Customer Satisfaction - 4T40-E Transaxle Converter Bearing Failure - Inspect/Replace

General Motors has decided that certain 2001 Chevrolet Cavalier, Pontiac Sunfire, Grand Am; and Oldsmobile Alero model vehicles equipped with 2.4L (RPO LD9 - VIN Code T) engine and 4T40-E automatic transaxle (MN4) may exhibit a condition in which the transaxle converter pump to stator bearing may prematurely fail, due to a raised metal condition on the bearing surface on the inside of the pump cover. This may cause transaxle noise and failure.

Dealers are to inspect the torque converter for certain production codes and replace the converter or, in certain cases, replace the transaxle.

Important: Vehicles previously repaired under warranty have been excluded from this campaign.

Involved are certain 2001 Chevrolet Cavalier; Pontiac Sunfire, Grand Am; and Oldsmobile Alero model vehicles equipped with 2.4L (RPO LD9 - VIN Code T) engine and 4T40-E automatic transaxle (MN4) and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.]

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.

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

Important: Although all service transaxles are labeled "remanufactured", transaxles supplied for this campaign during the 2001 model year will be new, original equipment transaxles.

Important: It is estimated that only 33% of involved vehicles will require converter or transaxle replacement. Please order parts accordingly.

Important: The service procedure contained in this campaign is different from the service procedure fond in the appropriate service manuals. As a result, the labor time allowance has been revised to correspond with this new service procedure. In the near future, the service manuals and labor time guides will be updated with this new information.

1. Raise and support the vehicle.
2. On the N car (Pontiac Grand Am, Oldsmobile Alero), remove the lower front air deflector.
3. Remove the transaxle torque converter inspection cover.
4. Using a light and looking between the flex plate and the transaxle case, inspect the torque converter for a paint stripe. Some converters may not have a paint stripe.

Important: This paint stripe is on the transaxle side of the converter, hub side of the weld, not the flex plate side of the weld.

4.1.	Rotate the engine crankshaft while closely inspecting for the paint stripe.

4.2.	Record the paint stripe color on the repair order.

•	If the paint stripe is Green, further diagnosis must be performed. A second crankshaft rotation may be necessary to detect the green stripe as other colors can be present. Reinstall the lower air deflector if equipped. Proceed to Transaxle R&R for the vehicle you are inspecting.

•	If no paint stripe is found, or the stripe is any color other than green, reinstall the transaxle torque converter inspection cover. Tighten the bolts to 10 N·m (89 lb in). Proceed to Step 5.

5. Reinstall the lower air deflector, if equipped, and lower the vehicle.
6. Open the hood and install the GM Campaign Identification Label.

Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable from the battery.
2. Remove the air cleaner outlet duct.
3. Remove the wire harness from the upper transaxle mount bracket.
4. Disconnect the shift cable and electrical connectors from the transaxle.
5. Remove the wiring ground cables from the engine block.
6. Remove the upper transaxle to engine bolts.
7. Install the Engine Support Fixture J 28467-500 to the vehicle.

7.1.	Install Bracket Assembly J 28467-6A to the support fixture.

7.2.	Install Hook Assembly J 28467-8A to the left rear engine lift hook and the bracket assembly.

7.3.	Install Lift Hook Wing Nut and Washer J 28467-34 to the hook assembly.

7.4.	Spin wing nut to end of travel to secure the engine and transaxle in place.

8. Raise the vehicle on the hoist.
9. Remove both front tire and wheel assemblies.
10. Remove the screws and push-in retainers from both fender front inner liners and remove the liners.
11. Drain the transaxle oil into a suitable container by loosening the oil pan bolts and removing the transaxle oil pan.
12. Reinstall transaxle oil pan and secure with the bolts.
13. Remove the nut and the oil cooler line block from the transaxle.
14. Disconnect the front antilock brake system (ABS) wheel speed sensor (WSS) wiring connectors, and disconnect the wiring routing clips from the lower control arm and frame.
15. Disconnect the VSS wiring connector from the sensor and the harness from the clip.
16. Remove the bolt retaining the LH front brake pipe bracket to the body.
17. Remove the brake hose from the retaining clips at the cross-vehicle suspension support (frame).
18. Remove the cotter pins and the nuts from the ball joint studs.

Notice: Use only the recommended tool for separating the ball joint from the knuckle. Failure to use the recommended tool may cause damage to the ball joint and seal.

