1980 AND EARLY 1981 PHOENIX TRANSAXLE SPECIAL POLICY

THIS BULLETIN 81-1-198A, (PAGES 1 AND 2) SUPERSEDES AND SHOULD REPLACE PAGES 1 AND 2 OF BULLETIN 81-1-198.

SOME 1980 AND EARLY 1981 MODEL PHOENIX MAY EXPERIENCE AN OIL LEAK AT THE FRONT DRIVE AXLE SEALS. THESE SAME VEHICLES, WHEN EQUIPPED WITH A FOUR SPEED MANUAL TRANSMISSION, MAY ALSO EXPERIENCE HARD SHIFTING.

BECAUSE THESE CONDITIONS COULD OCCUR BEYOND THE WARRANY PERIOR, OWNERS ARE BEING ADVISED OF THE SPECIAL POLICY. A COPY OF THE OWNER LETTER IS ATTACHED. OWNER NOTIFICATION DATA WAS OBTAINED FROM PONTIAC MOTOR DIVISION RECORDS AND STATE MOTOR VEHICLE REGISTRATION RECORDS.

THIS POLICY WILL COVER, AT NO CHARGE,THE FOLLOWING ITEMS FOR A PERIOD OF FIVE YEARS OR 50,000 MILES, WHICHEVER OCCURS FIRST FROM THE ORIGINAL SERVICE DATE.

AUTOMATIC TRANSAXLE - REPAIR THE CAUSE OF THE RIGHT DRIVE AXLE SEAL LEAK. THE REPAIR TO THE VEHICLE SHOULD BE PERFORMED ACCORDING TO THE INSTRUCTIONS INCLUDED IN THIS BULLETIN.

MANUAL TRANSAXLE - REPAIR THE CAUSE OF THE LEFT AND/OR RIGHT DRIVE AXLE SEAL LEAK(S). REPAIR WORN FIRST OR SECOND GEAR, OR THIRD AND FOURTH GEAR, SHIFT FORKS. THE REPAIR(S) TO THE VEHICLE SHOULD BE PERFORMED ACCORDING TO THE INSTRUCTIONS IN THIS BULLETIN.

AFTER THE REPAIRS ARE COMPLETED, THE DEALER IS TO SUBMIT A WARRANTY CLAIM IN THE NORMAL MANNER USING THE APPROPRIATE LABOR OPERATION NUMBER AND TIME AS INDICATED IN THIS BULLETIN.

OWNER REIMBURSEMENT

CONSIDERATION SHOULD ALSO BE GIVEN TO OWNERS OF INVOLVED PHOENIX WHO PREVIOUSLY PAID FOR REPAIRS COVERED BY THIS POLICY. IN THE EVENT AN OWNER REQUESTS REIMBURSEMENT THE DEALER SHOULD OBTAIN THE OWNER'S ORIGINAL PAID RECEIPT(S) OR INVOICE(S) TO VERIFY THE EXPENSE. THE OWNER SHOULD, HOWEVER, BE ADVISED TO RETAIN COPIES OF THIS DOCUMENT(S) FOR HIS PERSONNAL RECORDS BEFORE SURRENDERING THE ORIGINAL.

THE DEALER IS TO ADVISE THE OWNER THAT THE INVOICES WILL BE REVIEWED BY A PONTIAC REPRESENTATIVE AND THAT THE OWNER WILL BE ADVISED AS QUICKLY AS POSSIBLE OF THE AMOUNT THAT WILL BE REINBURSED.

REIMBURSEMENT CONSIDERATION SHOULD INCLUDE ANY DEDUCTIBLE AMOUNTS PAID UNDER POWER TRAIN PROGRAMS.

WHEN A REQUEST IS APPROVED, THE DEALER IS TO ISSUE THE OWNER A CHECK FOR REIMBURSEMENT.

DEALERS WILL BE CREDITED THROUGH THE SUBMISSION OF A WARRANTY CLAIM FOR THE REIMBURSEMENT TO THE CUSTOMER. INSTRUCTIONS FOR SUBMISSION ARE INCLUDED IN THIS BULLETIN.

