For 1990-2009 cars

# TRANSMISSION EXCHANGE PROGRAM BORG WARNER 5-SPEED

#### Models Affected: 1988-91 BORG WARNER 5-SPEED MANUAL (EXCHANGE PROGRAM)

This bulletin cancels and replaces bulletin 90-7-21 issued 1/90. This bulletin has been revised to add the 1991 model year to the Exchange Program. The tag on the transmission refers to the Divisional bulletin for this corporation bulletin number.

To gain needed product feedback on the 1988-91 Borg Warner 5-speed transmission, an exchange program is now in effect and will continue until further notice. This program is applicable to any transmission which falls within the warranty coverage for that year.

The exchange program will be administered by the Borg Warner Automotive Transmission Systems Division. All requests for exchange units will be handled by using the Toll Free 800 phone number provided in this bulletin.

DO NOT DISASSEMBLE OR REPAIR any 1988 - 1991 Borg Warner 5-speed transmission unless the repair is allowed under Steps A, B or C of this bulletin.

The following information thoroughly explains all requirements regarding diagnosis, serviceable and non-serviceable items, warranty claims processing procedures and shipping instructions.

In the event your dealership receives a comment on a 1988-91 Borg Warner 5-speed, follow the procedure listed below. Your cooperation will greatly improve the effectiveness of the program.

A. Preliminary Diagnostic Procedure

Refer to attached Diagnosis chart Insure correct oil level Insure the clutch linkage is properly installed. Insure the clutch linkage is free and not blocked by the floor mats Insure the shift linkage is free and not impeded by the shift boot Insure that all engine and transmission mounts are tight

B. On-car service (without exchange)

Oil leaks at the following locations may be repaired without exchanging the transmissions.

1. Oil drain plug 2. Oil fill plug 3. Speedometer driven gear 4. Transmission vent to vent tube connection 5. Seal, transmission extension rear oil

In addition, replacement of a defective backup light switch may be made without exchanging the transmission.

C. Out-of-vehicle repair (without exchange)

Repairs may be made to leaks at the shift lever plate to extension housing shift lever tower connection without returning the transmission.

D. Exchange Procedure

Once the above preliminary diagnosis and/or repairs are made and an exchange unit is still deemed necessary.

Call Borg-Warner Automotive Transmission Systems at:

1-800-356-7301

#### IMPORTANT: Prior to calling, fill out the VEHICLE/DEALER INFORMATION FORM below, as well as the remainder of the information requested on the attached Warranty Information Reporting Form.

If no one is available to answer your call leave a message on the recording machine, and you will be contacted.

After obtaining the necessary information (Reporting Form) Borg Warner will arrange to ship an exchange unit to your dealership and will provide your dealership with an authorization number. This number must be written on the transmission case cover, before returning the unit to Borg-Warner.

Once the exchange unit is received, the removed transmission is to be shipped truck freight to:

BORG-WARNER AUTOMOTIVE TRANSMISSION SYSTEMS 5401 Kilgore Ave. Muncie, IN. 47302

To increase the effectiveness of the program, the removed unit should be returned IMMEDIATELY. Failure to return the removed unit will result in the dealership being billed $700.00 for the unit furnished.

The removed unit must be returned complete, as removed from the vehicle without examination of the unit. Dealerships returning units that have been even partially disassembled, excluding the removal of the shift lever during removal of the transmission from the vehicle, will be judged as violating this procedure and as such will be subject to being billed for all materials furnished.

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

Return shipping label Reporting form Return shipping carrier information Complaint tag Leak identification charts Identification tag explanation chart

E. Preparation For Shipping

Drain and measure the oil from the removed unit. Record the results on the complaint form. Replace the drain plug.

Remove all plastic shipping plugs and covers from the exchange unit and install them on the unit to be returned.

Complete the information on the complaint tag. Refer to the Identification Tag explanation chart.

Fold the report form, staple it to the complaint tag and secure the tag to a clutch housing bolt hole of the unit to be returned. Fold and staple the leak identification forms to the same tag.

Write the authorization number on the case cover on the unit to be returned.

Repack the return unit into the exchange shipping container.

Place the shipping label on the exchange shipping container.

F. Warranty Claims Processing Procedure

Upon completion of the repair, a warranty claim is to be submitted to Pontiac for the Removal and Replacement of the transmission and the transmission fluid.

Labor Operation Number: T1258

Labor Time 2.2 Hours

DIAGNOSIS CHART

This chart is intended as a tool to investigate concerns on transmissions. Below are listed some common causes for concerns on transmission problems which are non-transmission related. The concern may also be generated by a fault with the transmission. For consultation on transmission diagnosis contact a Borg Warner representative at 1-800-356-7301.

Clunk on acceleration a. Loose engine mount or deceleration b. Loose or defective universal joint c. Defective differential d. Defective clutch hub

Vibration a. Rough wheel bearing b. Bent drive shaft c. out-of-balance drive shaft d. out-of-round tires e. Tire balance

Noisy in neutral with a. Defective clutch dampener engine running

Noisy in all gears a. Insufficient lubricant b. Torn, loose shift lever boot c. Defective differential

Noisy in top gears a. Defective differential

Slips out of gear a. Improper boot adjustment b. Loose transmission mounts

Leaks lubricant a. Engine oil tracking on transmission b. Over fill oil from factory fill

High shift effort a. Air in clutch hydraulic system b. Defective pressure plate c. Improperly installed clutch fork

SERVICE INFORMATION BORG-WARNER AUTOMOTIVE TRANSMISSION SYSTEMS

Dealership Service Department

This replacement unit has been shipped to your dealership from Borg-Warner Automotive, Muncie, IN. The concerned unit should be returned immediately. You will be billed for tlie replacement unit if it is not returned within 30 days. All procedural steps must be followed to insure that your dealership is not billed for this transmission.

LISTED BELOW ARE THE PROCEDURAL STEPS TO BE FOLLOWED

A reporting form and complaint tag have been provided. Both items must be completely filled out and attached to the concerned unit.

Check fluid level and note findings on the reporting form provided.

If transmission leaks, (See leak charts attached) clean leak areas with powder and mark leak area on transmission. Note area of leakage on leak charts.

The unit must be returned intact as removed from the concerned vehicle. DO NOT ATTEMPT TO REPAIR THE CONCERNED UNIT.

After unit has been removed, drain oil measuring amount drained and indicate on report form provided. Remove all plastic plugs and covers from unit provided and reinstall in concerned unit.

Write the authorization number on the transmission case cover.

Fold the completed reporting form and staple it to the complaint tag, secure the tag to the clutch housing mounting bolt hole of the complaint unit. Staple the leak identification charts to the complaint tag.

Carefully place the concerned unit into the original shipping container. Affix the return shipping label provided to the container.

Return the concerned unit to Borg-Warner Automotive, Muncie using the return shipping instructions which were included with the exchange unit.

YOUR COOPERATION IS GREATLY APPRECIATED, PROMPT RETURN OF YOUR CONCERNED UNIT WILL INCREASE THE EFFECTIVENESS OF THIS PROGRAM. IF YOU HAVE ANY QUESTIONS REGARDING THE EXCHANGE PROGRAM ADMINISTRATIVE PROCEDURES, PLEASE CONTACT BORG-WARNER AT 1-800-356-7301.

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.