19. Separate the ball joint studs from the steering knuckle using J 43828.
20. Remove the bolts and the left front suspension support brace.
21. Remove the power steering gear mounting bolts and support the gear with mechanics wire.
22. Remove the front engine mount strut-retaining bolts, leaving the other end attached to the front frame.
23. With assistance and jack stands, remove all front frame to body bolts, and lower the crossmember from the vehicle.

Notice: Care must be exercised to prevent the drive axle joints from being over-extended. When either end of the shaft is disconnected, over-extension of the joint could result in separation of the internal components and possible joint failure. Drive axle joint boot protectors should be used any time service is performed on or near the drive axles. Failure to observe this can result in interior joint or boot damage and possible joint failure.

24. Disconnect the transaxle output shafts from the transaxle and support with mechanics wire.
25. Remove the bolts retaining the transaxle to engine support brace at the extension housing.
26. Remove the shift cable from the mounting bracket.
27. Remove the shift cable bracket lower retaining bolt. Reposition the oxygen sensor wiring harness from between the shift cable bracket and the transaxle.
28. Remove the flex plate to torque converter bolts.
29. Remove the transaxle side mount to body bolts.
30. Place the transaxle support under the transaxle.
31. Remove the remaining transaxle to engine bolts.
32. Slide the transaxle away from the engine and carefully lower the transaxle support.
33. Inspect the flex plate side of the converter for the large painted identification numbers. These numbers appear as two groups. They are the torque converter production date and times of the day.

•	Converter Julian Date: 332# / Time (Military): Anytime / Vehicle Mileage: Less than 100 / Action Required: A

•	Converter Julian Date: 332# / Time (Military): Anytime / Vehicle Mileage: More than 100 / Action Required: B

•	Converter Julian Date: 333# / Time (Military): Before 10:00 hrs / Vehicle Mileage: Less than 100 / Action Required: A

•	Converter Julian Date: 333# / Time (Military): Before 10:00 hrs / Vehicle Mileage: More than 100 / Action Required: B

•	Converter Julian Date: 333# / Time (Military): After 10:00 hrs / Vehicle Mileage: NA / Action Required: C

34. Refer to the action-required instructions in the previous steps to determine your next step.

-	A. Replace the torque converter and reinstall the original transaxle. Proceed to Step 36.

-	B. Flush the transmission cooler and the lines using the procedure listed below. Replace the torque converter and the transaxle assembly with a new assembly. Proceed to Step 41.

-	C. Reinstall the original converter and transaxle assembly. Proceed to Step 46.

35. Remove the torque converter assembly from the transaxle.
36. Remove the torque converter O-ring seal from the end of the turbine shaft. Use a screwdriver.
37. Install a new torque converter O-ring seal on the end of the turbine shaft.
38. Place a thin film of clean chassis grease, GM P/N 1051344, or the equivalent, on the torque converter pilot hub.
39. Install the torque converter onto the transmission. Ensure that the torque converter is properly seated in the oil pump. If replacing the torque converter only, go to Step 45. If replacement of the complete transaxle assembly is required, continue with Step 41.
40. Remove the old transaxle from the support.
41. Uncrate the new transaxle.
42. With assistance, install the new transaxle onto the support.
43. Transfer the following components from the old transaxle to the new transaxle.

•	Transaxle side mount. Tighten the bolts to 66 N·m (49 lb ft)

•	Shift cable bracket

•	Shift lever

•	Park/Neutral position switch. Tighten the bolts to 24 N·m (18 lb ft)

•	Cooler pipe block stud

•	Transaxle case bushing

44. Place the old transaxle in the crate for return.
45. Position the transaxle in the vehicle.

Notice: Ensure that the transaxle assembly is properly lined up to the engine (properly aligned and in-full contact with the engine) before installing the engine to transaxle bolts. Pulling the transaxle into place with the mounting bolts may cause the flex plate to fail in the future.

46. Install the lower transaxle to engine bolts and the 2 studs.

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

47. Install the transaxle side mount to body bolts.

Tighten
Tighten the bolts to 66 N·m (49 lb ft).

48. Install the torque converter to flex plate bolts.

Tighten
Tighten the bolts to 62 N·m (42 lb ft).

