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Technical Service Bulletins From GM/Pontiac

This is a discussion on Technical Service Bulletins From GM/Pontiac within the GTO forums, part of the Vehicle Specific category; Purchased a 2004 GTO and am wondering if there are a lot of recall issues to be dealt with in ...

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    Technical Service Bulletins From GM/Pontiac

    Purchased a 2004 GTO and am wondering if there are a lot of recall issues to be dealt with in regards to this car? The car is now allowed into Canada as most of the world seems to know and why four years late which really sucks as now we have to learn the whole list of stuff to deal with in regards to these cars-- issues like the gas cap and steering probs and rear seal leaks and so on. Nuf said hope to hear more from the rest of the canadian group who are just starting out with th much saught after GTO.

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    Welcome to the site man....sure here are all the Technical Service Bulletins from GM/Pontiac for your car....
    Adv. Service Info-Fuel Gauge Inoperative, Fuel Gauge Needle Stuck in One Position (Temporary Fix-Remove Two Fuses for One Mintue to Reset Gauge) #04-08-49-005 - (Feb 17, 2004)
    Fuel Gauge Inoperative, Fuel Gauge Needle Stuck in One Position (Temporary Fix -- Remove Two Fuses for One Minute to Reset Gauge)

    2004 Pontiac GTO

    Condition
    Some customers may comment that the fuel gauge does not respond to the amount of fuel in the tank after being filled and/or the gauge stays in one position all the time.

    Correction
    To temporarily correct this condition, remove the two fuses identified below for at least one minute and then reinstall them. This should reset the fuel gauge.

    Instruments Theft Horn fuse (10 amp) located in the fuse block under the steering column.
    Engine Control BCM fuse (10 amp) located in the underhood fuse block.
    Engineering is currently developing a permanent fix. Once the fix is available, this bulletin will be reissued. DO NOT replace the instrument cluster for this condition.

    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation
    N1720
    Fuse -- Replace
    0.2 hr

    Info - Proper Jump Starting Procedure #04-06-03-006 - (Sep 14, 2004)
    Proper Jump Starting Procedure
    2004-2005 Pontiac GTO

    This bulletin is meant to inform technicians of the possibility of burnt-out headlamp bulbs as the result of incorrect jump-starting of the vehicle, especially if the battery is at an extremely low state of charge (less than 3 volts).

    If the jumper cables are disconnected too quickly, the generator creates a momentary voltage spike until the regulator is able to adjust to the new load condition.

    When jump-starting, ensure that both vehicles run for at least one minute prior to disconnecting the jumper cables. This allows the battery voltage to stabilize and avoid any spike in the voltage

    Info - Refinishing GTO Silver Painted Wheels #04-03-10-010 - (Aug 24, 2004)
    Refinishing GTO Silver Painted Wheels
    2004 Pontiac GTO


    This bulletin is being issued to announce the color for the new GTO wheels. WA927K is for 2004 model year and WA251L is for 2005.

    2004 Model Year
    Paint Manufacture
    Refinish code

    Akzo Noble
    GMA927KM

    BASF
    WA927K

    PPG
    906661

    Nexa
    4DJYB

    Sherwin Williams
    68248

    Martin Senour
    68248

    Dupont
    927k

    Spies Hecker
    927k

    Sandox
    927k

    Informational - Discolored, Dirty, Dark, Sludge and/or Grease in the Clutch Fluid Reservoir #04-07-31-002 - (Feb 16, 2004)
    Discolored, Dirty, Dark, Sludge and/or Grease in the Clutch Fluid Reservoir
    2004 Pontiac GTO

    with Transmission, Manual 6 Speed, Tremec, 85 mm, 2.97 First, 0.57 Sixth, Overdrive (RPO M12)

    It may be observed on some vehicles that the clutch fluid in the reservoir appears to be discolored, dirty, have sludge or grease contaminates in it after being in service for a period of time.

    The level of discoloration will vary with factors such as driving conditions, under hood temperatures etc.

    This is a phenomenon that may occur with time due to the interaction between the clutch system rubber parts with hydraulic clutch fluid.

    The small amount of sludge or grease that may be noticed is, in fact, grease that has migrated from the master cylinder assembly. The grease is used during assembly of the master cylinder.

