For 1990-2009 cars

# CAMPAIGN: 3T40 PISTON SEAL INTERMEDIATE SERVO COVER

#### Subject: INTERMEDIATE SERVO COVER PISTON BORE

#### Models/Years: 1990 CUTLASS CALAIS WITH 2.5L ENGINE (VIN CODE U) AND HYDRA-MATIC 3T40 TRANSAXLE (RPO MD9)

#### CONDITION

General Motors has determined that some 1990 Oldsmobile Cutlass Calais model vehicles equipped with 2.5L (VIN Code U; RPO L68) engine and Hydra-Matic 3T40 (RPO MD9) transaxle may have been assembled with a Transaxle Intermediate Servo Cover with a rough piston bore. The rough finish could eventually wear the lip of the (inner) Intermediate Servo Seal (134 in Figure 2), causing a leak in the second clutch circuit (intermediate servo apply). This leak may cause Intermediate Band and Direct Clutch wear. This may cause a "no second gear" condition.

To prevent this condition from occurring, dealers are to inspect the transaxle I.D. plate on involved vehicles for Julian Dates, and if necessary, install an Intermediate Servo Cover Kit or replace the Transaxle as instructed in the SERVICE PROCEDURE section of this bulletin.

#### VEHICLES INVOLVED

Certain 1990 Oldsmobile Cutlass Calais model vehicles equipped with 2.5L (VIN Code U; RPO L68) engine and Hydra-Matic 3T40 (RPO MD9) transaxle within the following VIN breakpoints and Julian Dates:

Engine Transaxle Transaxle Transaxle Through and VIN Code Model Code Julian Dates Beginning Including -------- -------- -------- ------------ ---------- --------- U 3T40 (RPO MD9) PNC 194 thru 200 LM789321 LM790715

While all involved vehicles will require inspection of the transaxle I.D. plate for Julian dates, it is expected that only about 11% of inspected vehicles will require installation of the Intermediate Servo Cover Kit. Very few, if any, vehicles should require a SRTA Transaxle.

All vehicles listed on the dealer printout will require inspection, and, if necessary, repair. Other suspect vehicles should be checked for campaign involvement by utilizing the Vehicle Information Service System (V.I.S.S.).]

DEALER ACTION

Dealers are to service all vehicles involved in this campaign, at no charge to owners, regardless of mileage, age of vehicle, or ownership.

Whenever a vehicle subject to this campaign is taken into your new or used car inventory, or it is in your dealership for service, you are to ensure the campaign correction has been made before selling or releasing the vehicle.

Dealers are to contact owners of vehicles recently sold from your new or used vehicle inventory and arrange for the campaign correction to be performed.

SERVICE PROCEDURE

1. Inspect the Transaxle ID Plate (see Figure 1). If the Julian Dates are within the range 194 thru 200, inclusive (July 13, 1990 thru July 19, 1990), proceed to Step 2. If the Julian Dates are not within the range 194 thru 200, skip to Step 4 and install a Campaign Identification Label.

2. If the vehicle odometer reads less than 12,000 miles, go to Step 3 and install Kit P/N 8681967 as instructed.

If the vehicle odometer reads 12,000 miles or more, perform the following test drive:

A. Start vehicle and let idle on a flat surface for three (3) minutes.

B. Verify correct transaxle fluid level and fluid color.

C. Drive the vehicle in drive range and verify the following proper vehicle operation conditions:

1 - 2 upshift at 1/4 throttle, should occur between 12 to 20 m.p.h.

2 - 3 upshift at 1/4 throttle, should occur between 20 to 35 m.p.h.

Manually select low range and verify 3 - 2 and 2 - 1 coastdown shifts.

D. Verify vehicle has correct reverse engagement and no slippage in reverse range.

E. During the test drive, the driver should not feel any slips and/or bumps.

If the vehicle has normal transaxle operation, proceed to Step 3 and install Kit P/N 8681967, as instructed.

If the vehicle does not have normal transaxle operation, replace the transaxle with a Hydra-Matic 3T40 SRTA Assembly, (OPNC 8665980), following the instructions and cautions listed in the 1990 Oldsmobile Cutlass Calais Service Manual, pages 7A-26 thru 29.