REQUESTS FOR REIMBURSEMENT NOT SPECIFICALLY COVERED BY THE POLICY SHOULD BE REVIEWED WITH THE LOCAL PONTIAC ZONE SERVICE DEPARTMENT.

THE PURPOSE OF THIS POLICY IS TO INSURE CONTINUED CUSTOMER SATISFACTION WITH OUR PRODUCTS; THEREFORE, YOUR PERSONAL INVOLVEMENT IS REQUESTED TO MAKE SURE THAT THIS INFORMATION IS CONVEYED TO ALL MEMBERS OF YOUR SERVICE DEPARTMENT.

VEHICLES INVOLVED

INVOLVED ARE ALL 1980 PHOENIX MODELS AND 1981 PHOENIX MODELS BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS.

PLANT VIN BREAKPOINTS

1981 TARRYTOWN SOP-BT122737 (INCLUSIVE) OKLAHOMA CITY SOP-B6123325 (INCLUSIVE)

1. SERVICE INFORMATION AUTOMATIC TRANSAXLE

SOME 1980 PHOENIX AND EARLY PRODUCTION 1981 PHOENIX AUTOMATIC TRANSMISSIONS HAVE A CONDITION OF PERMATURE WEAR OF THE FINAL DRIVE DIFFERENTIAL CARRIER. THIS CAN RESULT IN A TRANSMISSION OIL LEAK AT THE RIGHT DRIVE AXLE SEAL.

A. DIAGNOSIS OF LEAK

1. INSPECT TRANSMISSION IN AREA OF RIGHT DRIVE AXLE SEAL.

2. IF AXLE SEAL IS LEAKING, PORTIONS OF THE TRANSMISSION CASE FROM THE SEAL TO THE OIL PAN RAIL WILL BE WET "TO THE FEEL" WITH RED TRANSMISSION OIL. OIL STAINS ON THE CASE ARE NOT SIGNS OF A CURRENT LEAK, BUT INDICATION OF A PREVIOUS LEAK.

IF WET TRANSMISSION OIL IS EVIDENT, BE SURE SOURCE IS NOT FROM SOME OTHER AREA, SUCH AS SPEEDOMETER DRIVEN GEAR SLEEVE O-RING.

IF RIGHT AXLE SEAL IS LEAKING, PROCEED WITH PART B OF PROCEDURE.

B. INSPECTION OF DIFFERENTIAL CARRIER BORE

THIS INSPECTION IS TO DETERMINE IF ONLY DRIVE AXLE SEAL SHOULD BE REPLACED, OR IF BOTH SEAL AND CARRIER AND SIDE GEARS SHOULD BE REPLACED:

1. RAISE THE CAR ON A HOIST THAT DOES NOT USE THE FRONT WHEELS OR CONTROL ARMS FOR SUPPORT (FRAME HOIST, ETC.) LEAVE THE STEERING WHEEL UNLOCKED SO FRONT WHEELS CAN BE TURNED.

2. REMOVE RIGHT FRONT WHEEL AND TIRE ASSEMBLY.

3. REMOVE SPLASH SHIELD AND RETAINING SCREWS FOR BOTH BRAKE LINE AND HOSE BRACKETS AT CROSS-MEMBER SIDE RAIL (REFER TO FIGURE 1 ON FOLLOWING PAGE).

4. INSTALL TOOL J-28712 AXLE BOOT SEAL PROTECTORS AS SHOWN IN FIGURE 2 ON FOLLOWING PAGE.

5. REMOVE THE BALL JOINT RETAINING BOLT AND NUT. DO NOT REUSE BOLT (REFER TO FIGURE 3 ON PAGE 4).

6. INSERT A PRY BAR BETWEEN ENGINE CRADLE SIDE MEMBER AND THE RIGHT LOWER CONTROL ARM. PRY DOWNWARD UNTIL THE HUB AND BEARING ASSEMBLY ARE DISENGAGED FROM THE BALL JOINT STUD (REFER TO FIGURE 4 ON PAGE 4).