    Engineering investigations of returned fluid samples show that discoloration and grease in the fluid DO NOT negatively affect the performance of the clutch hydraulic fluid.

    Field reports indicate that where clutch fluid and or clutch system components have been replaced to address this condition, the vehicles have returned with the same condition causing a repeat repair and a dissatisfied customer.

    Discolored clutch fluid should not be replaced in a normal operating system.

    For Clutch System Concerns and Diagnosis, refer to Diagnostic Starting Point - Clutch SI Document ID #1338362.

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    Info - Key Cutting Procedure for Obtaining Replacement Key #03-00-89-037 - (Nov 4, 2003)
    Key Cutting Procedure for Obtaining Replacement Key
    2004 Pontiac GTO


    Important
    "GM of Canada" dealers are not authorized to utilize this service bulletin.

    Due to the uniqueness of the Pontiac GTO key blank, special equipment is required to cut a key for the Pontiac GTO.

    To obtain a replacement key, the following procedure is suggested:

    Obtain the vehicle key code by accessing the "Key Code Look Up" application through GM DealerWorld under the Parts tab or from the Security Card provided to the owner at the time of delivery.
    Submit a part order through the GMSPO Parts System for a key blank. Be sure to include the key code in the "note" field of the order and indicate the preferred method of shipment (i.e. overnight, etc.).

    Important
    The order will be shipped the same day if received by 3:00 p.m. EST, or within 24 hours - Monday through Friday.

    Assemble the new key to the key remote head (transmitter) using two screws.
    Insert the key into the ignition and turn to the RUN position.

    Important
    This is a one-time program meaning a key can only be programmed once. Once programmed, the key cannot be revised whether on the same vehicle or on a different one.

    Program the transmitter to the vehicle. This can be done either through the Tech 2 (TIS CD #11 available 10/20/03 via the web, or 10/24/03 via CD) or by using a manual procedure. For the manual procedure , refer to Document ID #1349159 Transmitter Programming in the Keyless Entry sub-section of SI. The path to access this set-up through the Tech 2 is:
    Diagnostics
    2004
    Pass car
    Pontiac
    Body
    Body Control Module
    Special Function
    Program Key FOBs
    Enter
    As an alternate to Step 2, the following equipment can be purchased through 1-800-GM-TOOLS.

    Equipment
    Description
    Part Number

    Machine Duplicating
    Used to produce a duplicate key from an existing key
    74 -- Matrix S

    Computerized Duplicating and Code Cutting
    Used to produce a key from a key code
    74 -- Triax

    Parts Information
    Part Number
    Description
    Qty

    92141426
    Key -- Ignition
    1

    92138596
    Screw -- Remote Coded Key
    1 pkg

    92123129
    Key Asm -- Door Lock and Ignition Lock Transmitter
    2


    Parts are currently available from GMSPO.

    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation
    S0011
    Keys -- Cut/Replace
    0.2 hr

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    Knock or Thud Noise When Cruise Control is On or Off (Install Washer at Rear Mounting Point) #04-08-68-003 - (Sep 24, 2004)
    Knock or Thud Noise When Cruise Control is On or Off (Install Washer at Rear Mounting Point)
    2004 Pontiac GTO

    Condition
    Some customers may comment that a knock or thud noise can be heard in their vehicle when the cruise control is on and even when it is off.

    Cause




    This noise may be caused by a lack of clearance between the cruise control module (1) and the ABS/cruise control module mounting bracket. The noise is transmitted into the vehicle through the body at the contact point (2) shown.


    Correction

    Install a washer (1), P/N 11509262, to the rear mounting point as shown in the illustration above. This will provide clearance between the cruise control module assembly (1) and the sheet metal bracket.

    Parts Information
    Part Number
    Description
    Qty

    11509262
    Washer
    1


    Parts are . . .available from GMSPO.

    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation
    R1220
    Module, Cruise Control - Replace
    Use Published Labor Operation Time

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    Whistle Noise While Vehicle is Stationary with Brakes Applied (Replace Vacuum Brake Booster Check Valve) #04-05-22-001 - (Sep 15, 2004)
    Whistle Noise While Vehicle Is Stationary with Brakes Applied (Replace Vacuum Brake Booster Check Valve)
    2004 Pontiac GTO

    Condition
    Some customers may comment on a light, barely audible whistle noise while their vehicle is stationary, with the brakes applied. This noise will disappear when the brakes are released.

