Technical Service Bulletin

Transcription

1 Technical Service Bulletin Group Number TRANSAXLE Subject REMANUFACTURED AUTOMATIC TRANSAXLE (ATM) PROGRAM Date Model APRIL, 2007 ALL This TSB supercedes bulletin to include 6-speed automatic transaxle information. DESCRIPTION: The automatic transaxle warranty repair policy has been revised to authorize in-dealership repairs of the following components for both OEM (new) and remanufactured automatic transaxles: NOTE: Do not replace the automatic transaxle to service the condition and components listed below. Instead, repair/replace the following components according to the related shop manual or TSB. ALL EXCEPT 6-SPEED AUTOMATIC TRANSAXLE VEHICLES: REPAIR OEM REMAN SYMPTOM TSB Adjust kickdown servo X X 2-3 shift flare Replace kickdown servo switch X X P Replace range switch X X P0705, P0707, P Replace pulse generators X X P0717, P Replace input & output speed sensors X X P0715, P0716, P0717, P0720, P0721, P Replace oil temperature sensor X X P0711, P0712, P Replace oil pan gasket and/or oil pan X X Oil leak Replace axle seals X X Oil leak Replace oil pump seal (P/N ) Replace solenoids (All except 2007~ Elantra & 2007~ Veracruz) X X Oil leak at bellhousing X X Solenoid codes Page 1 of 6

2 ALL 6-SPEED AUTOMATIC TRANSAXLES, FOR VERACRUZ: REPAIR NEW REMAN VERACRUZ SHOP MANUAL Replace manual valve lever oil seal (under TCU) X X AT-14 Replace oil pump oil seal X X AT-14 Replace axle oil seal (case side/driver s side) X X AT-15 Replace axle oil seal (converter housing side/passenger s side) X X AT-16 Reseal valve body cover (oil pan) X X AT-221~226 Replace TCU (with proper diagnosis) X X AT-233~234 Replace transfer case oil seals X X AT-283~290 NOTE: Second and subsequent remanufactured ATM replacements on the same VIN will require Tech Line (800/ ) approval/authorization prior to repair and DPSM approval/authorization for claim payment. TRAINING: The ATM Diagnosis and and Certification Course (#SVC ) provides detailed instructions on how to properly diagnose and when to repair or replace an ATM. DPSM approval is necessary when installing remanufactured transaxles if your dealership does not currently employ a technician who has attended this course. AFFECTED MODELS: This program applies to all models. SPECIAL SERVICE TOOLS: Your dealership must have on hand the following Special Service Tools/supplies: Hyundai Transmission Cooler Flush (aerosol), P/N Hyundai Automatic Transaxle Tester II (Kent-Moore #09450-AT000) GDS and/or Hi-Scan Pro (Kent-Moore #J44410) DIAGNOSIS PROCEDURE: 1. The Service Advisor opens a Repair Order (R.O.) documenting the customer s detailed comments. A road test by a technician or Service Advisor may be necessary to verify the customer s description. 2. The Service Advisor carefully completes the top section of the ATM Diagnosis Worksheet (P/N NP ). Page 2 of 6

3 Technical Service Bulletin Group Number TRANSAXLE The ATM Diagnosis Worksheet and shop copy of the R.O. are dispatched to the technician. (The remaining copies of the R.O. can be distributed according to established dealership procedures.) 4. The technician follows the Diagnostic Flow Chart on the back of the Worksheet to assist in the diagnosis of the ATM and to make a repair/replace decision. The technician enters the appropriate Condition from the list on the back of the worksheet. NOTE: **Diagnostic trouble codes and ATM Tester results must be recorded on the ATM Diagnosis Worksheet whenever the Hi-Scan Pro or ATM Tester is used. If the HDS is used, a printout of the readings must be retained with the shop copy of the R.O. 5. If it is determined that a remanufactured unit must be ordered and installed, the technician must obtain the Service Manager s approval and signature on the Worksheet. 6. The technician sends both the Worksheet and the R.O. to the Parts Department. 7. The Parts Department orders a remanufactured ATM from the facing PDC and retains the R.O. and Worksheet, filed by R.O. number. 8. The Parts Department receives a remanufactured ATM, shipped prepaid in a reusable box, and provides the ATM to the technician. NOTE: Retain the reusable box and use to return the removed ATM and torque converter to the remanufacturing center. A complete package of forms is included with each remanufactured ATM unit as shown below: Core Return Checklist Pre-addressed shipping label Parts Bulletin Reman Core Return Program Reminders 9. The Parts Department completes all required fields of information on the Core Return Checklist. Failure to do so will result in a debit. 10. The technician completely drains all fluids and removes the ATM and torque converter from the vehicle. NOTE: Do not disassemble any part of the ATM. Page 3 of 6

