Rear Differential/Transfer Case - Exchange Program
File In Section: 04 - Driveline AxleBulletin No.: 01-04-20-002A
Date: March, 2001
EXCHANGE PROGRAM
Subject:
Exchange Program for 2001 Model Year
(Transfer Case/Rear Differential)
Models:
2001 Pontiac Aztek
with 3.4 L Engine (VIN E - RPO LA1) and Versatrak All-Wheel Drive System
This bulletin is being revised to correct the Warranty Information. Please discard Corporate Bulletin Number 01-04-20-002 (Section 04-Driveline Axle).
During the 2001 Model Year the following engines and components will be under an exchange program:
Engines
^ 8.1 L Engine Assembly
^ 6.6 L Engine Assembly
^ 4.2 L Engine Assembly (2002 Model)
Components
^ 6.6 L Fuel Injector
^ 6.6 L Fuel Injector Control Module
^ 6.6 L Fuel Injection Pump
^ B-Van AWD Transfer Case Assembly
^ B-Van AWD Rear Differential and Torque Tube Assembly
Product teams continually seek valuable information for product engineering improvements. An exchange program will be administered by GM Powertrain during the 2001 model year. The duration of the program is six months for the above applications. Guidelines for honoring exchange requests under the exchange program are being strictly enforced for the 2001 model year.
This bulletin will cover the Transfer Case and Rear Differential and Torque Tube Assemblies Exchange Program only for the 2001 Models listed above. This exchange program will be in effect until May 30, 2001. Additional bulletins will be published for each engine or component as they are introduced.
You must call the Technical Assistance Center (TAC) to request an exchange as shown in the table.
If any internal components of 2001 model year Transfer Case or Rear Differential assemblies require replacement, the assembly must be exchanged. Parts of a 2001 assembly which may be serviced without exchange or removed for diagnosis are identified by an "X" below in the Transfer Case or the Rear Differential columns in the table shown.
Transfer Case and Rear Differential assembly components on the Serviceable Components list above must be serviced according to the repair procedures in the applicable Service Information publication (Manual). Components NOT included in the above list will require a Transfer Case or Rear Differential assembly exchange.
Important:
Transfer Case or Rear Differential assembly repairs or failures that are caused by components external to the Transfer Case or Rear Differential assemblies will NOT fall under the exchange program. For example, loss of fluid from an external component causing a transmission and transfer case failure will have to go through GMSPO to obtain a transfer case assembly. The exchange program is created as a way to correct internal concerns and to take what is learned and find a way to eliminate these concerns. External components causing a failure do not provide any useful information in improving a component. The Transfer Case and Rear Differential assemblies received from GMSPO will be new service assemblies.
Procedures
A thorough diagnosis must be performed on the condition in order to prevent unnecessary component replacements. Contact the Technical Assistance Center to verify that proper diagnosis has been performed. Please complete the worksheet as shown prior to calling TAC. Upon review of the diagnosis, Technical Assistance will establish a case reference number and make arrangements for shipping an exchange unit to your dealership. To increase the effectiveness of the program, the Warranty Parts Center (WPC) will request the return of the unit removed only upon submission of a warranty reimbursement claim. Therefore the dealer is strongly encouraged to submit these claims as quickly as possible in order to facilitate the WPC request. DO NOT SHIP A COMPONENT TO THE WPC WITHOUT AN OFFICIAL WPC REQUEST.
Important:
Failure to return the concerned component will result in the dealership being billed the dealership net cost of the exchanged component.
The removed unit must be returned complete in the original exchange component shipping container. For effective engineering analysis, please do not remove any components. Dress items on the removed unit must remain the same as the exchange unit (e.g., exhaust manifolds, throttle body, etc.). Dealerships returning components having been even partially disassembled will be judged as violating this procedure and, as such, will be billed for all materials furnished.
Notice:
The exchange unit will be shipped without oil; fill and check oil level before operating the vehicle. Low oil level could result in internal damage to the component. The Transfer Case and Rear Differential units require unique synthetic gear oil, P/N 12378514, (in Canada, P/N 88901045). Any other oil will create noise concerns requiring future replacement of the component. The 0.5-liter containers may be ordered from SPO.
Important:
^ The end play clearance between the transmission and transfer case internal components is adjusted by selection of the proper size selective washer (located behind the transmission sun gear). The transmission-to-transfer case washer selection procedure must be performed each time a transmission and/or transfer case assembly or the internal components (excluding gaskets and seals) are replaced.
^ Transmission oil circulates between the transmission assembly and the transfer case differential carrier and three helical gear set. In situations where transmission related failures circulate fiber type debris, such as clutch friction disc material into the transfer case, the helical gear portion of the transfer case must be disassembled, cleaned, and inspected for damage. In situations where transmission or transfer case related failures circulate metal type debris, such as bearing material, repair or overhaul of the transmission or exchange of the Transfer Case may be required.
Included with the exchange unit will be return shipping instructions, including a return shipping label (freight collect at destination) and partially completed Bill of Lading.
WPC/CPR Request
A request for return of engine component will be received at the dealership when the appropriate warranty reimbursement claim is paid. (Credit memos and WPC requests are received every Tuesday and Friday.)
Shipping Preparation
1. Remove the Transfer Case or Rear Differential assembly as outlined in the applicable Service Manual. Drain all fluids from the removed assembly.
2. Remove any plastic shipping plugs and covers from the exchange unit and install them on the removed unit.
3. If the concerned component leaks, mark the area directly on the component with a permanent marker.
4. Write the TAC case reference number on the repair order form.
5. Write the TAC case reference number on the component in a visible location.
6. Place the removed component into the original shipping container. Attach completed return shipping tag to component.
Shipping Instructions
1. Place a copy of the repair order, the completed return checklist and product feedback forms into the plastic press on envelope.
2. Remove the original shipping tag and attach the plastic press on envelope with the return shipping label on it to the container. The Bill of Lading and Custom Papers (for Cross-Border Shipments) provided with the exchange unit are the only other documents required to be inserted into the clear envelope to return the removed component.
3. Write the WPC request number and the TAC case reference number on the outside of the container with a permanent marker.
4. To simplify the Exchange Program's core return process, the WPC will be coordinating all activities for core returns. See Corporate Service Bulletin # 99-00-89-019 (Dealers in Canada should refer to Home Office Letter # 99-201) for detailed shipping information.
5. Ship all returned exchanges/components with appropriate paperwork to:
Third Party Freight Collect
GM Warranty Parts Center
45 Northpointe Drive
Orion, MI 48359
Warranty Claims Processing Procedure
Use the table as shown for claim submission.
DISCLAIMER