MUNCIE 5-SP. TRANSAXLE PROGRAM DIAGNOSIS - P/N'S FOR REPAIRS. Cadillac Cimarron 1987

For 1990-2009 cars

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

#### MODELS AFFECTED: 1987 CIMARRONS EQUIPPED WITH A 2.8 LITER V-6 ENGINE WITH MPFI AND MG2 5-SPEED TRANSAXLE

All 1987 Cadillac Cimarrons equipped with manual transaxles will be the Muncie/MG282 5-speed transaxles.

To gain direct product feedback and to minimize vehicle down time, a transaxle exchange program is now in effect and will continue untit further notice.

All requests for exchange units will be handled through the Cadillac Technical Assistance System (CAD-STAR).

The attached information explains all requirements regarding (A) diagnosis; (B) on car serviceable items; (C) out of car serviceable items; (D) serviceable part numbers; (E) exchange procedure; (F) preparation for shipping and (G) warranty claims processing procedures.

The Cadillac Technical Assistance System will administer an exchange program for the MG2 5- speed transaxle. In the event service is required on an MG2, follow the procedure listed below.

A. Preliminary Diagnosis 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 transmission mounts are tight.

B. On-Car Service (without exchange)

#### NOTE: Numbers in brackets refer to item numbers on disassembled views, Figures 1 and 2.

o Oil Leaks At: o Special Tool Requirements and Torque Specifications - Axle Seals (23) - Install using J 26939 & J 8092 - Shift Shaft Cover (140) - No special tool required - Shift Shaft Seal (208) - Install using J 35923 - Clutch Fork Seal (164) - No special tool required - End Plate-to-Case Leaks (85/90) - Bolt torque 21 Nm(15 lb.ft.) - Back-up Light Switch (B) - Bolt torque 23 Nm (24 lb.ft.) - Speedometer Driven Gear (C) - Bolt torque 5.5 Nm (4 lb.ft.) - Transaxle Drain Plug/Washer(79/80) - Drain plug torque 24 Nm (15 lb ft.) - Fluid Indicator/Washer (100/101) - Fully seated, not stripped - Fill Plug & Washer (82/83) - Fill plug torque 24 Nm (15 lb.ft.) - Plug (2O4), Shift Rail - No special tool required

C. Out-of-Car Repairs (without exchange) Refer to item D - Serviceable Parts Item Number/GM Part Number Cross Reference List.

o Oil Leak at Detent Cover (174) o Clutch Fork Bushing Replacement (1631177) o Clutch Fork Replacement (165) o Clutch Release Bearing Service/Replacement (22) o Any Clutch Repair/Replacement

- Bushing (163), using J 36037 (remove/install) Bushing (177), using J 36032 and J 23907 to remove/install using J 36033 and J 36190

- Clutch fork (165), using J 36037 to remove/install bushing (163)

D. Part Numbers For Serviceable Components

ITEM NUMBER NAME PART NUMBER

22 Bearing, Clutch Release 14080591 23 Seal, Axle 8631156 79 Plug, Oil Drain 14056604 80 Washer 476755 81 Bolt (Case to CL Hsg) 11500822 82 Washer 14080243 83 Plug, Fill 476753 99 Washer, Oil Slinger 14092033 90 End Plate, Transmission Case 10051657 91 Bolt (End Plate to Case) 10051637 l00 Washer 10051663 101 Dipstick (Oil Level Indicator) 10051636 130 Retainer, Selector Lever (Sunbird & 6000) 14091795 130 Retainer, Selector Lever (Sunbird & Turbo) 14091794 131 Pin, Selector Lever Pivot 14091786 132 Bolt (All except Sunbird Turbo) 14091792 132 Bolt (Sunbird Turbo) 14091793 133 Lever, Selector 14091781 134 Collar, Shift Shaft 11513884 135 Lever, Shift 14091787 136 Washer 14091790 137 Nut 11507027 138 Pin 11513394 139 Ring, Snap 14080596 140 Cover, Shift Shaft 14080595 163 Bushing, Upper Clutch Fork 14092055 164 Seal, Clutch Fork 14092820 165 Shaft, Clutch Fork 14092026 174 Cover, Detent 14082039 177 Bushing, Lower Clutch Fork 14092054 204 Plug, Shift Rail 14080573 208 Seal, Shift Shaft 14080587

Serviceable parts item number/GM part number cross reference

E. Exchange Procedure

o ANY repair which necessitates separating the clutch housing from the transaxle case (20/85).

o Call your Technical Assistance System 1-800 (CAD-STAR) for authorization.

o Provide the Technical Assistance System with the required information by filling out the Reporting Form (attached) prior to calling. (Serial number tag location is Item A, Figure 1.)

o Technical Assistance System will arrange to ship an exchange unit.

o Technical Assistance System will provide an authorized "Request Number." This number must be written on the unit (clutch housing) as well as the shipping container used to return the unit to HMD-Muncie.

o Once the exchange unit is received, the complaint unit must be returned to HMD- Muncie, 1200 West Eighth Street, Muncie, Indiana 47302.

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

- Return Shipping Label - Administrative Procedures - MG282 Reporting Form - Return Shipping Carrier Information - Identification Tag

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

F. Preparation For Shipping

o Drain the oil and reinstall the drain plug.

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

o Fold the Reporting Form, staple it to the Identification Tag and secure the tag to the clutch housing of the complaint unit.

o Package the complaint unit into the exchange unit shipping container.

o Place the shipping tabel on the original shipping container.

G. Warranty Claims Processing Procedure

For warranty purposes, use Labor Operation K3120 for 2.8 hours. Add 0.2 hours administration allowance as "Other Labor Hours."

DIAGNOSIS CHART

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

Noise most pronounced on turns a. Differential gear noise.

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

Clicking noise in turns a. Worn outboard CV joint.

Vibration a. Rough wheel bearing. b. Bent drive axle shaft. c. Out of round tires. d. Tire unbalance. e. Worn CV joint in drive axle shaft. 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.

Noisy 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-speed gear or output gear.

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

CONDITION PROBABLE CAUSE --------- --------------

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

Leaks Lubricant a. Fluid level indicator not seated in fill port, 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. 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.