49. Route the oxygen sensor wiring harness in between the shift cable bracket and the transaxle.
50. Install the shift cable bracket lower retaining bolt.
51. Install the shift cable to the mounting bracket.
52. Install the bolts retaining the transaxle to the engine support brace at the extension housing.

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

53. Install the axle shafts to the transaxle.
54. With the assistance and jack stands, position the front frame into place. Install the frame to body bolts.

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

55. Install the front engine mount strut and the retaining bolt.

Tighten
Tighten the bolt to 66 N·m (49 lb ft).

56. Install the steering gear mounting bolts.

Tighten
Tighten the bolts to 120 N·m (89 lb ft).

57. Install the left front suspension support brace and the retaining bolts.

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

58. Reconnect the ball joints to the steering knuckles and install the nuts.

Tighten
Tighten the nuts to 55 N·m (41 lb ft) plus 180 degrees.

Important: Never loosen the ball joint nut to install the cotter pin. If the cotter pin slots will not line up, tighten the nut slightly.

59. Install the cotter pin in both ball joints.
60. Install the brake pipe to the retaining clips at the frame.
61. Install the bolt retaining the LH front brake hose bracket to the body.
62. Connect the VSS wiring connector to the sensor and position the harness into the retaining clip.
63. Connect the front antilock brake system (ABS) wheel speed sensor (WSS) wiring connectors, and connect the wiring routing clips to the lower control arm and frame.

Notice: Failure to lubricate the cooler line seals with DEXRON®III before installing the cooler line pipes into the seals may cause damage to the seals.

64. Install the oil cooler line block and the nut.

Tighten
Tighten to 8 N·m (71 lb in).

Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury.

Notice: A torque wrench or J 39544 must be used to ensure that the wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on the wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut and/or stud damage.

65. Install both tire and wheel assemblies.
66. Install the wheel nuts. Tighten the nuts to 140 N·m (100 lb ft). This should be done in 3 steps using the star pattern to avoid excessive rotor run-out.

66.1.

Hand tighten all 5 lug nuts using the star pattern.

66.2.

Tighten all 5 nuts to approximately 1/2 spec. using the star pattern.

66.3.

Tighten all 5 nuts to full spec. using the star pattern.

67. If reinstalling the original transaxle, remove the transaxle oil pan. Otherwise, skip to Step 72.
68. Clean and inspect the transaxle oil pan for dents or damage. Dry the transaxle oil pan before installation.
69. Install the transaxle oil pan gasket. Use a new transaxle oil pan gasket if the sealing ribs are damaged.
70. Install the oil pan and the attaching bolts. Replace the pan if damaged.

Tighten
Tighten the bolts to 14 N·m (124 lb in).

71. If reinstalling the original transaxle, fill the transaxle with approximately 6.5L (6.9 qts) of DEXRON®III Automatic Transmission Fluid.
72. Lower the vehicle.
73. Remove the engine support fixture from the vehicle.
74. Install the upper transaxle to engine bolts.

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

75. Install the ground cables to the engine block.

Tighten

•	Tighten the stud to 25 N·m (18 lb ft).

•	Tighten the nut to 18 N·m (13 lb ft).

76. Connect the shift cable and electrical connectors to the transaxle.
77. Install the wire harness to the upper transaxle mount bracket.
78. Install the air cleaner outlet duct.
79. Connect the negative battery cable.

Tighten to 16 N·m (12 lb ft).

80. Check the automatic transaxle fluid level following the procedure below.

80.1.

Start the engine and allow the engine to idle until the transmission fluid temperature has reached at least 40°C (104°F).

80.2.

Depress the brake pedal and move the gear shift lever through the gear ranges, pausing a few seconds in each range. Place the shift lever in Park.

Caution: The engine must be running when the transmission fluid fill plug is removed, or excessive fluid loss will occur. Transmission fluid may be hot. Since the actual fluid level is unknown, stand clear when removing the fill plug. Have a container ready to capture any lost fluid. Do not turn the engine OFF with the fill plug removed, as you can be injured by hot transaxle fluid being expelled out of the oil fill opening.

80.3.

With the engine running, and the shift lever in Park, raise the vehicle on a hoist. (The vehicle must be level.) Remove the transmission oil level control plug.

80.4.

Check the fluid level. The fluid level should be even with the bottom of the threaded hole. Add DEXRON®III Automatic Transmission Fluid until the fluid drains from the hole.

80.5.

Lower the vehicle.

