CAMPAIGN: CLUTCH COVER TO FLYWHEEL BOLTS/CRANKSHAFT

CLUTCH COVER-TO-FLYWHEEL BOLTS AND FLYWHEEL-TO-CRANKSHAFT BOLTS

1988 Oldsmobile Calais, Pontiac Grand Am Equipped with Quad 4 (LD2) Engine and HM-282 Manual 5-Speed Transaxle (MG2)

TO: ALL AFFECTED DEALERS:

CONDITION:

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General Motors of Canada has determined that certain 1988 Oldsmobile Cutlass Calais and Pontiac Grand Am 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.

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.

VEHICLES INVOLVED:

Certain 1988 Oldsmobile Cutlass Calais and Pontiac Grand Am Models equipped with Quad 4 (LD2) Engine and HM-282 Manual 5-speed (MG2) Transaxle within the following vehicle breakpoints:

Plant Beginning Through and Including ----- --------- ----------------------

Calais Lansing (M) SOP JM229408

Grand Am Lansing (C) SOP JC662081

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 service all vehicles Subject to this campaign 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 vehicle inventory, or it is in your Dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling 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 for this campaign should be ordered through regular channels:-

Clutch Fork Shift Assembly P/N 23047092 as 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 ----------- ----------- --------------

6A Inspect, Tighten Bolts and 3.4 Hrs. Replace Damaged Parts as Required

Time allowance includes 0.1 hour for Dealer administrative detail associated with this campaign. Parts credit should be claimed as Dealer net plus 30% to cover parts handling.

SERVICE PROCEDURE:

1. Remove transaxle from vehicle following the procedure listed in the appropriate 1988 Product Service Manual.

In 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 Technical Assistance).

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 an 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 and tools listed on Pages SA7-33 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. J29074. 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 (18 lbs. ft.).

E. Tighten the remaining bolts to 26 N.m (18 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.

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.

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.