MUNCIE 5-SP. TRANSAXLE PROGRAM DIAGNOSIS - P/N'S FOR REPAIR

MODELS/YEARS: 1987 FIRENZA WITH 2.8L ENGINE (VIN CODE W) AND MUNCIE 5-SPEED TRANSAXLE (OPT. MG2)

To gain needed product feedback on the above transaxles, and to minimize vehicle downtime, a transaxle exchange program is now in effect and will continue until further notice.

To gain needed product feedback on the above transaxles, and to minimize vehicle downtime, a transaxle exchange program is now in effect and will continue until further notice.

The exchange program will be administered by Detroit Diesel Allison Division and all requests for exchange units will be handled through the Oldsmobile Technical Service-Communication System (TSCS).

The following information from DDA Muncie Division thoroughly explains all requirements regarding diagnosis, serviceable and non-serviceable items, serviceable part numbers, warranty claims processing procedures and shipping instructions.

In the event your dealership receives a complaint on a MG2, follow the procedure listed below. Your cooperation will greatly improve the effectiveness of the program.

NOTE: - Serial number tag location is item (A), Figure 1. - Numbers in brackets refer to item numbers on disassembled views, Figure 1 and 2. - A serviceable parts item number/WDDGM part number cross reference is provided for your convenience, Figure 3.

A. Preliminary

o Refer to DIAGNOSIS CHART. o Insure correct oil level. o Insure that the shift linkage is properly adjusted. o Insure that the clutch linkage is properly adjusted. o Insure that all engine and transaxle mounts are tight.

B. On-Car Service (Without Exchange)

o Oil Leaks at: o Special tool requirements and torque specifications: -Axle Seals (23) -Install using J 26938 and J 8092 -Shift Shaft Cover (140) -Shift Shaft Seal (208) -Install using J 35823 -Clutch Fork Seal (164) -End Plate-to-Case Leaks (85/90) -Bolt torque 21 N-m (15 lbs. ft.) -Back-up Light Switch (B) -Speedometer Driven Gear (C) -Bolt torque 5.5 N - m (4 lbs. ft.) -Transaxle Drain Plug/Washer (79180) -Drain plug torque 24 N-m (18 lbs.ft.) -Fluid Level Indicator/Washer (100) -Fully seated, not stripped -Fill Plug and Washer (82/83) -Fill plugtorque24 N-m (18lbs. ft.) -Plug (204), Shift Rail

C. Out-of-Car Repairs (Without Exchange)

o Oil Leak at Detent Cover (174) o Clutch Fork Bushing Replacement (163/177) o Clutch Fork Replacement (165) o Clutch Release Bearing Service/Replacement (22) o Any Clutch Repair/Replacement

o Special tool requirement

- Bushing (163), using J 36037 (remove/install) Bushing (177), using J 36032 and J 23907 to remove/install using J 36033 and J36190 - Clutch fork (165), using J 36037 to remove/install bushing (163)

D. Out-of-Car Repairs (WITH Exchange)

o ANY repair which necessitates splitting the clutch housing and the transaxle case (20185).

E. Exchange Procedure

1. Call your Oldsmobile Technical Service Communication System (TSCS) for handling the exchange request.

2. Provide them with the necessary information. Fill out the MG2 Reporting Form (attached) prior to calling.

3. TSCS will arrange to ship an exchange unit to your dealership.

4. TSCS will provide dealership with an authorized "Case Request Number." This number must be written on the unit (clutch housing) as well as the shipping container used to return the unit to DDA-Muncie.

5. Once the exchange unit is received, the complaint unit is to be returned to: DDA-Muncie 1200 West Eighth Street Muncie, IN 47302

6. The exchange unit will have an envelope attached to it. This envelope will contain:

- Return Shipping Label - Administrative Procedures - MG2 Reporting Form - Return Shipping Carrier Information - Identification Tag

7. The complaint unit MUST be returned within 5-7 days after receipt of the exchange unit.

F. Preparation For Shipping

1. Drain the oil and replace the drain plug.

2. Remove plastic shipping plugs from the exchange unit and install them into the complaint unit.

3. Fold the Reporting Form, staple it to the identification tag and secure the tag to the clutch housing of the complaint unit.

4. Write the TSCS "Case Request Number" on clutch housing and shipping container.

5. Repack the complaint unit into the original shipping container.

6. Place the shipping label on the original shipping container.

G. Warranty Claims Procening Procedure

Upon completion of the repair, a warranty claim is to be submited to Oldsmobile for only the labor for the R&R and transmission fluid. A special labor operation is provided for this situation and is the only labor operation to be used in the event an exchange unit is used.

Labor Operation: T3158 Labor Time: 5.6 hrs. Trouble Code: 92 Sublet/Material Allowance: $5.30 (For Transmission Fluid)

DIAGNOSIS CHART

CONDITION PROBABLE CAUSE --------- --------------- A knock at low speeds a. Worn drive axle or joints b. Worn side gear hub counterbore.

Noise most pronounced on turns Differential gear noise.

Clunk on acceleration or a. Loose engine mounts deceleration b. Worn drive axle inboard joints. c. Worn differential pinion shaft in case. d. Side gear hub counterbore in case worn oversize.

Clicking noise in turns Worn outboard drive axle joint.

Vibration a. Loose engine mounts b. Bent drive axle shaft. c. Out of round tires. d. Tire unbalance. e. Worn drive axle joint. f. Incorrect drive axle angle. (Trim Height)

Noisy in Neutral with a. Worn input gear bearings. Engine Running b. Worn clutch release bearing.

Noisy in First Only a. Chipped, scored, or worn first-speed constant-mesh gears. b. Worn 1-2 synchronizer.

Nosiy in Second Only a. Chipped, scored, or worn second speed constant-mesh gears. b. Worn 1-2 synchronizer.

Noisy in Third Only a. Chipped, scored, or worn third-gear constant-mesh gears. b. Worn 3-4 synchronizer.

Noisy in Fourth Only a. Worn 3-4 gear synchronizer. b. Chipped, scored, or worn fourth-gear or output gear.

Noisy in Fifth Gear Only a. Worn 5th gear synchronizer. b. Chipped, scored, or worn fifth-speed gear or output gear.

Noisy in reverse Only a. Chipped, scored, or worn reverse idler gear, idler gear bushing, input or output gear(s).

Noisy in All Gears a. Insufficient lubricant. b. Worn bearings. c. Chipped, scored, or worn input gear (shaft) and/or output gear (shaft)

Slips out of Gear a. Worn or improperly adjusted linkage. b. Shift linkage does not work freely; binds. c. Bent or worn cables. d. Input gear bearing retainer or loose. e. Worn or bent shift fork.

Leaks Lubricant a. Fluid level indicator not seated causing fluid leakage at vent plug. b. Worn axle shaft seals. c. Excessive amount of lubricant in transaxle. d. Loose or broken input gear (shaft) bearing retainer. e. Worn input gear bearing and/or lip seal damaged. f. Worn shift lever seal. g. Lack of sealant between case and clutch cover or loose clutch cover.

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.