81. Road test the vehicle to determine proper operation of all systems.
82. Open the hood and install the GM Campaign Identification Label.

Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable from the battery.
2. Remove the air cleaner outlet assembly.
3. Disconnect the electrical connectors and the harness from the transaxle.
4. Disconnect the shift cable and remove the shift lever from the transaxle.
5. Remove the upper transaxle to engine bolts.
6. Secure the cooling fan assemblies to the upper radiator support using mechanics wire.
7. Install the Engine Support Fixture J 28467-500 to the vehicle.

7.1.	Install Bracket Assembly J 28467-6A to the support fixture.

7.2.	Install Hook Assembly J 28467-8A to the left rear engine lift hook and the bracket assembly.

7.3.	Install Lift Hook Wing Nut and Washer J 28467-34 to the hook assembly.

7.4.	Spin wing nut to end of travel to secure the engine and transaxle in place.

8. Raise the vehicle on the hoist.
9. Remove both front tire and wheel assemblies.
10. Remove the screws and push-in retainers from both fender front inner liners and remove the liners.
11. Drain the transaxle oil into a suitable container by loosening the oil pan bolts and removing the transaxle oil pan.
12. Reinstall transaxle oil pan and secure with the bolts.
13. Remove the nut and the oil cooler line block from the transaxle.
14. Disconnect the front antilock brake system (ABS) wheel speed sensor (WSS) wiring connectors, and disconnect the wiring routing clips from the lower control arm and frame.
15. Disconnect the VSS wiring connector from the sensor and the harness from the clip.
16. Remove the brake hose from the retaining clips at the frame.
17. Remove the nut retaining the Electronic Brake Traction Control Module (EBTCM) to the frame.
18. Remove the cotter pins and the nuts from the ball joint studs.

Notice: Use only the recommended tool for separating the ball joint from the knuckle. Failure to use the recommended tool may cause damage to the ball joint and seal.

19. Separate the ball joint studs from the steering knuckle using J 43828.
20. Support the steering gear in position with mechanics wire.
21. Remove the 2 nuts and bolt from the rear mount bracket to frame.
22. Loosen the stabilizer link nuts just to the end of travel of the bolt threads.
23. Remove the front transaxle mounting through-bolt.
24. Support the frame with jack stands.
25. Remove the frame bolts. Loosen the rear bolts just enough to be removed from the body.
26. Lower the frame enough to gain access to the stabilizer shaft insulator bracket bolts.
27. Remove the bolts retaining the stabilizer shaft insulator brackets to the frame.
28. Remove the RH steering gear mounting bolt.
29. Raise the stabilizer shaft to gain access to the LH power steering gear mounting bolt and remove the bolt.
30. With assistance and jack stands, remove the frame from the vehicle.
31. Remove the rear mount to transaxle bolts.

Notice: Care must be exercised to prevent the drive axle joints from being over-extended. When either end of the shaft is disconnected, over-extension of the joint could result in separation of the internal components and possible joint failure. Drive axle joint boot protectors should be used any time service is performed on or near the drive axles. Failure to observe this can result in interior joint or boot damage and possible joint failure.

32. Disconnect the transaxle output shafts from the transaxle and support with mechanics wire.
33. Remove the bolts retaining the transaxle to engine support brace at the transaxle extension housing.
34. Remove the shift cable from the mounting bracket.
35. Remove the side transaxle mount through-bolt.
36. Remove the flex plate to torque converter bolts.
37. Place the transaxle support under the transaxle.
38. Remove the remaining transaxle to engine bolts.
39. Slide the transaxle away from the engine and carefully lower the transaxle support.
40. Inspect the flex plate side of the converter for the large painted identification numbers. These numbers appear as two groups. They are the torque converter production date and times of the day.

•	Converter Julian Date: 332# / Time (Military): Anytime / Vehicle Mileage: Less than 100 / Action Required: A

•	Converter Julian Date: 332# / Time (Military): Anytime / Vehicle Mileage: More than 100 / Action Required: B

•	Converter Julian Date: 333# / Time (Military): Before 10:00 hrs / Vehicle Mileage: Less than 100 / Action Required: A

•	Converter Julian Date: 333# / Time (Military): Before 10:00 hrs / Vehicle Mileage: More than 100 / Action Required: B

•	Converter Julian Date: 333# / Time (Military): After 10:00 hrs / Vehicle Mileage: NA / Action Required: C

41. Refer to the action-required instructions in the previous steps to determine your next step.

-	A. Replace the torque converter and reinstall the original transaxle. Proceed to Step 42.