4 11. Flush the transaxle oil cooler and hoses using Hyundai Transmission Cooler Flush (P/N ). Follow instructions in TSB # NOTE: *The ATM oil cooler and hoses must be flushed prior to installation of the replacement remanufactured ATM. If a thorough flushing is not performed, the remanufactured ATM can be contaminated by debris left in the cooler and hoses, resulting in shop comebacks and possible claim chargeback. 12. Install the remanufactured ATM according to the appropriate shop manual. Fill the ATM to the specified level according to the procedure in the shop manual or TSB Use the following ATF: Hyundai SPIII - all except 6-speed ATM (P/N ) Hyundai JWS 3309 T-4 ATF - all 6-speed ATM (P/N ). 13. Secure the removed torque converter to the removed ATM using the torque converter retaining strap and bolts removed from the remanufactured ATM. 14. Install all plugs removed from the remanufactured ATM onto the removed ATM before packaging to prevent residual fluid from leaking. 15. Place the top copy of the ATM Diagnosis Worksheet and the top copy of the Core Return Checklist in the plastic bag provided with the remanufactured ATM and close the envelope securely. Ensure both forms are completely filled out. NOTE: Failure to properly complete and/or return the designated Core Return Checklist and ATM Diagnosis Worksheet will result in a $50.00 reduction of the core credit and/or chargeback of your warranty claim. 16. Place the removed ATM into the shipping container provided with the remanufactured ATM. Secure the lid with the retaining straps. 17. Attach the address label provided with the remanufactured ATM and ship the removed ATM with the ATM Diagnosis Worksheet and Core Return Checklist. NOTE: Freight charges are prepaid by HMA for returning the removed ATM to the remanufacturing center, when the request is submitted through RETURN CORES on DCS online (see Parts Bulletin 1307 Reman Core Return Progrom Reminder ) and the ATM is shipped via ROADWAY, HMA s approved carrier. DO NOT SUBMIT A WARRANTY CLAIM FOR THESE CHARGES. 18. Retain the bottom copy of the Core Return Checklist in the dealership s Parts Department, filed by the repair order number indicated in the top right hand corner of the checklist. 19. Retain the canary copy of the ATM Diagnosis Worksheet together with the shop copy of the R.O. in the dealership s service files. Page 4 of 6

5 Technical Service Bulletin Group Number TRANSAXLE The remanufacturing center receives the removed ATM, Core Return Checklist and ATM Diagnosis Worksheet. 21. The remanufacturing center checks the documents and sends the forms to HMA. 22. The dealer is reimbursed for the core ATM. NOTE: If an incorrect transaxle has been ordered and not installed or damaged, you may return it to the PDC through DCS using the new 45-day BC Return Program. If an incorrect transaxle has been installed or damaged, it must be returned to the remanufacturer. Please write ordered in error or damaged in the space for the old ATM serial number on the Core Return Checklist. HMA may deny/chargeback all portions of ATM claims and/or core credits on remanufactured units if: Oil cooler was not properly flushed, causing damage to the remanufactured ATM Remanufactured ATM damaged due to: Improper handling Improper installation/removal Improper packaging No trouble found/incorrect diagnosis Comeback repair/incorrect diagnosis Incomplete or missing Core Return Checklist and/or ATM Diagnosis Worksheet NOTE: Dealers must contact their facing PDC regarding lost packaging and paperwork. NOTE: Dealer Parts Department accepts full responsibility for ensuring that transaxles sold over the counter: Have an ATM Diagnosis Worksheet that is completely and accurately filled out Page 5 of 6

6 PARTS INFORMATION: The ATM oil cooler is flushed to HMA specifications using Hyundai Transmission Cooler Flush (P/N ) Genuine Hyundai transmission fluid is used to refill the ATM MODELS All except 6-speed automatic transaxle 6-speed automatic transaxle, including Veracruz ATF P/N Hyundai SPIII Hyundai JWS 3309 T-4 OIL COOLER FLUSH WARRANTY INFORMATION: DESCRIPTION OP. TIME OP. QTY CAUSAL PART NATURE CAUSE 45000R R0A 45000R0D 45000R0E 45000R0P Replace ATM - (includes cable & range switch adjustment, pressure test, stall test ) Current Labor Time Standard (LTS) hours apply 1 Part number of reman ATM installed Nature Cause NOTE: The warranty information listed below can be claimed as additional operation codes if these diagnosis operations were performed and required the use of the ATM Tester, Hi-Scan Pro and/or GDS R RP RQ0 DESCRIPTION Flush oil cooler Hi-Scan & A/T Tester operation GDS & A/T Tester operation OP. TIME OP. QTY CAUSAL PART Part number of reman ATM installed NATURE Nature CAUSE Cause Page 6 of 6