Vauxhall/Opel Astra & Zafira Petrol (Feb 98 – Apr 04) R-04 reg.
Astra Hatchback, Saloon & Estate, & Zafira MPV, inc. special/limited editions.
Does NOT cover Coupe or Convertible, new range introduced May 2004, Diesel or bi-fuel models
1.4 litre (1389cc), 1.6 litre (1598cc), 1.8 litre (1796cc), 2.0 litre (1998cc) & 2.2 litre (2198cc).
Does NOT cover 1.6 litre ‘Twinport’ or 2.0 litre turbo engines
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1994-1997 Ford Probe, Mazda MX3 with 4 cyl. & A/T 1994-2000 Mazda 626 with 4 cyl. & A/T 1998-2000 Mazda 626 with 6 cyl. & A/T 1995-2000 Ford Contour/Mercury Mystique with 6 cyl. & A/T 1999-2001 Mercury Cougar with A/T SUBJECT Vehicles with the Ford CD4E automatic transmission. CONDITION The driver’s side front CV axle has a 6-½ inch male inboard stub that fits into the transmission’s side gear. On the stub next to the housing seal surface is a carrier support surface that fits into the final drive sun gear inside the transmission (see figure 1). This sprocket assembly is chain driven with the reverse/overdrive sprocket by the planetary gear sets (see figure 2). The final drive sprocket assembly rides on the axle stub carrier support surface using a pressed, center bored bushing. This bushing wears the carrier support surface causing damage to the axle and eventually the transmission. SOLUTION If the carrier support surface of the axle being replaced appears rough and worn, then several possible failures need to be checked before replacing the axle or premature failure of the axle or possible damage to the transmission could occur. If the transmission’s internal oiling solenoid that lubricates this bushing fails, then the 2nd and 3rd gearshifts will not function. Although the Aftermarket lists this bushing, no tool exists to replace it. Ford only offer the bushing in a complete sprocket assembly making its replacement a very costly repair. The most common contributor to premature wear of this bushing is the vehicle not being within proper alignment specs. Without a four-wheel alignment, even though the front wheels may be centered to the rack, the rear thrust is pushing the front wheels causing stress on the front CV joints. The thrust forces acting on the front wheels while driving changes ALL the alignment specs resulting in the front wheels being in a constant turning action. This will wear the side gears and transmission seals as well as stressing this bushing. Another possible sign that alignment is affecting these items is a worn or torn inboard boot. Do not forget that worn motor mounts will also affect alignment thrust forces.
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Engine miss, spark knock, buck/jerk, surge and other driveability concerns may be caused by induction crossfire. This occurs because of improperly routed spark plug wires. ACTION: If spark plug replacement is performed, the correct firing order and spark plug wire routing is essential to prevent the possibility of induction crossfire between cylinders. Refer to the following procedures for inspection of the spark plug wire routing and firing order. Properly reroute the spark plug wires if required. FIRING ORDER ^ The firing order for 1987-1993 vehicles is 1-5-4-2-6-3-7-8. If # 7 and # 8, or # 2 and # 4 spark plug wires are routed next to each other at the separation bracket, an induction crossfire condition can occur. ^ The firing order for 1994 vehicles is 1-3-7-2-6-5-4-8. On these vehicles the # 1 and # 3, or # 5 and # 6 spark plug wires must be separated to eliminate the possibility of an induction crossfire. ^ To eliminate the possibility of the coil wire becoming disconnected, route the coil wire under the spark plug wires at the distributor cap. 1987-1993 VEHICLES
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REMOVAL Wheels must be in a straight forward position and the key must be in the Lock position when removing or installing column to ensure proper alignment of components during installation. 1. Remove inflator module as outlined in Air Bag. Refer to Air Bags and Seat Belts/Air Bags(SRS). 2. Remove knee bolster and steering column reinforcement plate. 3. Disconnect electrical connectors from column. 4. Remove pinch bolt from intermediate shaft, Fig. 13. 5. Remove lower support bracket from vehicle. 6. Remove upper column support from instrument panel, then the column from vehicle. INSTALLATION 1. Install column in vehicle and support at upper bracket with two bolts, Fig. 14, do not tighten at this time. 2. Install column lower support bracket in vehicle, do not tighten at this time. 3. Connect column intermediate shaft to steering rack, install pinch bolt and torque to 35 ft. lbs. 1994 Cadillac Seville SLS V8-4.6L VIN Y 4. 5. 6. 7. Torque upper and lower column support bolts to 20 ft. lbs., then the lower bracket to column screws to 12 ft. lbs. Connect electrical connectors to column. Install knee bolster and column reinforcement plate. Install steering wheel inflator module as outlined in Air Bag. Refer to Air Bags and Seat Belts/Air Bags(SRS).
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Models: 1992-94 Buick Skylark 1993-96 Buick Park Avenue 1989-92 Cadillac Allante 1991-93 Cadillac Eldorado, Seville 1991-95 Cadillac DeVille 1991-95 Oldsmobile Ninety Eight 1992-93 Oldsmobile Achieva 1994-99 Pontiac Bonneville This bulletin is being revised to clarify when this bulletin may be used to turn the service suspension lamp off. Also, a step has been added to the 1991 Cadillac Eldorado and Seville repair. Please discard Corporate Bulletin Number 00-03-11-001 (Section 3 – Suspension). Some owners may bring their vehicles in for service with an illuminated service suspension light. The service suspension indicator lamp is telling the owner that the vehicle is due for strut/shock replacement, a maintenance item. The customer may elect to have passive struts installed in their vehicles due to repair cost savings and/or parts availability. The installation of passive shock/struts will result in handling characteristics which are the equal to a like vehicle without the computer controlled ride, with all other components such as tires, tire pressure, springs, etc. being equal. The installation of (4) new passive struts will cause the continued illumination of the service suspension indicator. If desired by the customer, the service indicator may be disabled AFTER THE INSTALLATION OF THE (4) NEW PASSIVE STRUTS, using the appropriate service procedure listed below. This bulletin DOES NOT authorize this procedure unless (4) NEW PASSIVE STRUTS WERE INSTALLED ON THE VEHICLE.
