For 1990-2009 cars

# F CAR REAR AXLE EXCHANGE PROGRAM-FOR NOISE RELATED CON.

REVISION: 11/13/95

THIS BULLETIN IS BEING REVISED TO CANCEL THE 1995 MODEL YEAR EXCHANGE PROGRAM AND INITIATE THE 1996 MODEL YEAR EXCHANGE PROGRAM. PLEASE DISCARD BULLETIN 47-42-01 (SECTION 4 - DRIVE AXLE). **********************************************************************

REVISION: 01/22/96

THIS BULLETIN IS BEING REVISED TO ADD ADDITIONAL INFORMATION. PLEASE DISCARD BULLETIN 47-42-01 (SECTION 4 - DRIVE AXLE). **********************************************************************

#### SUBJECT: INFORMATION ON F CAR REAR AXLE EXCHANGE PROGRAM (FOR NOISE RELATED CONCERNS ONLY)

#### MODELS: 1996 CHEVROLET CAMARO 1996 PONTIAC FIREBIRD

********************************************************************** GM OF CANADA AND NAES DEALERS ARE NOT AUTHORIZED TO UTILIZE THIS SERVICE BULLETIN. **********************************************************************

TO GAIN NEEDED PRODUCT FEEDBACK ON THE F CAR REAR AXLE, AN EXCHANGE PROGRAM IS NOW IN EFFECT.

IN THE EVENT YOUR DEALERSHIP RECEIVES A COMMENT ON A 1996 F-CAR REAR AXLE, FOLLOW THE PROCEDURES BELOW. YOUR COOPERATION WILL GREATLY IMPROVE THE EFFECTIVENESS OF THIS PROGRAM.

YOUR DEALERSHIP MAY RECEIVE A REAR AXLE NOISE COMMENT, EITHER GEAR OR BEARING RELATED.

THERE ARE OTHER NOISE CONDITIONS THAT MAY APPEAR TO BE AXLE RELATED, BUT WILL NOT NECESSITATE AN AXLE EXCHANGE IN ORDER TO RESOLVE THE CONCERN.

1. FUEL PUMP NOISE 2. REAR AXLE LIMITED SLIP CHATTER

THE FUEL PUMP MAY PRODUCE A WHINE TYPE NOISE WHEN THE ENGINE IS HOT. THIS NOISE CAN BE MAGNIFIED BY INCREASING THE ELECTRICAL LOAD TO THE ENGINE BY CYCLING THE POWER WINDOWS OR BY TURNING ON THE REAR DEFOGGER. REFER TO APPLICABLE SERVICE BULLETINS OR PRELIMINARY INFORMATION (PI), FOR FUEL PUMP SERVICE PROCEDURES.

REAR AXLE LIMITED SLIP CHATTER OCCURS WHEN A VEHICLE IS MAKING A TURN AT LOW SPEEDS. THIS CHATTER MAY SOUND SIMILAR TO WHEEL HOP. A COMPLETE PROPER AXLE LUBRICANT FLUSH AND FILL OF THE REAR AXLE WILL ELIMINATE THIS CONDITION AND WILL NOT REQUIRE AN EXCHANGE AXLE.

REAR AXLE FLUSH AND FILL PROCEDURE:

1. REMOVE REAR AXLE COVER AND GASKET. 2. DRAIN ALL AXLE LUBRICANT FROM HOUSING. 3. FULLY FLUSH AND CLEAN THE INTERIOR OF THE AXLE WITH BRAKE CLEAN SPRAY.

#### NOTICE: ALL INTERNAL COMPONENTS OF THE AXLE, ESPECIALLY THE LIMITED SLIP DIFFERENTIAL PARTS, MUST BE BRUSHED AS PART OF THE CLEANING PROCEDURE IN ORDER TO REMOVE ANY RESIDUE FROM THE ORIGINAL LUBRICANT.

#### CAUTION:

EYE PROTECTION AND RUBBER GLOVES MUST BE WORN WHEN USING BRAKE CLEAN SPRAY. ALSO AVOID BREATHING VAPORS FROM THE BRAKE CLEAN SPRAY. 4. INSTALL REAR AXLE COVER AND NEW GASKET. 5. TORQUE COVER FASTENERS TO 30 N.M (22 LBS. FT.). 6. FILL AXLE WITH THE PROPER AMOUNT OF LUBRICANT AND 188 ML (4 OZ.) OF ADDITIVE AS STATED IN THE APPLICABLE SERVICE MANUAL.

AFTER YOU HAVE VERIFIED THE NOISE CONDITION, AND THE ABOVE OTHER POSSIBLE CONDITIONS WERE NOT APPLICABLE, CONTACT YOUR TECHNICAL ASSISTANCE DEPARTMENT (TAC/TAN) TO OBTAIN AN EXCHANGE AXLE PER PROCEDURES SHOWN BELOW.

DO NOT REMOVE AXLE CARRIER HOUSING COVER.

EXCHANGE PROCEDURE

ONCE THE NOISE IS DEEMED AXLE RELATED, AND AN EXCHANGE UNIT IS NECESSARY, CONTACT YOUR TECHNICAL ASSISTANCE DEPARTMENT (TAC/TAN).

TAC/TAN WILL REQUIRE THE AXLE CODE (STAMPED ON THE AXLE TUBE) AND COMPLETE VEHICLE INFORMATION.

