Recall Description, Vehicles Affected, Parts Information
This bulletin supersedes SR-93-003, dated May 1993, which should be discarded.The revised Information Includes:
1. The latest Getrag transfer case return policy and Material Return.
2. Clarification of a Transaxle Inspection (steps 2 & 3).
3. Corrects the warranty Information screen labor times.
PURPOSE
The Getrag transfer case on 1991 3000GT VR-4 vehicles must be checked for lubricating oil leakage. Excessive transfer case lubricating oil loss could result in bearing or gear damage within the transfer case assembly. Dependent on the amount of oil contained within the transfer case, the transfer case should be modified or replaced with a modified unit. The modification consists of adding an O-ring between the extension housing and the transfer case. A letter has been sent to the affected vehicle owners telling them to return their vehicle to their Mitsubishi Motors dealer for the Inspection and modification or replacement of the transfer case. A sample customer notification letter is shown in this bulletin.
AFFECTED VEHICLES
1991 3000GT VR-4 All Wheel Drive vehicles equipped with a transfer case having identification numbers MAA0001 through MBC0100 (vehicles which have been updated to the newer style transaxle and transfer case are not affected). This recall does not apply to any other models.
REQUIRED OPERATIONS (condensed Information)
1. Read the transfer case's identification number and look for an identifying color mark (blue or black) to determine If the unit is effected. If the unit is not affected, no repairs are necessary, then submit an inspection only claim.
2. Carefully examine the transfer case for evidence of leakage.
If no leakage is found, measure the amount of transfer case oil by draining into a measuring cylinder/cup. Record the amount of oil drained on the repair order.
Note:
A full transfer case has approximately 270cc (9 fl oz) of oil.
If the amount of oil is MORE than 180 cc (6 fl oz), remove the transfer case, modify the transfer case by installing an O-ring, and refill the transfer case with 75W-85W GL4 oil.
If the amount of oil is LESS than 180 cc (6 fl oz), remove the transfer case, replace the transfer case with a modified unit, and refill the transfer case with 75W-85W GL4 oil.
Note:
Do not remove the front exhaust pipe and the propeller shaft for these procedures.
If leakage is found, REPLACE the transfer case with a modified unit and refill the transfer case with 75W-85W GL4 oil.
Note:
Do not remove the front exhaust pipe and the propeller shaft for these procedures.
WARRANTY INFORMATION
Submit as Recall Claim type "C", menu option "E-5" on your Diamond Network System. Do NOT submit as a "W" claim.
Labor operation code: C9303EXX
Note:
The "O" in the above labor code is the number ZERO.
Labor Time Allowance (1 only per claim)
Transfer case number inspection: 0.2 hr.
Note:
An inspection claim is only allowed to be submitted if the vehicle actually appears on the involved list of VINS and/or if the owner brings in a recall notification letter. No claim may be submitted for non-involved vehicles.
OR
Transfer case modification: 1.5 hr.
OR
Transfer case replacement: 0.9 hr.
A sample transfer case number inspection work claim is shown in this bulletin.
A sample transfer case modification work claim is shown in this bulletin.
A sample transfer case replacement work claim is shown in this bulletin.
Getrag Transfer Case Core Charge
The core charge policy has been replaced by the existing warranty parts return material system. A core charge will not be involved at all. Replaced Getrag transfer case assemblies must be stored at the dealer until a material return request letter is received. See "MATERIAL RETURN" below.
PARTS INFORMATION
Required parts (modifying or replacement of the transfer case only).
Exhaust pipe gasket: MB687002, quantity 2
Exhaust pipe nut: MB059359, quantity 4
Mitsubishi Diamond Gear Lube: A991ZC2X01
The maximum amount which may be charged for Diamond Gear Lube is $8.00 per vehicle. See the sample recall claims at the end of this bulletin for the proper claim coding entry.
Conditional Parts
Transfer case modification
O-ring: MR165235, quantity 1
Transfer case replacement
Transfer case: MR165234, quantity 1
Note:
No other parts can be claimed for this recall.
MATERIAL RETURN
When requested by a material return request letter, replaced Getrag transfer case assemblies MUST be returned to the MMSA Material Return Center using, a properly filled out, orange "GETRAG CORE RETURN LABEL" (MSSF026DOO). If the unit does not arrive at the MMSA Material Return Center, the claim will be charged back.
Note:
If an orange "GETRAG CORE RETURN LABEL" (MSSF026D00) is not available, photo-copy the label example shown in this bulletin, cut out as indicated, and securely affix the copy on the box.
REQUIRED TOOLS
Plastic scraper - a plastic body filler spreader or old plastic credit card is acceptable.
Plastic brush - i.e. an old tooth-brush or similar plastic bristle brush. Plastic hammer. Black permanent marker or black paint. Mechanic's wire.
MISCELLANEOUS SEALANTS AND LUBRICANTS
LOCTITE 242 thread locking compound or equivalent. 3M Super Weatherstrip Adhesive - 8001 or equivalent. Mitsubishi Genuine Sealant - MD997740. Mitsubishi White Lithium Grease - A999ZC1X05 or equivalent. Mitsubishi Multi-Purpose Cleaner - A991ZClX04 or equivalent. After-market sealant remover.
Note:
The maximum dollar amount which may be charged for miscellaneous sealant and lubricants is $5.00. Claim these materials as "NPN". Refer to the sample recall claims at the end of this bulletin.