Campaign - A/T Water Intrusion: Overview
Bulletin No.: 06051Date: July 10, 2006
CUSTOMER SATISFACTION
Subject:
06051 - Transmission Water Intrusion
Models:
2006 Pontiac Solstice
2007 Saturn SKY
With Automatic Transmission
**********THIS RECALL IS IN EFFECT UNTIL JULY 31,*******************
Condition
Certain 2006 Pontiac Solstice and 2007 Saturn Sky vehicles equipped with an automatic transmission may have a condition where the cowl is not firmly against the lower edge of the windshield. If the engine is hot and a large amount of water flows down the windshield, water can enter the transmission through a vent.
Each vehicle undergoes an assembly plant leak test and water entered some, but not all, transmissions at that time.
If there is excessive water in the transmission fluid, within a few hundred miles an electrical short will develop inside the transmission. The Service Engine Soon lamp will be illuminated. The occupants of the vehicle would feel harsh downshifts as the vehicle comes to a stop. Once the vehicle starts to move again, the vehicle will be in fifth gear and would remain in that gear.
Correction
Dealers are to inspect the transmission fluid. If signs of water are present, the transmission will be replaced. If no signs of water are present, a new transmission vent tube will be installed to eliminate susceptibility to very heavy water exposure.
Vehicles Involved
Involved are certain 2006 Pontiac Solstice and 2007 Saturn Sky vehicles equipped with an automatic transmission and built within the VIN breakpoints shown.
Important:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.
- US GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
- Saturn US retailers should use A5400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned.
- US GM dealers - GM DealerWorld Recall Information
- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program.
Parts Information
GM and Saturn Canada Only: Parts required to complete this program are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.
Saturn US Only: A pre-shipment of the required parts to perform this repair has been sent to involved Saturn US retailers from Saturn Service Parts Operations (SSPO). Please place orders as necessary for any additional needs.
Service Procedure
Inspection Procedure
1. Inspect to see if the vehicle was repaired under Product Enhancement Bulletin 06046. This can be accomplished by checking the vehicle's warranty history for labor code Y0086 and a visual inspection for the installation of 3M tape on the air inlet grille.
^ If the vehicle was repaired under Product Enhancement Bulletin 06046, do NOT re-inspect the transmission fluid. Proceed to Step 3 in the section below titled, Vehicle Passes Transmission Fluid Test.
^ If the vehicle was not repaired under Product Enhancement Bulletin 06046, continue the inspection. Proceed to the next step.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Note:
Read the instructions below to avoid transmission damage:
^ Loosen but do not remove the drain plug from the transmission.
^ Do NOT remove more than 59 ml (2 oz) of transmission oil from the transmission.
^ Do NOT discard the transmission drain plug.
^ Torque the transmission fluid drain plug to 20 N.m (15 lb ft).
3. Loosen, but do not remove the transmission fluid drain plug and drain 59 ml (2 oz) of transmission oil into a clean container.
^ If the transmission oil color is red, the transmission oil is normal and has not been contaminated. Torque the transmission fluid drain plug to 20 N.m (15 lb ft). Refer to the section below titled, Vehicle Passes Transmission Fluid Test.
^ If the transmission oil color is pink (like Pepto-Bismol), the fluid has been contaminated and a transmission replacement is required. The transmission cooler and lines must be flushed prior to installing the new transmission. Refer to the section below titled, Transmission Replacement Information.
Vehicle Passes Transmission Oil Test
Tools Required
1. Tighten the drain plug to 20 N.m (15 lb-ft).
2. Lower the vehicle.
3. Remove the air inlet grille. Refer to Air Inlet Grille Replacement procedure in SI.
Note:
Carefully remove the vent cap (2) with a pry bar, or equivalent, to avoid damaging the vent (1). Pry the vent cap (2) off of the vent (1) at the bottom of the vent cap (3).
(1) Vent Cap
(2) Base of Vent
(3) Portion of Vent that Resides in Transmission
4. Remove the vent cap (2) from the vent (1) using a pry bar or equivalent.
Note:
Failure to route and secure the revised transmission vent hose in the recommended position may result in water ingestion and transmission failure.
5. Cut 406 mm (16 in) of 11/32 in ID hose, P/N 9438124, meeting GM specification 1688M to make the vent hose.
6. Install the vent hose with a 16 mm (5/8 in) worm gear clamp to the base of the vent (2). Push the vent hose down onto the vent until the vent hose meets the bottom of the vent base (2).
Tighten
Tighten the worm gear clamp.
6.1. Install the new vent, P/N 15771000, into the end of the vent hose.
6.2. Route the vent hose (1) between the radiator hose and A/C lines.
6.3. Attach the vent hose to the cowl pencil brace, which is located on the driver's side of the vehicle. Use a tie strap to secure the vent hose. Attach the tie strap above the clip used to attach the hood release cable to the pencil brace.
7. Install the air inlet grille. Refer to the Air Inlet Grille Replacement procedure in SI.
^ Make sure that the vent cap is not making contact with the air inlet grille. The vent cap must be free of contact with any part of the car that would restrict its ability to vent transmission pressure.
^ Ensure that the windshield pillar seal, which attaches to the air inlet grille, has a secure seal to the windshield pillar.
Transmission Replacement Information
If the inspection determines that the transmission requires replacement, contact the GM Product Quality Center (PQC) at the number to order a replacement transmission. DO NOT ORDER A TRANSMISSION FROM GMSPO. Please be prepared with the VIN, mileage, dealer code, and any diagnostic
DTC codes prior to contacting the PQC.
Note:
This service procedure is for vehicles that did not pass the transmission oil test. There is contaminated fluid in the transmission cooler and transmission lines. To avoid transmission damage, flush the transmission cooler and transmission lines before installing a new transmission.
1. Remove the transmission from the vehicle. Refer to the Transmission Replacement procedure in SI.
2. Flush the transmission cooler and transmission lines.
3. Install the new transmission. Refer to the Transmission Replacement procedure in SI.
4. The new transmission comes with a revised vent location. During the installation of the transmission, you must:
4.1. Install the vent hose assembly to the transmission vent. Do not use any lubricant to install the hose assembly to the transmission vent.
Note:
Failure to route and secure the revised transmission vent hose assembly in the recommended position may result in water ingestion and transmission failure.
4.2. Route the vent hose assembly (1) in front of the radiator hose (2) as shown.
4.3. The vent hose must be secured to the air inlet brace as shown.
4.4. Remove the air inlet cover and attach the transmission remote vent to the air inlet cover to cowl pencil brace, which is located on the driver's side of the vehicle.
^ The tie strap should be above the clip used to attach the hood release cable to the pencil brace.
^ The vent end of the hose should be routed toward the center of the vehicle.
^ Make sure that the vent cap is not making contact with the air inlet grille. The vent cap must be free of contact with any part of the car that would restrict its ability to vent transmission pressure.
^ Ensure that the windshield pillar seal, which attaches to the air inlet grille, has a secure seal to the windshield pillar.
5. Clear all diagnostic trouble codes (DTCs).
Courtesy Transportation - For US and Canada [GM Only]
The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.
Claim Information - GM and Saturn Canada Only
Submit a Product Claim with the information shown.
Claim Information - Saturn US Only
z/4:
Submit a Product Claim with the information shown.
Customer Notification - For US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin).
Dealer Program Responsibility - All
All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles.
Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through July 31, 2007. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through July 31, 2007, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle.
Disclaimer