-	B. Flush the transmission cooler and the lines using the procedure listed below. Replace the torque converter and the transaxle assembly with a new assembly. Proceed to Step 47.

-	C. No further action is required, reinstall transaxle. Proceed to Step 52.

42. Remove the torque converter assembly from the transaxle.
43. Remove the torque converter O-ring seal from the end of the turbine shaft. Use a screwdriver.
44. Install a new torque converter O-ring seal on the end of the turbine shaft.
45. Place a thin film of clean chassis grease, GM P/N 1051344, or the equivalent, on the torque converter pilot hub.
46. Install the torque converter onto the transmission. Ensure that the torque converter is properly seated in the oil pump.
47. Remove the old transaxle from the support.
48. Uncrate the new transaxle.
49. With assistance, install the new transaxle onto the support.
50. Transfer the following components from the old transaxle to the new transaxle.

•	Transaxle front mount. Tighten the bolts to 130 N·m (96 lb ft)

•	Transaxle side mount. Tighten the bolts to 66 N·m (49 lb ft)

•	Shift cable bracket

•	Park/Neutral position switch. Tighten the bolts to 24 N·m (18 lb ft)

•	Cooler pipe block stud

•	Transaxle case bushing

•	2 wire retaining clips

51. Place the old transaxle in the crate for return.
52. Position the transaxle in the vehicle.

Notice: Ensure that the transaxle assembly is properly lined up to the engine (properly aligned and in-full contact with the engine) before installing the engine to transaxle bolts. Pulling the transaxle into place with the mounting bolts may cause the flex plate to fail in the future.

53. Install the lower transaxle to engine bolts and the 2 studs.

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

54. Install the torque converter to flex plate bolts.

Tighten
Tighten the bolts to 62 N·m (42 lb ft).

55. Install the side transaxle mount through-bolt.

Tighten
Tighten the bolts to 55 N·m (41 lb ft).

56. Install the shift cable to the mounting bracket.
57. Install the bolts retaining the transaxle to the engine support brace at the extension housing.

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

58. Install the axle shafts to the transaxle.
59. Install the rear mount to transaxle bolts.

Tighten
Tighten the bolts to 66 N·m (49 lb ft).

60. With the assistance and jack stands, position the front frame into place. Install the 2 center frame to body bolts.

Tighten
Tighten the bolts to 245 N·m (180 lb ft) plus 180 degrees rotation.

61. Install the 2 front frame to body bolts.

Tighten
Tighten the bolts to 115 N·m (84 lb ft) plus 120 degrees rotation.

62. Raise the stabilizer shaft and install the LH power steering gear mounting bolt.

Tighten
Tighten the bolt to 110 N·m (81 lb ft).

63. Install the RH power steering gear mounting bolt.

Tighten
Tighten the bolt to 110 N·m (81 lb ft).

64. Install the bolts retaining the stabilizer shaft insulator brackets to the frame.

Tighten
Tighten the bolts to 66 N·m (49 lb ft).

65. Install the front transaxle mount through bolt.

Tighten
Tighten the bolt to 75 N·m (55 lb ft).

66. Tighten the stabilizer link nuts until the nuts meet the end of the bolt threads for torque value.

Tighten
Tighten the nuts to 17 N·m (13 lb ft).

67. Install the 2 nuts and the bolt attaching the rear mount bracket to the frame.

Tighten
Tighten the nuts and bolt to 66 N·m (49 lb ft).

68. Install the 4 remaining frame support bolts.

Tighten
Tighten the bolts to 110 N·m (81 lb ft).

69. Reconnect the ball joints to the steering knuckles and install the nuts.

Tighten
Tighten the nuts to 55 N·m (41 lb ft) plus 180 degrees.

Important: Never loosen the ball joint nut to install the cotter pin. If the cotter pin slots will not line up, tighten the nut slightly.

70. Install the cotter pin in both ball joints.
71. Install the brake pipe to the retaining clips at the frame.
72. Connect the VSS wiring connector to the sensor and position the harness into the retaining clip.
73. Connect the front antilock brake system (ABS) wheel speed sensor (WSS) wiring connectors and connect the wiring routing clips to the lower control arm and frame.