WITHIN 48 HOURS, TAC/TAN WILL ARRANGE FOR AN EXCHANGE AXLE TO BE SHIPPED TO YOUR DEALERSHIP.

#### IMPORTANT: THIS EXCHANGE AXLE WILL BE COMPLETE EXCEPT FOR BRAKE ROTORS (ON DISC BRAKE VEHICLES) AND BRAKE CABLES. THE EXCHANGE AXLE WILL BE SHIPPED WITH LUBRICANT. ALSO BLEED BRAKE HYDRAULIC SYSTEM PER SECTION 5 OF THE SERVICE MANUAL.

A TAC/TAN CASE NUMBER WILL BE PROVIDED FOR EACH AXLE EXCHANGE. THIS NUMBER MUST BE RECORDED ON THE IDENTIFICATION CARD SUPPLIED WITH THE EXCHANGE AXLE AND BE AFFIXED TO THE REMOVED AXLE BEING RETURNED. FILL OUT THE IDENTIFICATION CARD COMPLETELY.

TO AVOID A CHARGEBACK, THE REMOVED UNIT MUST BE RETURNED WITHIN 10 WORKING DAYS FROM DATE OF RECEIPT IN THE ORIGINAL SHIPPING CONTAINER. FAILURE TO RETURN THE REMOVED UNIT WILL RESULT IN THE DEALERSHIP BEING BILLED $1,500.00, THE VALUE OF THE EXCHANGE UNIT.

PREPARATION FOR SHIPPING

REMOVE AXLE ASSEMBLY FROM VEHICLE PER SERVICE MANUAL. REMOVE ALL PLASTIC SHIPPING PLUGS AND COVERS FROM THE EXCHANGE UNIT AND INSTALL THEM ON THE REMOVED UNIT.

RECORD THE TAC/TAN CASE NUMBER ON THE SUPPLIED IDENTIFICATION CARD AND ATTACH THE CARD TO THE REMOVED AXLE.

RECORD THE TAC/TAN CASE NUMBER ON THE DEALER REPAIR ORDER (RO). STAPLE A COPY OF THE RO TO THE IDENTIFICATION CARD.

PLACE THE REMOVED UNIT INTO THE ORIGINAL SHIPPING CONTAINER.

SHIPPING INSTRUCTIONS

PLACE THE SUPPLIED RETURN SHIPPING LABEL OVER THE ORIGINAL CONTAINER SHIPPING LABEL.

THE BILL OF LADING WILL BE COMPLETE, EXCEPT FOR THE DATE AND CARRIER SIGNATURE. AFTER THE BILL OF LADING HAS BEEN DATED AND SIGNED BY THE CARRIER, RETAIN THE LAST COPY AND ATTACH IT TO YOUR "WARRANTY" COPY OF THE RO. PROVIDE THE OTHER TWO COPIES TO THE CARRIER. YOUR COPY OF THE BILL OF LADING, SIGNED BY THE CARRIER, IS YOUR PROOF OF RETURNING THE AXLE.

THE REMOVED AXLE IS TO BE SHIPPED FREIGHT COLLECT (ROADWAY, IF POSSIBLE) TO:

AMERICAN AXLE AND MANUFACTURING--BUFFALO PLANT 1001 EAST DELEVAN AVE. BUFFALO, NY 14240

#### ATTENTION:

QUALITY ASSURANCE SCOTT JONES

TO INCREASE THE EFFECTIVENESS OF THE EXCHANGE PROGRAM, THE REMOVED UNIT MUST BE RETURNED WITHIN 10 WORKING DAYS AFTER THE RECEIPT OF THE EXCHANGED UNIT. FAILURE TO RETURN THE REMOVED UNIT WILL RESULT IN THE DEALERSHIP BEING BILLED $1,500 FOR THE EXCHANGED UNIT FURNISHED, PLUS AN ADMINISTRATIVE CHARGE.

WARRANTY CLAIMS PROCESSING INFORMATION

UPON THE COMPLETION OF THE EXCHANGE, A WARRANTY CLAIM IS TO BE SUBMITTED AS FOLLOWS:

LABOR OPERATIONS **OTHER *NET DESCRIPTION NUMBER LABOR HOURS HOURS AMOUNT ___________ __________ ___________ _______ _______ REAR DIFFERENTIAL F3200 USE PUBLISHED .2 $161.81 ASSEMBLY REPLACE LABOR TIMES.

* THE AMOUNT IDENTIFIED IN THE "NET AMOUNT" FIELD ABOVE REPRESENTS THE DEALERSHIP'S HANDLING ALLOWANCE ON THE PARTS THAT WERE FURNISHED FREE OF CHARGE TO YOU BY GENERAL MOTORS. IT IS 40% OF THE DEALER NET COST FOR PARTS, SUCH AS GEAR SET, BEARINGS, SEALS, ETC. FOR A TYPICAL AXLE REPAIR FOR NOISE RELATED CONDITIONS.

#### IMPORTANT: ALSO ADD APPLICABLE MISCELLANEOUS ITEMS SUCH AS BRAKE FLUID TO THE NET AMOUNT FIELD OF THE CLAIM.

** ADMINISTRATIVE ALLOWANCE

FIGURES: 0 ATTACHMENTS: 0

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER." THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS OCCURRING 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 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.

COPYRIGHT 1996. GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.