If the transaxle is replaced, please reset the memory functions for the owner, or advise the owner that these memory functions were lost due to disconnecting the battery.

#### NOTICE: Cooler flushing MUST be performed; the time allowance for Transaxle Removal and Replacement provides for this.

If the transaxle is replaced, do NOT install Kit P/N 8681967.

3. Install Kit P/N 8681967 as follows:

A. Raise vehicle and suitably support (see section OA in service manual).

B. Remove fluid pan and gasket. Discard gasket.

C. Remove strainer and multi-lip seal. Save both parts for reinstallation.

D. Remove reverse fluid pipe retainers and bolts (1 40 - 143 in Figure 2).

E. Remove intermediate servo cover (1 37) and gasket (i 36) and discard.

F. Remove third accumulator exhaust valve (126) and exhaust spring (125) and discard.

G. Remove the intermediate servo assembly (shown as parts 128 thru 135 in Figure 2).

H. Install new seals (132 & 134) on new intermediate servo piston (133) from the kit. Transfer parts (128 thru 131, and 135) to the new intermediate servo piston to make a new intermediate servo assembly. Discard the old piston and old seals.

I. Install new third accumulator exhaust valve (126) and exhaust spring (125).

J. Install new intermediate servo cover and new gasket (137 and 136).

K. Reinstall reverse fluid pipe retainers and bolts (140 - 143). Torque bolts to 24 N.m (18 lb. ft.).

L. Reinstall fluid strainer and multi-lip seal.

M. Reinstall fluid pan with a new gasket. Retain gasket with TRANSJEL J 36850. Torque bolts to 11 N.m (96 lb. in.).

N. Adjust fluid level as required.

4. Install a Campaign Identification Label.

CAMPAIGN IDENTIFICATION LABEL

Each label provides space to print the campaign number, and the five (5) digit dealer code of the dealer performing the campaign. Insert this information with a typewriter or ballpoint pen. When installing label, clean and dry the surface of the radiator support tie bar and apply the campaign label where it is readily visible.

#### PARTS INFORMATION

To ensure parts are obtained as soon as possible, order them from GM Service Parts Operations (GMSPO) on a C.I.O. order, with NO special instruction code, but order on an advise code (2). Use the following part numbers:

Description Part Number Quantity Per Vehicle ----------------------------------------------- ------------ ----------- Servo Cover Kit 8681967 1

KH consists of:

intermediate Servo Piston & Seals (Assembly) 8652911 1 Intermediate Servo Piston (.64 ratio) 8652447 1 Intermediate Servo Piston Inner Seal 8652443 1 Intermediate Servo Piston Outer Seal 8652446 1

Intermediate Servo Cover & Gasket 8631704 1

3rd Accumulator Exhaust Valve & Spring (Assembly) 8643996 1 3rd Accumulator Valve 8643408 1 3rd Accumulator Spring 8643965 1

Fluid Pan Gasket 8678168 1

Service Replacement Transmission Assy (SRTA) OPNC 8665980 If Required

It is expected that only about 1 1 % of inspected vehicles will require replacement of the intermediate Servo Cover; order parts accordingly.

#### WARRANTY CLAIM INFORMATION

Submit claims using only one of the labor-ops below for each vehicle.

REPAIR PERFORMED TOT-PTS FC LAB-OP LHRS ------------------- ------- -- ------- ----- Inspect Transaxle ID 96 V6550 .2* Plate Only (No Repair & No Test Drive Required)

Inspect Transaxle ID 96 V6551 .6* Plate and Install Kit (No Test Drive)

Inspect Transaxle ID Plate, 96 V6552 1.1* Perform Test Drive, and Install Kit

Inspect Transaxle ID Plate, 96 V6553 5.0* Perform Test Drive, and Replace The Transaxle With A Hydra-Matic 3T40 SRTA Assembly (Do NOT Install Kit)

* .1 hour for clerical administration may be added to the published labor hours.

Parts allowance: Current dealer price, plus 30% handling allowance; fluid allowance may be applied for in the usual manner.

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.