7. USING TOOL J-28468 AXLE SHAFT REMOVER, DISENGAGE THE AXLE FROM THE TRANSMISSION (REFER TO FIGURE 2).

8. MOVE THE FRONT WHEELS TO A FULL LEFT TURN POSITION.

9. PUSH THE HUB AND BEARING ASSEMBLY TO THE REAR OF THE WHEEL WELL AND PULL THE DRIVE AXLE OUT OF THE TRANSMISSION, SWING THE END PAST THE ENGINE CRADLE SIDE MEMBER UNTIL IT IS FREE TO HANG DOWN FROM THE WHEEL HUB (REFER TO FIGURE 5).

10. REMOVE THE RIGHT AXLE OIL SEAL FROM THE TRANSMISSION CASE, BEING CAREFUL NOT TO DAMAGE THE TRANSMISSION CASE BORE.

11. INSPECT DIFFERENTIAL CARRIER AXLE SHAFT BORE FOR STEP WEAR (REFER TO FIGURE 6 AND FIGURE 6A ON THE FOLLOWING PAGE).

A. IF THERE IS A SLIGHT EVEN STEP 360 DEG AROUND BORE, REPLACE ONLY AXLE SHAFT SEAL, PART NUMBER 8631156, PART C OF THIS PROCEDURE.

B. IF THERE IS A LARGER STEP IN BORE IN THE DIRECTIO OF THE DIFFERENTIAL PIN AS SHOWN IN FIGURE 6, A NEW CARRIER AND SIDE GEAR PACKAGE SHOULD BE INSTALLED IN TRANSMISSION. PART NUMBERS ARE AS FOLLOWS:

PART NAME PART NUMBER

DIFFERENTIAL CARRIER W/PINIONS 8637972 2.53 AND 2.84 RATIO

DIFFERENTIAL GEAR KIT 8637919

ALSO REPLACE THE RIGHT HAND DRIVE AXLE SEAL, PART NUMBER 8631156, AND TRANSMISSION OIL STRAINER, PART NUMBER 8631951. FOLLOW THE PROCEDURES OUTLINED IN THE APPLICABLE PHOENIX SERVICE MANUAL FOR REPLACEMENT OF DIFFERENTIAL CARRIER.

AFTER DIFFERENTIAL CARRIER AND SIDE GEARS HAVE BEEN REPLACED AND TRANSMISSION REINSTALLED IN VEHICLE, REINSTALL THE RIGHT DRIVE AXLE FOLLOWING PART C OF THIS PROCEDURE.

C. INSTALLATION OF RIGHT DRIVE AXLE SHAFT OIL SEAL AND AXLE

1. CLEAN SEAL BORE AND INSTALL NEW AXLE OIL SEAL USING J-26938 (REFER TO FIGURE 7). BE CAREFUL NOT TO DAMAGE SEAL DURING INSTALLATION.

2. APPLY LUBE TO DRIVE AXLE SEAL AND INSTALL DRIVE AXLE IN TRANSMISSION. USE EXTREME CARE TO PREVENT AXLE SHAFT FROM DAMAGING SEAL DURING INSTALLATION.

3. WITH FRONT WHEELS STRAIGHT AHEAD, INSTALL THE BALLJOINT STUD TO THE HUB AND WHEEL BEARING ASSEMBLY. INSTALL A NEW BALL JOINT RETAINING BOLT, PART NUMBER 14034747, AND NUT AND TORQUE TO 50 N.M (40 FT.LBS.) REFER TO FIGURE 3.

4. REMOVE TOOL J-28712 AXLE SHAFT BOOT SEAL PROTECTORS.

5. INSTALL THE RIGHT SIDE FRONT BRAKE PIPE AND HOSE BRACKETS AND SPLASH SHIELD.

6. LOWER THE CAR.

7. IF OIL PAN WAS REMOVED, FILL TRANSMISSION WITH FIVE QUARTS OF DEXRON II AUTOMATIC TRANSMISSION FLUID.

8. CHECK TRANSMISSION FLUID LEVEL AND ADD AS REQUIRED.

A. PLACE TRANSMISSION IN "PARK" AND LEAVE IN "PARK". APPLY PARK- ING BRAKE AND BLOCK WHEELS START ENGINE AND LET IDLE (CARB- URETOR OFF FAST IDLE STEP.) DO NOT RACE ENGINE. MOVE THE LEVER THROUGH THE RANGES.