    Correction
    Install a new vacuum brake booster check valve. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement (SI Document ID #1367021).

    The new valve (1) can be easily identified from the old valve (2) by the black cover.

    Parts Information
    Part Number
    Description
    Qty

    92148176
    P/B Booster Valve
    1

    Parts are currently available from GMSPO.

    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation
    H1240
    Valve, Filter, Hose and/or Pipe, Vacuum Power Brake - Replace
    Use Published Labor Operation Time

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    Speedometer MPH Indicator Too Bright (Reduce MPH Indicator Brightness Using Tech 2) #04-08-49-023 - (Sep 10, 2004)
    Speedometer MPH Indicator Too Bright (Reduce MPH Indicator Brightness Using Tech 2)
    2004 Pontiac GTO

    Built Prior to VIN Breakpoint 4L299640

    Condition
    Some customers may comment that the MPH indicator on the speedometer is too bright during night driving and that it does not dim with the IP lamps.

    Correction
    Follow the procedure below using the Tech 2 to reduce the brightness of the speedometer MPH indicator. This procedure must be followed exactly.


    Important
    The Tech 2 must contain software version 24.005 or later available from Techline starting July 2004, on the TIS 2000 version TIS 07/2004 data update or later.


    Install the Tech 2 to the vehicle and power on.
    Select "Diagnostic" from the menu.
    Build the vehicle from the menu options.
    Select "Body" from the menu.
    Select the correct transmission type.
    Select "Instrument Panel Cluster" from the menu.
    Select "Special Functions" from the menu.
    Select "Programming" from the menu.
    Select " Instrument Configuration" from the menu.
    Press Enter.
    Press "Change Data". Even though the screen deals with tire size and speed pulses, the data stream changes the MPH indicator brightness.
    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation
    N4199
    Instrument Panel Cluster (IPC) Module Reprogram
    0.2 hr

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    Knock Noise from Front Suspension When Driving at Low Speeds Over Bumps/Uneven Road Surfaces (Install New Strut-to-Steering Knuckle Attaching Bolts and Nuts or New Front Lower Control Arm Rod Nut) #04-03-08-014 - (Aug 25, 2004)
    Knock Noise from Front Suspension When Driving at Low Speeds Over Bumps/Uneven Road Surfaces (Install New Strut-to-Steering Knuckle Attaching Bolts and Nuts or New Front Lower Control Arm Rod Nut)
    2004 Pontiac GTO

    Condition
    Some customers may comment on a knock noise from the front suspension when driving at low speeds over bumps or uneven road surfaces.

    Cause

    This condition may be caused by the lower coil of the spring touching on the side lip of the spring seat.

    The spring coils contacting the body sheet metal within the wheelhouse area may also cause this condition.

    Correction
    Inspection
    Inspect the tightness of all front suspension fasteners. If they are OK, proceed to Step 2.
    Inspect the body sheet metal around the inside of the strut tower for signs of spring coil rubbing.
    Inspect the second lower coil on the inboard side of the spring for signs of chipped or marked paint, as shown in the previous illustration.
    If marks are found as described in Steps 2 and 3, proceed to Procedure A.
    Procedure A


    Tools Required
    J 45059 Angle Meter

    Remove the spring from the strut assembly and re-install it upside down (with the thin coil end resting on the spring seat).
    Carefully reinstall the upper bearing (yellow plastic housing), ensuring that it is located correctly in the upper spring seat.
    While the strut is removed from the vehicle, cycle the control arm up and down.
    If a noise is heard from the lower control arm rod front insulator bushing, reinstall the strut assembly to the vehicle and proceed to Procedure B.
    If no noise is heard, install new strut-to-steering knuckle attaching bolts and nuts. Tighten the nuts while applying pressure to the top of the brake rotor. This will ensure that the camber adjustment bolt is against the strut tube, eliminating the need to perform a front end alignment. Tighten
    Tighten the nuts to 85 Nm (62 lb ft).
    Tighten the nuts to 100 Nm (74 lb ft).
    Use the J 45059 in order to tighten the nuts an additional 90 degrees.
    Procedure B
    Only perform this procedure if Step 3 from Procedure A confirms that it is necessary.