Notice: Failure to lubricate the cooler line seals with DEXRON®III, before installing the cooler line pipes into the seals, may cause damage to the seals.

74. Install the oil cooler line block and the nut.

Tighten
Tighten to 8 N·m (71 lb in).

75. Install the fender front inner liners, the push-in retainers and the screws.

Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury.

Notice: A torque wrench or J 39544 must be used to ensure that the wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on the wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut and/or stud damage.

76. Install both tire and wheel assemblies. Align the locating mark of the tire and wheel to the hub.
77. Install the wheel nuts. Tighten the nuts to 140 N·m (100 lb ft). This should be done in 3 steps using the star pattern to avoid excessive rotor run-out.

77.1.

Hand tighten all 5 lug nuts using the star pattern.

77.2.

Tighten all 5 nuts to approximately 1/2 spec. using the star pattern.

77.3.

Tighten all 5 nuts to full spec. using the star pattern.

78. If reinstalling the original transaxle, remove the transaxle oil pan.
79. Clean and inspect the transaxle oil pan for dents or damage. Dry the transaxle oil pan before installation.
80. Install the transaxle oil pan gasket. Use a new gasket if the sealing ribs are damaged.
81. Install the transaxle oil pan and the attaching bolts. Replace the pan if damaged.

Tighten
Tighten the bolts to 14 N·m (124 lb in).

82. If reinstalling the original transaxle, fill the transaxle with approximately 6.5L (6.9 qts) of DEXRON®III Automatic Transmission Fluid.
83. Lower the vehicle.
84. Remove the engine support fixture from the vehicle.
85. Install the remaining upper transaxle to engine bolts.

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

86. Install the shift lever and connect the shift cable.
87. Install the wire harness to the transaxle and connect all electrical connectors.
88. Install the air cleaner assembly.
89. Connect the negative battery cable.
90. Check the automatic transaxle fluid level.

90.1.

Start the engine and allow the engine to idle until the transmission fluid temperature has reached at least 40°C (104°F).

90.2.

Depress the brake pedal and move the gear shift lever through the gear ranges, pausing a few seconds in each range. Place the shift lever in Park.

Caution: The engine must be running when the transmission fluid fill plug is removed, or excessive fluid loss will occur. Transmission fluid may be hot. Since the actual fluid level is unknown, stand clear when removing the fill plug. Have a container ready to capture any lost fluid. Do not turn the engine OFF with the fill plug removed, as you can be injured by hot transaxle fluid being expelled out of the oil fill opening.

90.3.

With the engine running, and the shift lever in Park, raise the vehicle on a hoist. (The vehicle must be level.) Remove the transmission oil level control plug.

90.4.

Check the fluid level. The fluid level should be even with the bottom of the threaded hole. Add DEXRON®III Automatic Transmission Fluid until the fluid drains from the hole.

90.5.

Lower the vehicle.

91. Road test the vehicle to determine proper operation of all systems.
92. Open the hood and install the GM Campaign Identification Label.

GM studies indicate that plugged or restricted transmission oil coolers and pipes cause insufficient transmission lubrication and elevated operating temperatures which can lead to premature transmission wear-out. Following published procedures for transmission oil cooler flushing and flow checking could have prevented many cases. This procedure includes flushing and flow checking the auxiliary transmission oil cooler, if equipped. GM requires that transmission oil cooler flushing and flow checking be performed whenever a transmission is removed from the vehicle for service within warranty, including:

Goodwrench SRTA

Major overhaul

Torque converter replacement

Oil pump replacement

Tools Required

Important: Do not substitute with solutions that contain alcohol or glycol. Use of solutions that contain alcohol or glycol may damage the J 35944-A, oil cooler components or transmission components.

The flushing fluid (J 35944-22) is environmentally safe, yet powerful enough to cut through transmission fluid to dislodge any contaminants from the cooler. The safety precautions on the label regarding potential skin and eye irritations associated with prolonged exposure, are typical precautions that apply to many similar cleaning solutions. It should be noted that, use of other non-approved fluids for cooler flushing could have an adverse reaction to the seals inside the transmission.

