For 1990-2009 cars

# CAMPAIGN: 5 SPEED MANUAL TRANSAXLE REPLACEMENT

#### Models: 1989 Cavalier, Sunbird, Grand Am and Cutlass Calais

#### TO: ALL AFFECTED DEALERS:

General Motors of Canada has determined that certain 1989 Chevrolet Cavalier, Pontiac Sunbird and Grand Am and Oldsmobile Cutlass Calais models were produced with 5-speed manual transaxles which may have gears with a high carbon content in the tooth surfaces. 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 transaxles are to be replaced to prevent the above condition from recurring on the same vehicles as mileage accumulates.

#### VEHICLES INVOLVED:

Only the following VIN's are included in this recall.

1G1JC11W0KJ294042 1G1JC11W3KJ294309 1G1JC11W6KJ294322 1G1JC11W9KJ294024 1G1JC11W9KJ294122 1G1JC11W9KJ294248 1G1JC11WXKJ294694 1G1JF11WOK7236601 1G1JF11W0K7236789 1G1JF11WOK7236887 1G1JF11WOK7236937 1G1JF11W1K7236316 1G1JF11WIK7236686 1G1JF11WlK7236851 1G1JF11W1K7236865 1G1JF11WIK7236879 1G1JF11WlK7237286 1G1JF11W2K7236521 1G1JF11W2K7236731 1G1JF11W2K7236759 1G1JF11W2K7236874 1G1JF11W3K7236320 1G1JF11W3K7236625 1G1JF11W3K7236639 1G1JF11W3K7236981 1G1JF11W3K7237001 1G1JF11W3K7237211 1G1JF11W3K7237225 1G1JF11W4K7236407 1G1JF11W4K7236696 1G1JF11W4K7236990 1G1JF11W5K7236710 1G1JF11W5K7237176 1G1JF11W5K7237274 1GlJF11W6K7236425 1G1JF11W6K7236652 1G1JF11W6K7236909 1G1JF11W6K7237218 1G1JF11W6K7237333 1G1JF11W7K7236420 1G1JF11W7K7236532 1G1JF11W7K7236644 1G1JF11W8K7236507 1G1JF11W8K7236765 1G1JF11W8K7236779 1G1JF11W9K7236340 1G1JF11W9K7236418 1G1JF11W9K7236449 1G1JF11WXK7236802 1G1JF31W1K7236313 1G2JU11M6K7624951 1G2NE11DOKC825833 1G2NE11D4KC825897 1G2NE11D8KC824736 1G3NK11D3KM301882

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:

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 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 contacted by the dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.

#### 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. 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:

Engine Engine Transaxle Transaxle Service Engine Type RPO VIN Code RPO Model Code Part Number ----------- --- -------- --- ---------- ----------- 2.3L LD2 D MG2 XAX 8672340 2.8L LB6 W MG2 XBX 8672341 2.0L LT3 M MG1 XCX 8672342

#### RETURN SHIPPING INSTRUCTIONS

Transmission core MUST be fully drained before shipping,

The shipping container will include return shipping instructions that apply to U.S. Dealers only. There is, however, a data form (see Figure 1) that must be completed. (Only complete the lines marked with (**).

Please enclose this form in an envelope securely attached to the exterior of the shipping container, when returning the transmission core LE T, to the following address:

General Motors of Canada Limited 1401 Parkinson Road East Woodstock, ON N4S 8K8 Attention: Mike Gale

#### PARTS AND LABOUR CLAIM INFORMATION:

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

Repair Code Description Time Allowance ----------- ----------- --------------- 2A Replace Transaxle Assembly, and 3.7 Make Required Adjustments*

*An allowance of $10.00 is included in repair 2A for manual transmission fluid.

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:

1. The transaxle in each involved vehicle is to be replaced, using the procedures listed in the appropriate Service Manual, including observing the CAUTIONS, and making the adjustments required.

Refer to the 1990 Service Manual for an improved procedure to remove and replace the manual transaxle assembly.

2. Install a 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 has determined that certain 1989 Chevrolet Cavalier, Pontiac Sunbird and Grand Am and Oldsmobile Cutlass Calais models were produced with 5-speed manual transaxles which may have gears with a high carbon content in the tooth surfaces. 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 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.

To prevent this condition from occurring on your vehicle, your GM Dealer will replace the transaxle at no charge to you.

Contact your GM Dealer to arrange a service date. Instructions have been sent to your dealer. Your dealer will need to order the specific type traxsaxle which is designed for your vehicle; hence, you should expect to arrange a service date which will be several working days after your call. The labour time to replace the transaxle is about three (3) hours. Please allow additional time for your Dealer to process your vehicle.

Even if you have already had a gear repair in the transaxle on your vehicle, you need to contact your dealer to have the transaxle replaced; the condition may recur with other gears in the transaxle.

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.

Further assistance, if required, may be obtained from our Customer Assistance Centre, toll free, by calling 1-800-263-3777.

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.