    Remove the front lower control arm rod nut.
    Install a new nut, but do not fully tighten.
    Bounce the front of the vehicle up and down several times to stabilize the suspension.
    Tighten the control arm rod nuts to 148 Nm(109 lb ft).
    Parts Information
    Part Number
    Description
    Qty

    11090821
    Bolt, Front Suspension Strut
    4

    92138205
    Nut, Front Suspension Strut
    4

    11084241
    Nut, Control Arm Rod Lower
    2


    Parts are currently available from GMSPO.

    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation
    E9418*
    Invert Spring - Both Sides
    1.7 hrs

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    This labor operation is for use only with this bulletin. It will not be published in the Labor Time Guide.
    Front Door Lock Will Not Unlock or Will Lock Intermittently (Install New Door Lock Assembly) #04-08-64-018 - (Aug 24, 2004)
    Front Door Lock Will Not Unlock or Will Lock Intermittently (Install New Door Lock Assembly)
    2004 Pontiac GTO

    Built Prior to VIN Breakpoint 4L225024

    Condition
    Some customers may comment that the front door lock will not unlock or will lock intermittently.

    Cause
    This condition may be due to internal friction within the door lock mechanism at the rivet which attaches the door external handle lever to the lock base. The lever is returned to the rest position by the return (or torsion) spring. The door lock will not release unless the lever returns fully to the rest position.

    Correction
    Install a new door lock assembly. Refer to Lock Replacement-Door (SI Document ID #1340736).

    Parts Information
    Part Number
    Description

    92143359
    Front Side Door Lock (LH)

    92143360
    Front Side Door Lock (RH)


    Parts are currently available from GMSPO.

    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation

    B4260
    Lock, Front Door-Right - R&R or Replace
    Use Published Labor Operation Time

    B4261
    Lock, Front Door-Left - R&R or Replace

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    Loss of Pedal Height/Low Clutch Pedal, Clutch Does not Release Fully Untill Full Pedal Travel, Difficulty Changing Gears (Tighten Clutch Pressure Plate Bolts) #04-07-31-003 - (Jun 30, 2004)
    Loss of Pedal Height/Low Clutch Pedal, Clutch Doesn't Release Fully Until Full Pedal Travel, Difficulty Changing Gears (Tighten Clutch Pressure Plate Bolts)
    2004 Pontiac GTO Built Prior to VIN Breakpoint 4L234149

    with Manual Transmission

    Condition
    Some customers may comment on progressive loss of pedal height (which, if not addressed, could result in the clutch not fully releasing until full pedal travel), difficulty in changing gears or a low clutch pedal.

    Cause
    Root cause analysis has identified that the clutch pressure plate bolt torque on vehicles produced before the above VIN breakpoint may loosen in service. This condition was corrected in production by increasing the torque of the clutch pressure plate bolts. This change became effective in vehicle production beginning with VIN 4L234149, built on 2/11/04.

    Correction

    Important
    This correction MUST be performed before retail delivery of new vehicles built prior to VIN breakpoint 4L234149.
    Whenever performing repairs to the clutch assembly on vehicles built both prior to and after the specified VIN breakpoint, ensure that all six pressure plate retaining bolts are tightened in sequence as shown in the illustration.

    Apply additional torque to the clutch pressure plate-to-flywheel bolts to the revised torque specification of 70 Nm +/-7 Nm (52 lb ft +/-5 lb ft).

    SI will be updated with this revised torque specification in the future.

    Tighten the bolts in sequence in 4 steps:

    Tighten all bolts to 15 Nm (11 lb ft).
    Tighten all bolts to 35 Nm (26 lb ft).
    Tighten all bolts to 55 Nm (41 lb ft).
    Tighten all bolts to 70 Nm (52 lb ft).
    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation

    K0800
    Clutch Pressure Plate - Replace
    3.2 hrs

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    Paint Peeling from the Steerign Wheel Spokes (Replace Covers) #04-02-35-007 - (Apr 20, 2004)
    Paint Peeling from the Steering Wheel Spokes (Replace Covers)
    2004 Pontiac GTO

    Condition
    Some customers may comment that the silver paint is peeling from the spokes on the steering wheel.

