CAMPAIGN: CLUTCH COVER TO FLYWHEEL BOLTS/CRANKSHAFT
CERTAIN 1988 CUTLASS CALAIS MODELS EQUIPPED WITH QUAD 4 (LD2) ENGINE AND HM-282 MANUAL 5-SPEED TRANSAXLE (MG2)
CONDITION
General Motors has determined that certain 1988 Cutlass Calais models equipped with Quad 4 (LD2) Engine and HM-282 Manual 5-Speed (MG2) Transaxle may have been produced with inadequately tightened flywheel-to-crankshaft bolts and/or clutch cover-to-flywheel bolts which could result in one or more of the following conditions; noise, slipping, "knocking" sound or inoperative clutch.
VEHICLES INVOLVED
Certain 1988 Cutlass Calais models equipped with Quad 4 (LD2) Engine and HM- 282 Manual 5-Speed (MG2) Transaxle within the following vehicle break points:
Plant Beginning Through and Including ------- --------- ---------------------
Lansing - North Start of Production JM229408
DEALER ACTION
Dealers are to inspect, tighten bolts, and,if required, replace damaged parts as directed in the Service Procedure of this product campaign bulletin.
Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of mileage, age of vehicle, or ownership from this time forward.
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 vehicle inventory and arrange for the campaign correction to be performed.
SERVICE PROCEDURE
1. Remove transaxle from vehicle following the procedure listed on pages 7B3-1 through 7B3-4 of the 1988 Cutlass Calais New Product Service Manual.
In Step 14 of the above procedure, drain the manual transmission fluid into a clean container and save to reinstall later.
2. Remove the clutch cover from the flywheel, taking note of any loose bolts.
3. Remove the flywheel from the crankshaft, again noting any loose bolts.
4. If bolts were found loose in Steps 2 and 3, inspect the flywheel, crankshaft, clutch parts and the bolts themselves for damage.
If galling or metal transfer is found between the flywheel and crankshaft flange mating surfaces, replace the flywheel. Check for high spots on the crankshaft flange (Figure 1). If high spots are found, clean the flange surface with a flat file taking off the high spots only. The new flywheel should fit flat against the crankshaft flange.
If the bolt holes or threads in the crankshaft are damaged, replace the crankshaft (While Quad 4 engine exchange program is in effect, telephone PSE at (517) 885-6537 for instructions).
Replace damaged bolts, clutch cover-to-flywheel or flywheel to crankshaft.
Replace other clutch parts as necessary.
5. Before installing bolts, flywheel-to-crankshaft, the original thread adhesive must be removed from the threads of the bolts with a wire brush and from the threads in the crankshaft flange with a M10 x 1.00-4H thread tap.
Apply thread locking compound part number 12345493, Loctite 272, or equivalent to all flywheel-to-crankshaft bolts; then install flywheel and bolts using the torque angle tightening procedure hand tools listed on pages 6A7-33 and 34 of the 1988 Cutlass Calais New Product Service Manual. The torque specification for these bolts is: 30 N-m (22 lbs. ft.) plus rotate bolt 45 degrees.
6. The clutch parts are to be installed and bolts torqued in the following sequence:
FAILURE TO FOLLOW THIS BOLT TORQUING SEQUENCE WILL RESULT IN BOLTS WHICH ARE INADEQUATELY TIGHTENED.
A. Install clutch cover and clutch disc assembly with the bolts loose and align with tool No. J 29074. Be sure "light side" identification mark on clutch cover is aligned with "X" on flywheel (see Figure 2).
B. Tighten the 3 bolts at holes stamped"L"to 10 N-m (88 lbs. in.).
C. Tighten the remaining bolts to 10 N - m (88 lbs. in.).
D. Tighten the 3 bolts at holes stamped "L" to 26 N - m (19 1bs. ft.).
E. Tighten the remaining bolts to 26 N - m (19 lbs. ft.).
7. Reinstall transaxle using procedure on pages 7B3-1 through 7B3-4.
8. Reinstall transmission fluid, check fluid level, and top off if required with Manual Transmission Fluid, GM Part Number 12345349, or equivalent.
9. Install 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 obtain the parts required to complete this campaign 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). As of the printing of this bulletin, the clutch fork shaft assembly was listed in the GMSPO parts catalog incorrectly as part number 14092026; the correct part number is 23047092.
WARRANTY CLAIM INFORMATION
PC PART-NO. TOT-PTS TC LAB-OP LHRS ST SUBLET -- -------- ------- -- ------ ---- -- ------
Inspect, tighten bolts, and replace damaged parts as required
96 V4430 3.3* -- -----
*.1 hour for clerical administration may be added to the above operation.
Parts allowance: Current dealer price, plus 30%.
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.
