M/T - ZF 6 Speed Exchange Program
File In Section: 07 Transmission/TransaxleBulletin No.: 00-07-29-002
Date: September, 2000
EXCHANGE PROGRAM
Subject:
ZF 6-Speed Manual Transmission Exchange Program (RPO ML6)
Models:
2001 Chevrolet and GMC C/K 2500/3500 Pickup Models
With ZF 6-Speed Manual Transmission (RPO ML6)
Important:
"IPC" Dealers are not authorized to utilize this service bulletin.
In order to gain product feedback on the new ZF 6-speed manual transmission (RPO ML6), an exchange program is in effect from start of production until September 30, 2001.
The following information explains all the requirements regarding diagnosis, serviceable and non-serviceable items, warranty claims processing procedures and shipping information. File this information in the Special Exchange Policy Procedures Manual.
In the event your dealership receives a concern on the ZF 6-speed manual transmission (RPO ML6), follow the procedures listed below. Your cooperation in adhering to these procedures will greatly improve the program effectiveness.
Direct all requests for exchange to the U.S. Technical Assistance Center (TAC) at 1-877-446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263-7960 (French). THE DIAGNOSTIC WORKSHEET AND ALL DIAGNOSIS MUST BE COMPLETED BEFORE ANY REQUEST FOR AN EXCHANGE TRANSMISSION IS ACCEPTED.
Preliminary Diagnosis Procedure
Important:
The ZF 6-speed manual transmission must NOT be disassembled or repaired unless indicated by the Dealer Serviceable Components section in this exchange bulletin.
Refer to the Diagnostic Worksheet in this bulletin. Misdiagnosis results not only in a dissatisfied customer, but also a repeat repair for the dealership.
Dealer Serviceable Components
The following parts may be replaced without exchanging the transmission:
^ Backup lamp switch
^ Vehicle speed sensor (VSS)
^ Shift lever assembly
^ Vent, transmission
^ Heated Oxygen Sensor (H025) Bracket (8.1L Only)
^ Oil Plugs (Drain and Fill)
^ Clutch Actuator
^ Power Takeoff (PTO) cover/gasket (if PTO installation is required)
^ Manual transmission lubricant
For exchange units that are leaking, indicate by circling the location(s) of transmission fluid leakage on the Leak Identification Locator sheet at the end of this bulletin. Using a permanent marker, also circle the leak area on the transmission case.
Diagnostic Worksheet
Below are some common symptoms that are transmission related. Also listed below are some common concerns that are not transmission related. If additional information is required concerning the clutch and transmission diagnosis, contact U.S. TAC at 1-877-446-8227. For Canadian dealers, call
1-800-263-7740 (English) or 1-800-263-7960 (French). Before calling, have all the necessary information available per the Diagnostic Worksheets below in order to help further diagnose your customer's concern.
Use the diagnostic symptom tables and the repair procedures in the 2001 C/K Silverado and Sierra Service Manual to diagnose the customer's concern. The list of diagnostic symptom tables for diagnosing the transmission can be found in the Symptom-Manual Transmission procedure located in the Transmission/Transaxle section in the Manual Transmission-ZF S6-650 subsection. The list of diagnostic symptom tables for diagnosing the clutch can be found in the Symptom-Clutch System procedure in the Transmission/Transaxle section in the Clutch subsection.
The clutch diagnostic symptom tables include the following conditions:
^ Clutch Does Not Disengage
^ Clutch Slipping
^ Clutch Grabbing
^ Clutch Rattle
^ Release Bearing Noisy with Clutch Engaged
^ Clutch Noisy
^ Pedal Stays on Floor (Clutch Disengaged)
^ Clutch Pedal Hard to Push
^ Clutch Master and Actuator Cylinder Fluid Leaks
^ Clutch Pedal Spongy
^ Clutch Pedal Sticks or Binds
^ Vibration
The transmission diagnostic symptom tables include the following conditions:
^ Transmission Leaks
^ Hard Shifting into All Gears
^ Hard Shifting into One Gear
^ Locked in One Gear
^ Gears Clash When Shifting
^ Transmission Jumps Out of Gear
^ Excessive Transmission Noise
^ Vibration
^ Broken Transmission Housing
^ Driveline Clunk
^ Back-up Lamps Inoperative
^ Speedometer Inoperative or Inaccurate
After using the tables to properly diagnose the customer's concern, and the table indicates the transmission is faulty, complete the following diagnostic worksheets provided. The worksheets must be completed before calling TAC.
Diagnostic Worksheets
To complete the worksheets, select the appropriate symptom and mark the items as passed or failed. For the conditions, refer to the appropriate Symptom - Manual Transmission, Symptom - Clutch procedures in the appropriate Service Manual.
Exchange Procedure
Once the preliminary diagnosis/repairs are completed, and an exchange unit is still necessary, contact U.S. TAC at 1-877-446-8227. For Canadian dealers, call 1-800-263-7740 (English) or 1-800-263- 7960 (French). The ZF 6-speed manual transmission is not available from General Motors Service Parts Operations (GMSPO) for vehicles repaired under warranty. Any purchases through GMSPO without prior authorization from TAC may be disallowed on the warranty claim. For vehicles not repaired under warranty, contact the TAC for an authorization (case) number before ordering from GMSPO.
Be prepared to provide the necessary information by completing the Diagnostic Worksheet prior to calling.
Important:
The exchange transmission will be shipped with new synthetic lubricant, GM P/N 12378515 (In Canada use P/N 88900701). With the fluid fill plug removed, verify that the fluid is level with the bottom of the fill hole when the truck is level. Should lubricant be needed, use ONLY GM P/N 12378515 (In Canada use P/N 88900701). TAC will arrange to ship an exchange unit, normally within 24 hours, to your dealership and provide your dealership with a TAC case number. This number must be written, using a permanent marker, on the returned transmission top outer case before returning the unit.
UNDER NO CIRCUMSTANCES MAY THE REMOVED TRANSMISSIONS BE RETAINED OR PURCHASED BY THE DEALER.
The removed transmission must be returned complete, as removed from the vehicle, without disassembling. Failure to return a transmission, or returning a transmission that has been partially disassembled, will be considered as violating this procedure and will be subject to being billed for all materials and labor.
Preparation for Shipping
1. Securely attach the following items to a wired tag and secure the tag to a top bell housing bolt hole of the removed unit.
^ Diagnostic Worksheet
^ Copy of repair order (R.O.) (front and reverse side)
^ Leak Identification Locator sheet, if needed
^ Two ounce transmission lubricant sample (bottle in plastic bag provided)
2. Using a permanent marker, write the TAC case number on the top portion of the case of the removed transmission.
3. Repack the removed transmission into the original shipping container.
Shipping Instructions
In order to minimize the dealerships' workload, the removed transmission will be returned per the normal Warranty Parts Center (WPC) procedures outlined in Corporate Bulletin Number 99-00-89-019, dated October, 1999 (Dealers in Canada should refer to Home Office Letter 99-201). Please reference these bulletins for shipping instructions. In order to increase the effectiveness of this program; submit the warranty claim immediately for payment in order for the WPC to start the necessary return request.
Warranty Information
Upon completion of the repair, submit a warranty claim using table.