B. VEHICLE ON LEVEL SURFACE.

C. CHECK OIL LEVEL ON DIPSTICK.

THE OIL LEVEL AT ROOM TEMPERATURE OF APPROXIMATELY 70DEG F (21DEG C) SHOULD BE 14MM (1/2") ABOVE THE "FULL" MARK, OR BETWEEN THE TWO DIMPLES ON THE DIPSTICK. (THIS IS DUE TO A HIGHER THAN NORMAL OIL LEVEL IN THE PAN AS THE THERMO-ELEMENT DOES NOT OPEN UNTIL OIL WARMS UP). THE OIL LEVEL WILL DROP TO BETWEEN THE "ADD" AND "FULL" MARKS AS TRANSMISSION WARMS UP TO NORMAL OPERATING TEMPERATURE.

DO NOT OVERFILL TRANSMISSION, AS THIS MAY CAUSE FOAMING AND LOSS OF OIL THROUGH THE VENT.

9. INSPECT TRANSMISSION OIL PAN AND NEW AXLE SEAL FOR ANY LEAKS. CORRECT AS REQUIRED.

SERVICE INFORMATION MANUAL TRANSAXLE

WHEN REPAIRING 1980 OR 1981 PHOENIX MANUAL TRANSAXLES FOR EITHER AXLE SHAFT SEAL LEAKS DUE TO SIDE GEAR/CASE WEAR OR SHIFT FORK WEAR, AN INSPECTION SHOULD BE MADE FOR BOTH CONDITIONS TO DETERMINE WHAT THE EXTENT OF REPAIR SHOULD BE.

THE FOLLOWING PROCEDURES SHOULD BE ADHERED TO WHEN MAKING SUCH REPAIRS.

AXLE SHAFT SEAL LEAKS

CONDITIONS OF DRIVE AXLE SEAL LUBE LEAKAGE CAN BE THE RESULT OF THE SIDE GEAR BEING LOOSE IN THE DIFFERENTIAL CASE. THIS CAN RESULT IN AXLE SHAFT MOVEMENT EXCEEDING THE SEAL LIMIT THEREBY ALLOWING A LEAK.

IF EXAMINATION OF THE SEAL REVEALS NO DISCREPANCIES SUCH AS WEAR, CUTS, SPLITS OR IMPROPER INSTALLATION, AND IF THE AXLE SHAFT CAN BE MOVED BY HAND ENOUGH TO PRODUCE AN OIL LEAK, IT IS LIKELY THAT THE SIDE GEAR HAS WORN THE DIFFERENTIAL CASE. TO REPAIR, THE DIFFERENTIAL CASE, PART NUMBER 463058 MUST BE REPLACED ALONG WITH THE DIFFERENTIAL SIDE GEARS.

INSTALL NEW DIFFERENTIAL CASE, PART NUMBER 463058, NEW SIDE GEARS, PART NUMBER 14040530, WHICH HAVE IMPROVED FINISH AND NEW THRUST WASHERS, PART NUMBER 14040531, WITH FINE GRAIN PHOSPHATE COATING TO CORRECT THE CONDITION.

SHIFT FORK WEAR

CONDITIONS OF WORN 76MM TRANSAXLE SHIFT FORKS (BOTH 1-2 AND 3-4) HAVE BEEN FOUND TO BE CAUSED BY THE SHIFT FORK GROOVE SURFACE FINISH IN THE SYNCHRONIZER ASSEMBLY.

