Cust Satisf 00049 - Mismachined Sealing Surface on Fwd Clutch Housing;4T40-E

VEHICLES THAT COMPLETE THIS CAMPAIGN WILL BE RELEASED FROM THE STOP DELIVERY ISSUED MAY 5, 2000 AND LATER VIA DCS MESSAGES VSG20000319, VSG20000320, WIS20000006, OR PERSONAL PHONE CONTACT.

General Motors has decided that certain 2000 Chevrolet Cavalier and Pontiac Sunfire model vehicles equipped with 4T40-E automatic transaxle may exhibit a condition in which the vehicle will not operate in forward transaxle gear positions because of damage resulting from a mismachined sealing surface on the forward clutch housing of the transaxle.

Dealers are to replace the 4T40-E transaxle of the vehicles listed in this bulletin.

Involved are certain 2000 Chevrolet Cavalier and Pontiac Sunfire model vehicles equipped with 4T40-E automatic transaxle (RPO MN4-Model 0WKR).

The following list shows the vehicles involved and dealers of record in this campaign by VIN and Dealer Code.

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) prior to beginning campaign repairs.

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

Transaxles required to complete this campaign are being pre-shipped to dealers of record. Dealers will not be invoiced for the transaxle or associated core charge. DO NOT ORDER THIS TRANSAXLE.

Important: THESE TRANSAXLES WILL BE REQUESTED FOR RETURN BY THE WARRANTY PARTS CENTER (WPC) IN ACCORDANCE WITH WARRANTY ADMINISTRATION BULLETIN 99-00-89-019 (CANADIAN DEALERS REFER TO HOL #99-201). DO NOT RETURN TRANSAXLES WITHOUT THE WPC REQUEST PAPERWORK.

Important: Verify the VIN campaign eligibility before proceeding with this procedure.

1. Install the seat and the fender covers.
2. Disconnect both battery cables and remove the battery.
3. Disconnect the intake air temperature sensor wiring and loosen the air duct hose from the intake plenum.
4. Remove the push pin from the relay center. Lift the relay center and remove the air cleaner filter box assembly.
5. Remove the upper radiator filler panel.
6. Install the engine support fixture J 28467-B to the vehicle.
7. Disconnect the transaxle wiring harness from the transaxle and the park/neutral position switch.
8. Remove the screw from the front coolant pipe bracket to allow the pipe freedom of movement.
9. Remove the upper transaxle to engine bolts (3) and the stud (1).
10. Remove the two (2) top bolts from the transaxle mount.
11. Raise the vehicle.
12. Remove the front tire and wheel assemblies.
13. Remove both inner fender splash shields.
14. Disconnect the engine strut from the lower engine mount.
15. Disconnect the front and the rear oxygen sensor wiring harnesses from the shifter cable bracket and remove from all the retaining clips.
16. Remove the front exhaust pipe.
17. Disconnect the wheel speed sensor wires from both front wheels and unclip the retaining clips from the frame.
18. Remove the lower intermediate steering shaft pinch bolt.
19. Separate the tie rods from the spindles on both sides.
20. Remove the cotter pins and the retainers from the lower ball joints. Separate the ball joints from the spindle.
21. Unclip the brake line from the retainers on the frame (3 clips).
22. Place a drain pan in position to catch the power steering fluid as you remove the power steering lines from the rack and pinion gear assembly.
23. Remove the bolt that retains the power steering line to the right side of the suspension support brace.
24. Remove the left front suspension support brace.
25. With the aid of an assistant, lower the front suspension support assembly, the rack and pinion assembly and the six (6) suspension to body bolts from the vehicle.
26. Remove the two (2) bolts that hold the transaxle to the engine support brace to the transaxle at the right side transaxle output shaft.
27. Disconnect the shift cable from the shift linkage and the bracket.
28. Remove the flexplate inspection cover.
29. Remove the wiring from the starter. Remove the starter.
30. Remove the torque converter to flexplate bolts.
31. Disconnect the transaxle cooler lines by removing the nut holding the bracket to the transaxle case.
32. Disconnect the vehicle speed sensor wiring harness from the sensor.
33. Disconnect the transaxle output shafts from the transaxle and support in an out-of-the-way position with mechanics' wire.
34. Remove the two (2) bolts that retain the transaxle bracket to the body.
35. Remove the two (2) bolts retaining the bracket to the transaxle.
36. Remove the wiring harness from the body.
37. Lower the vehicle.
38. Remove the two (2) bolts from the transaxle to body bracket.
39. Lower the transaxle and the engine assembly rear with the J 28467 engine support tool.
40. Raise the vehicle.
41. Remove the remaining two (2) bracket bolts and the bracket.
42. Remove the lower transaxle to engine bolts (2).
43. Support the transaxle with the appropriate transaxle support jack.
44. Separate the engine and the transaxle. Remove the transaxle from the vehicle.
45. Transfer the shift cable bracket, the park position switch and the vehicle speed sensor to the new transaxle.
46. Remove the transaxle from the transaxle support stand. Place both items on a bench.
47. Place the new transaxle on the transaxle support stand.
48. Raise the transaxle and align the transaxle into position in the vehicle.
49. Install the lower transaxle to the engine bolts and studs (2).

