CAMPAIGN: INTERMEDIATE SERVO COVER PISTON BORE. Pontiac Tempest (Canada) 1990

For 1990-2009 cars

# CAMPAIGN: INTERMEDIATE SERVO COVER PISTON BORE

#### Subject: INTERMEDIATE SERVO COVER PISTON BORE

#### Models: 1990 Cutlass Calais with 2.5L Engine (VIN Code U) and 3T40 Transaxle (RPO MD9)

General Motors of Canada has determined that certain 1990 Oldsmobile Cutlass Calais model vehicles equipped with 2.5L (VIN Code U; RPO L68) engine and 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. 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 will 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:

ONLY the 2 vehicles listed below are involved in this campaign:

1G3NF11U8LM790270 1G3NF51U6LM789383

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 perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, 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, you are to ensure the campaign correction has been made before selling 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:

Part Number Description Quantity/Vehicle

8681967 Servo Cover Kit 1

Kit consists of:

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

8631704 Intermediate Servo Piston & Gasket 1

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

8678168 Fluid Pan Gasket 1

OPNC 8665980 Service Replacement Transmission Assy (SRTA) If Required

#### 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 ----- ------------------------- ------------- 1A Inspect Transaxle I.D. Plate Only .3 (No Repair & No Drive Audit Required)

2A Inspect Transaxle I.D. Plate and .7 Install Kit (No Drive Audit)

3A Inspect Transaxle I.D. Plate, 1.2 Perform Drive Audit and Install Kit

4A Inspect Transaxle I.D. Plate, Perform 5.1 Drive Audit, and Replace the Transaxle with a Hydra-Matic 3T40 SRTA Assembly (No Kit)

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

2. If the vehicle odometer reads less than 19,200 km, go to Step 3 and install Kit P/N 8681967 as instructed.

If the vehicle odometer reads 19,200 km 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 colour.

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 19 to 32 kph.

2-3 upshift at 1/4 throttle, should occur between 32 to 56 kph.

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 through 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 0A in Service Manual). B. Remove fluid pan and gasket. Discard gasket C. Remove strainer and multi-lip seal. Save both parts for reinstal- lation. D. Remove reverse fluid pipe retainers and bolts (140-143 in Figure 2). E. Remove intermediate servo cover (I 37) and gasket (1 36) and discard. F. Remove third accumulator exhaust valve (1 26) and exhaust spring (1 25) and discard. G. Remove the intermediate servo assembly (shown as parts 128 through 135 in Figure 2). H. Install new seals (132 & 134) on new intermediate servo piston (133) from the kit. Transfer parts (128 through 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.

#### 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 1990 Oldsmobile Cutlass Calais model vehicles equipped with 2.5L engiine and automatic transaxle may have been assembled with a Transaxle Intermediate Servo Cover with a rough piston bore. This may eventually cause a "no second gear" condition and internal damage to the transaxle.

To prevent this condition from occurring, General Motors dealers will inspect involved vehicles, and if necessary, install an Intermediate Servo Cover Kit or replace the Transaxle.

If your General Motors dealer determines that the transaxle in your vehicle needs to be replaced, a replacement transaxle will probably have to be ordered; then, after the transaxle arrives, your dealer will call you to schedule a new appointment.

This service will be performed for you at no charge.

Please contact your GM dealer as soon as possible to arrange a 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 die shortest possible time.

Further assistance, if required, may be obtained from our Customer Assistance Centre, toll free, by calling 1-800-263-3777, or if you live in Quebec, 1-800-263-7854.

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.