TO CORRECT THE WORN SHIFT FORK CONDITION, REPLACEMENT OF THE 1-2 SYNCHRONIZER ASSEMBLY WITH NEW PART NUMBER 14062629 OR 3-4 SYNCHRONIZER ASSEMBLY WITH NEW PART NUMBER 14062631, TOGETHER WITH THE SHIFT FORK (1-2 SHIFT FORK PART NUMBER 14008232, 3-4 SHIFT FORK PART NUMBER 14009112) IS MANDATORY.

WHILE THE OLD SYNCHRONIZER ASSEMBLY MIGHT APPEAR TO BE REUSEABLE, THE SHIFT FORK GROOVE IN THE SYNCHRONIZER ASSEMBLY WILL CONTAIN MICROSCOPIC BURRS FROM RUNNING METAL-TO-METAL WITH THE FORK AND WILL CAUSE CONDITION TO REPEAT ITSELF.

THE NEW SYNCHRONIZER ASSEMBLIES INCORPORATE A SMOOTHER SURFACE IN THE SHIFT FORK GROOVE.

SERVICE OF THE SYNCHRONIZER ASSEMBLY REQUIRES THE REMOVAL OF THE SPEED GEARS FROM THE INPUT OR OUTPUT SHAFTS AS OUTLINED IN THE SERVICE MANUAL.

WARRANTY CREDIT

DEALERS WILL BE CREDITED VIA WARRANTY DOCUMENT OR TERMINAL TRANSMISSION, WHICHEVER IS THEIR NORMAL METHOD OF SUBMISSION FOR PAYMENT. CLAIMS SHOULD CONTAIN ALL INFORMATION AS REQUIRED, AND SHOULD LIST THE APPROPRIATE LABOR OPERATION AS OUTLINED.

LABOR TROUBLE LABOR OPERATION HOURS CODE 1. T0090 0.8 HR. 42 DESCRIPTION: AUTOMATIC-INSPECT CARRIER BORE AND REPLACE RIGHT DRIVE AXLE SEAL.

2. T0091 1980-5.4 HR. 42 1981-6.2 HR. DESCRIPTION: AUTOMATIC - INSPECT CARRIER BORE AND REPLACE RIGHT DRIVE AXLE SEAL, REPLACE DIFFERENTIAL CARRIER AND GEAR KIT. 3. T0092 00 42 DESCRIPTION: AUTOMATIC - OWNER REIMBURSEMENT ONLY (ELIGIBILE VEHICLES WITHIN VIN BREAKPOINTS). FOLLOW "OWNER REIMBURSEMENT" CLAIM PROCEDURES AS OUTLINED IN "PONTIAC WARRANTY CLAIM PREPARATION MANUAL" ON PAGE 27. ZONE AUTHORIZATION IS REQUIRED.

4. T0093 1980-4.0 HR 06 1981-4.5 HR DESCRIPTION: MANUAL - REPLACE SHIFT FORK/SYNCHRONIZER.

5. T0094 1980-3.2 HR. 42 1981-3.7 HR. DESCRIPTION: MANUAL - REPLACE DIFFERENTIAL PARTS 6. T0095 1980-4.4 HR. 06 1981-4.9 HR. DESCRIPTION: MANUAL - REPLACE BOTH SHIFT FORK AND DIFFERENTIAL PARTS. 7. T0096 00 06 DESCRIPTION: MANUAL-OWNER REIMBURSEMENT ONLY (ELIGIBLE VEHICLES WITHIN VIN BREAKPOINTS)-FOLLOW "OWNER REIMBURSEMENT" CLAIM PROCEDURES AS AUTHORIZED IN "PONTIAC WARRANTY CLAIM PREPARATION MANUAL" ON PAGE 27. ZONE AUTHORIZATION IS REQURIED.

NOTE: THE ABOVE OPERATIONS ARE APPLICABLE ONLY TO THOSE VEHICLES ELIGIBLE UNDER THIS POLICY. IF SUBMITTED WITH NON-ELIGIBLE VEHICLES, THE CLAIM WILL BE REJECTED FOR ERROR CODE 33 - LABOR OPERATION INCOMPATIBLE TO VEHICLE.

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.