Tighten
Tighten the bolts to 90 N·m (66 lb ft).

50. Install the transaxle to body bracket with the two (2) lower bracket bolts.

Tighten
Tighten the bolts to 90 N·m (66 lb ft).

51. Lower the vehicle.
52. Raise the engine and transaxle assembly with the J 28467 engine support tool enough to install the two (2) bolts through the unibody frame into the transaxle to engine mount bracket.
53. Install the two (2) bolts.
54. Raise the vehicle.
55. Reposition the wiring harness into its clip on the body rail.
56. Install the axle shafts to the transaxle.
57. Install the wiring harness to the speed sensor.
58. Connect the transaxle cooler lines to the transaxle.

Tighten
Tighten the cooler line retainer to 8 N·m (71 lb in).

59. Install all flexplate to converter bolts (3) finger tight.

Tighten
Tighten the flexplate to converter bolts to 62 N·m (46 lb ft).

60. Attach the starter solenoid and the battery cable to the starter.
61. Install the starter.

Tighten

•	Tighten the starter bolts on the 2.2L engine to 50 N·m (37 lb ft).

•	Tighten the starter bolts on the 2.4L engine to 43 N·m (32 lb ft).

62. Tighten the battery cable to the starter nut.

Tighten
Tighten the battery cable to starter nut to 15 N·m (11 lb ft).

63. Tighten the starter wire to the starter solenoid wire.

Tighten
Tighten the starter wire to the starter solenoid wire to 11 N·m (8 lb ft).

64. Install the flexplate inspection cover.
65. Connect the shift cable to the bracket and the lever.
66. With the aid of an assistant, lift the front suspension support assembly and the rack and pinion assembly into place and install all six (6) bolts loosely.

Tighten
Tighten all bolts to 110 N·m (71 lb ft).

67. Install the left side suspension support brace.

Tighten
Tighten the suspension support brace bolts to 72 N·m (53 lb ft).

68. Install and tighten the power steering lines to the rack and pinion gear assembly.

Tighten
Tighten the power steering lines to 27 N·m (20 lb ft).

69. Install the bolt that secures the power steering lines to the front suspension support assembly.
70. Reconnect the ball joints to the steering knuckle.

Tighten
Tighten the ball joint nut to 60 N·m plus 180 degrees (50 lb ft plus 180 degrees).

71. Install the cotter key in both ball joints.
72. Reconnect the tie rod ball stud to the steering knuckle.

Tighten
Tighten the tie rod ball stud nut to 45 N·m (33 lb ft).

73. Install the lower intermediate steering shaft pinch bolt.

Tighten
Tighten the pinch bolt to 40 N·m (30 lb ft).

74. Re-route and clip the wheel speed sensor wiring into the proper position on both sides.
75. Lower the vehicle in order to loosen the J 28467 tool and allow the engine to assume its proper position.
76. Raise the vehicle.
77. Reinstall the exhaust system to the vehicle.

Tighten

•	Tighten the catalytic converter flange attaching bolts to 30 N·m (22 lb ft).

•	Tighten the exhaust pipe to manifold nuts to 45 N·m (33 lb ft).

78. Route and clip the rear oxygen sensor wires in the proper position and connect the wires.
79. Install the right side suspension support bolt (dog bone).

Tighten
Tighten the bolt to 72 N·m (53 lb ft).

80. Install the inner splash shields on both sides.
81. Install the front wheels and tires using the proper torque sticks.
82. Lower the vehicle.
83. Install the remaining top two (2) engine mount to transaxle bolts.

Tighten
Tighten the bolts to 90 N·m (66 lb ft).

84. Install the upper transaxle to motor bolts (3) and the stud (1).

Tighten
Tighten the transaxle to engine mount bolts and stud to 90 N·m (66 lb ft).

85. Install the engine wiring harness grounds to the transaxle to engine mount stud and install the nut.
86. Lower the vehicle and remove the engine support tool J 28467.
87. Install the heater pipe screw.
88. Connect the wiring harness to the transaxle and the park/neutral position switch.
89. Install the grille to the radiator filler panel.
90. Install the air cleaner assembly.
91. Re-position the relay center and install the push pin.
92. Connect the wire to the air temperature sensor and tighten the screw clamp.
93. Route the wiring harness through the clips on the air cleaner box.
94. Install the battery and attach the battery cables.
95. Start the vehicle and let it idle until the coolant temperature reaches normal operating temperature.
96. With your foot on the brake, shift the transaxle into all the gear ranges and hold in each range for five seconds.
97. Inspect and add DEXRON®III as necessary.
98. Road test the vehicle.
99. Install the GM Campaign Identification Label.
100. Return the transaxle core to the Warranty Parts Center per the instructions in this bulletin under the Parts Information section. DO NOT RETURN THE TRANSAXLE CORE TO GMSPO.

For US

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Additional Campaign Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

For Canada

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP91 when ordering.

Submit a Product Campaign Claim with the information indicated below.

Refer to the General Motors WINS Claim Processing Manual for details on Product Campaign Claim Submission.

For US

Customers will be notified of this campaign on their vehicles by the dealer of record.

For Canada

There will be no customer notification. Only vehicles in dealer inventory are involved.

All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.