M/T - Exchange Program for Revised Unit: Overview
Number 86-7-30 Date 7/86Subject: MUNCIE 5-SPEED MANUAL TRANSAXLE EXCHANGE PROGRAM
1986 FIERO MODELS WITH V6 ENGINES AND RPO MG1 OR MG2 5-SPEED TRANSAXLE
Beginning June 9, 1986, all 1986 Fieros ordered with 5-speed manual transaxle and V6 engine will be built with an RPO code MG1 or MG2 Muncie/Getrag MG282 5-speed transaxle. This transaxle is a new design and will also be used in various front wheel drive vehicles beginning with the 1987 model year.
To gain needed product feedback and to minimize vehicle down time, a transaxle exchange program is now in effect and will continue into the 1987 model year.
The exchange program will be administered by Detroit Diesel Allison Division and all requests for exchange units will be handled through the Pontiac Technical Assistance Center.
The attached 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.
Pontiac Technical Assistance Center (TAC) will administer an exchange program for the MG1/MG2 5-speed transaxle. In the event your dealership receives a complaint on an MG1/MG2, follow the procedure listed below. Your cooperation will greatly improve the effectiveness of the program.
NOTE:
Figure 1 - MG1/MG2 Gear and Case Group:
Figure 2 - MG1/MG2 Shift Mechanism Group:
^ SERIAL NUMBER TAG LOCATION IS ITEM (A), FIGURE 1.
^ NUMBERS IN BRACKETS REFER TO ITEM NUMBERS ON DISASSEMBLED VIEWS, FIGURES 1 AND 2.
^ A SERVICEABLE PARTS ITEM NUMBER/GM PART NUMBER CROSS REFERENCE IS PROVIDED FOR YOUR CONVENIENCE.
A. Preliminary Diagnostic Procedure
^ Refer to DIAGNOSIS CHART.
^ Insure correct oil level.
^ Insure that the shift linkage is properly adjusted.
^ Insure that the clutch linkage is properly adjusted.
^ Insure that all engine & transmission mounts are tight.
B. On-Car Service (without exchange)
Special tool requirements and
Oil Leaks at: torque specifications:
-Axle Seals (23) -Install using J-26938 & J-8092
-Shift Shaft Cover (140) -No special tool required
-Shift Shaft Seal (208) -Install using J-35823
-Clutch Fork Seal (164) -No special tool required
-End Plate-to-Case Leaks (85/90) -Bolt torque 21 N-m (15 ft.lbs.)
-Back-up Light Switch (B) -Bolt torque 33 N-m (24 ft.lbs.)
-Speedometer Driven Gear (C) -Bolt torque 5.5 N-m (4 ft.lbs.)
-Transaxle Drain Plug/Washer -Drain plug torque 24 N-m (15
(79/80) ft.lbs.)
-Fluid Level Indicator/Washer -Fully seated, not stripped
(100/101)
-Fill Plug & Washer (82/83) -Fill plug torque 24 N-m (15
ft.lbs.)
-Plug Shift Rail (204) -No special tool required
C. Out-of-Vehicle Repairs (without exchange)
^ Oil Leak at Detent Cover (174)
^ Clutch Fork Bushing Replacement (163/177)
^ Clutch Fork Replacement (165)
^ Clutch Release Bearing Service/Replacement (22)
^ Any Clutch Repair/Replacement
^ 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 J 36190
- Clutch fork (165), using J 36037 to remove/install bushing (163)
D. Out-of-Vehicle Repairs (WITH exchange)
^ ANY repair which necessitates splitting the clutch housing and the transaxle case (20/85)
E. Exchange Procedure
^ Call TAC for authorization.
^ Provide TAC with the necessary information. It would be a good idea to fill out the MG1/MG2 Reporting Form (attached) prior to calling.
^ TAC will arrange to ship an exchange unit to your dealership.
^ TAC will provide dealership with 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 DDA-Muncie.
^ Once the exchange unit is received, the complaint unit is to be returned to DDA-Muncie, 1200 West Eighth Street, Muncie, IN 47302.
^ The exchange unit will have an envelope attached to it. This envelope will contain:
- Return Shipping Label
- Administrative Procedures
- MG1/MG2 Reporting Form
- Return Shipping Carrier Information
- Identification Tag
^ The complaint unit must be returned within 5-7 days after receipt of the exchange unit.
F. Preparation For Shipping
^ Drain the oil and replace the drain plug.
^ Remove plastic shipping plugs from the exchange unit and install them into the complaint unit.
^ Fold the Reporting Form and staple it to the Identification Tag and secure the tag to the clutch housing of the complaint unit.
^ Repack the complaint unit into the original shipping container.
^ Place the shipping label on the original shipping container.
G. Warranty Claims Processing Procedure
Upon completion of the repair, a warranty claim is to be submitted to Pontiac 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.