bulletin. Campaign follow- up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign is taken into your new or used 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.

#### CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

#### OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors (see copy of owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.

#### PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- ------------ ---------------- 1994333 Neutral Start Switch 1 8682973 Shaft, Manual with Detent Lever and Hub 1 as required Arm, Pin, and Rod and Retainer Assembly 8631979 Package, Gasket, Case to Case Cover 1 as required 8678169 Gasket, Valve Body Cover 1 as required

#### NOTE: Service package 8682973 (containing shaft, manual lever and hub, and pin) must be serviced as a set. Do not replace one part without replacing the others.

#### PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ----------- -------------- Install New Neutral Start Switch 2A 2.3L SOHC (RPO L40) 6 3A 3.3L (RPO LG7) .9

Install New Neutral Start Switch and Inspect/Replace Manual Shaft Kit 4A 2.3L SOHC (RPO L40) 7.0 5A 3.3L (RPO LG7) 6.7

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 30% to cover parts handling.

SERVICE PROCEDURE: See illustration (Figure 1) on page 5

1. With gear selector in neutral, disconnect the negative battery cable.

2. Remove shift control cable lever assembly at transaxle and neutral start switch (see Figure 1).

3. Remove neutral start switch connector.

4. On 3.3L engine application only:

a) Raise vehicle.

b) Loosen lower coolant tube bracket bolt and unclip vacuum hose retainer and move vacuum hose aside.

#### IMPORTANT: Lower coolant tube bracket bolt needs to be loosened on 3.3L (RPO LG7) engine applications (only). This allows the coolant tube to be temporarily moved so sufficient clearance is available to vertically remove the neutral start switch. Failure to remove the switch vertically may cause internal alignment concerns in the switch and cause difficulty in adjusting the switch during reassemble.

c) Lower vehicle.

5. Remove neutral start switch mounting bolts.

6. Remove neutral start switch (move coolant tube aside for clearance on 3.3L application).

7. Place new neutral start switch over manual shaft.

#### IMPORTANT: Replace neutral start switch with a new switch. If new neutral start switch requires force to install, replace manual shaft assembly. If switch installs with no force, manual shaft does not need to be replaced.

a) If neutral start switch fits on manual shaft assembly without force, manual shaft assembly does not require replacement. Proceed to step 8.

b) If neutral start switch requires force to install on manual shift assembly, then manual shaft assembly requires replacing. Follow procedure in the appropriate 1993 Service Manual Section 7A-1B-32 for manual shaft (704); lever and hub assembly (703) pin detent lever to shaft (702) and rod and retainer assembly (701) replacement, Figure 94 in 1993 Service Manual.

Install kit part number 8682973. A-11 parts in package are to be installed.

8. Install new neutral start switch reversing steps 1 to 6. Mounting bolts should be torqued to 24 N.m (18 lb. ft.). See 1993 Service Manual, page 7A-12, for tightening sequence.

a) If bolt holes do not align with mountings boss on transaxle, verify shift shaft is in "Neutral" position, do not rotate neutral start switch. New switch is pinned in "Neutral" position.

b) If switch has been rotated and pin broken, neutral start switch can be adjusted by using the "Replacement - Using Old Switch" procedure. (Refer to Service Manual Section 7A "Automatic Transaxle On-Vehicle Service" for "Replacement - Using Old Switch" procedure.)

#### IMPORTANT: After switch adjustment, verify that engine will only start in "Park" or "Neutral." If engine will start in any other position re-adjust switch.

9. Switch Adjustment

a) Place transaxle control shifter assembly in the "Neutral" notch in detent plate.

b) Loosen neutral start switch attaching bolts.

c) Rotate switch on shifter assembly to align service adjustment hole with carrier tang hole.

d) Insert 2.34 mm (3/32") max. diameter gauge pin to a depth of 9.0 mm (9.64").

e) Tighten mounting bolts to 24 N.m (18 lbs. ft.). Follow tighten procedure in appropriate 1993 Service Manual, Page 7A-12.

f) Remove gauge pin.

10. Install Campaign Identification Label.

#### INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

Dear General Motors Customer:

General Motors of Canada Limited has determined that certain 1993 Pontiac Grand Am, Buick Skylark and Oldsmobile Achieva model vehicles contain a neutral start switch that was fractured at installation. Over time, this fracture could result in a no-start condition. A vehicle with this condition may also be started in gear which could cause a vehicle crash without prior warning.

To correct this condition, your dealer will inspect the manual shaft and replace the neutral start switch. The manual shaft will be replaced if an oversized condition exists.

This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department General Motors of Canada Limited

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.