Setup

1. Remove the fill cap on the J 35944-A and fill the flusher tank with 0.6L (20-21 oz) of the J 35944-22 flushing solution. Do not overfill.
2. Install the fill cap on the J 35944-A and pressurize the flusher tank to 550-700 kPa (80-100 psi), using the shop air supply at the tank air valve.
3. Connect the J 35944-A discharge hose to the oil cooler return pipe (bottom connector) using the J 35944-440, Cooler Flushing Adapter.
4. Clip the discharge hose onto the oil drain container.
5. Reattach both cooler lines to the radiator.
6. Attach the J 35944-A to the undercarriage of the vehicle with the hook provided and connect the flushing system feed supply hose from the J 35944-A to the oil cooler feed pipe (top connector) using the J 35944-440 Cooler Flushing Adapter.
7. With the water supply valve on the J 35944-A in the OFF position, connect the water supply hose from the J 35944-A to the water supply at the faucet.
8. Turn ON the water supply at the faucet.

Initial Flush

1. Turn the J 35944-A water supply valve to the ON position and allow water to flow through the oil cooler and the pipes for 10 seconds to remove any remaining transmission fluid. If water does not flow through the oil cooler and the pipes, the cause of the blockage must be diagnosed and the plugged component must be repaired or replaced. Continue with the cooler flushing and flow check procedure once the blockage is corrected.
2. Turn the J 35944-A water supply valve to the OFF position and clip the discharge hose onto a five-gallon (19L) pail with a lid, to avoid splash back.
3. Turn the J 35944-A water supply valve to the ON position and depress the trigger to mix cooler flushing solution into the water flow. Use the clip provided on the handle to hold the trigger down. The discharge will foam vigorously when the solution is introduced into the water stream.

Important: Flushing for approximately 2 minutes in each cooler line direction will result in a total of about 8-10 gallons of waste fluid. This mixture of water and flushing fluid is to be captured in a five-gallon bucket or similar container.

4. Flush the oil cooler and pipes with water and solution for two minutes. During this flush, attach the shop air supply 825 kPa (120 psi) to the flushing system feed air valve located on the J 35944-A for 3-5 seconds at the end of every 15-20 second interval to create a surging action.
5. Release the trigger and turn the J 35944-A water supply to the OFF position.

Back Flush

1. Disconnect both hoses from the oil cooler pipes and then connect them to the opposite oil cooler pipe. This will allow the oil cooler and pipes to be back flushed.
2. Repeat Steps 3 and 4 of the Initial Flush procedure.
3. Release the trigger of the J 35944-A and allow water only to rinse the oil cooler and pipes for one minutes.
4. Turn the J 35944-A water supply valve to the OFF position and turn OFF the water supply at the faucet.
5. Attach the shop air supply to the flushing system feed air valve on the J 35944-A and blow out the water from the oil cooler and the pipes. Continue until no water/water vapor comes out of the discharge hose.

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.

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.

Dealers in possession of vehicles included in the Stop Delivery are eligible for reimbursement of floor plan expense upon completion of this campaign. This reimbursement is limited to the number of days from the Stop Delivery message to receipt of the campaign parts and/or repair procedures. Floor plan reimbursement beyond these dates is not allowed. The amount of reimbursement should be charged as a "Net Item" amount expense using the campaign labor operation provided.

Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin).

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.

Dear General Motors Customer:

We want your experience owning your 2001 Chevrolet Cavalier; Pontiac Sunfire, Grand Am or Oldsmobile Alero to be better than any other you've had ... which is why we're writing.

We have learned that your 2001 Chevrolet Cavalier; Pontiac Sunfire, Grand Am or Oldsmobile Alero may have been built with a condition in which the transaxle converter pump to stator bearing may premature fail. This may cause transaxle noise and failure.

We've made the correct parts available to your dealer so that if your 2001 Chevrolet Cavalier; Pontiac Sunfire, Grand Am or Oldsmobile Alero was built with this condition, it can be serviced as quickly as possible. This service will be performed for you at no charge .

We recommend that you contact your <Division> dealer to arrange a service date.

Presenting the attached card to your dealer will assist in making the necessary correction in the shortest possible time.

If you no longer own this vehicle, please check the appropriate box and provide new owner information, if available.

If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below:

Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation.

We sincerely regret any inconvenience this causes you. Also, we want you to know that we will continue to do everything we can to ensure that you are completely satisfied with your 2001 Chevrolet Cavalier, Pontiac Sunfire, Grand Am or Oldsmobile Alero and with <Division>.

General Motors Corporation

Enclosure