    Remove the steering wheel. Refer to SI Document ID #1379596 and unscrew the covers from the wheel. Install the new covers and reinstall the wheel.

    Parts Information
    Part Number
    Description

    92147964
    Cover, Steering Wheel OPG


    Parts are currently available from GMSPO.

    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation
    E7020
    Wheel, Steering --Replace
    0.4 hr

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    Knocking Noise from Rear of Vehicle on Aggressive Launch or Acceleration (Install Rear Suspension Crossmember Front Mount Insulators) #04-03-09-003A - (Apr 20, 2004)
    Knocking Noise from Rear of Vehicle on Aggressive Launch or Acceleration (Install Rear Suspension Crossmember Front Mount Insulators)
    2004 Pontiac GTO

    Built Prior to VIN Breakpoint 4L246712

    This bulletin is being revised to change a torque specification within the correction procedure. Please discard Corporate Bulletin Number 04-03-09-003 (Section 03 -- Suspension).

    Condition
    Some customers may comment on a knocking noise coming from the rear of the vehicle. This noise occurs during an aggressive launch or acceleration and will be more common on vehicles with a manual transmission.

    Cause
    The cause of this condition may be contact between the body and the rear suspension crossmember.

    Correction
    Install insulators, P/N 90447991, and new bolts, P/N 92038482, between the body and the rear suspension crossmember using the procedure listed below.

    Important
    Only remove the bolts from one side of the suspension crossmember at a time, and DO NOT loosen the opposite side, until the insulator is installed on the first side and all fasteners have been tightened to the specified torque setting.

    Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. Position rear hoist.
    Support the rear suspension crossmember just under the brace using an adjustable jack stand.
    Remove the 3 brace to underbody bolts.
    Remove the front mount bolt attaching the rear suspension crossmember to the underbody.
    Lower the jack stand slightly to allow clearance between the crossmember and the underbody.

    Important
    When installing the insulator onto the crossmember front mount bushing, face the corrugated side upwards, so it bears against the underbody.

    Install the insulator between the underbody and the upper part of the crossmember, ensuring to seat the insulator firmly onto the center of the crossmember front mount bushing.
    Raise the crossmember using the jack stand until it is pressing firmly against the underbody.
    With the jack stand still in position to support the crossmember, install the new front mount bolt and the 3 brace to underbody bolts. Tighten
    Tighten the crossmember front mount bolt to 125Nm(92 lb ft). Use J 45059 Torque Angle Meter in order to tighten the bolt an additional 40 degrees.

    Tighten
    Tighten the brace bolts to 65Nm(48 lb ft).

    Remove the jack stand.
    Repeat steps 2 to 9 for the opposite side.
    Parts Information
    Part Number
    Description
    Qty

    90447991
    Insulator, Rear Suspension Crossmember Front Mount (2 Per Package)
    1

    92038482
    Bolt, Rear Suspension Crossmember Front Mount
    2

    Parts are currently available from GMSPO.

    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation
    E9407*
    Rear Suspension Crossmember Front Mount Insulators -- Install
    0.5 hr

    *This is a unique labor operation number for use only with this bulletin. This number will not be published in the Labor Time Guide.

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    Poor Radio Reception or Radio Static/Increased Interference with Rear Window Defogger On or Some Rear Window Defogger Grids May Be Inoperative (Diagnose and Repair Rear Window Defogger Heating Grid) #03-08-44-005B - (Jan 14, 2004)
    Poor Radio Reception or Radio Static/Increased Interference with Rear Window Defogger On or Some Rear Window Defogger Grids May Be Inoperative (Diagnose and Repair Rear Window Defogger Heating Grid)

    2004 Pontiac GTO

    This bulletin is being revised to provide additional models. Please discard Corporate Bulletin Number 03-08-44-005A (Section 08 -- Body and Accessories).

    Condition
    Some customers may comment that the radio has poor reception or radio static/increased interference when the rear window defogger is turned on. Also, some rear window defogger grids may be inoperative.

    Cause
    This condition may be due to microscopic cracks in the electrically heated grids of the rear window defogger. These cracks may cause electrical interference when the rear defogger is on and this could affect radio reception.

    Background
    The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. New design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective.

    Materials Required
    Permatex Quick Grid, P/N 15067, or equivalent
    A small ball of fine steel wool Type 00, or
    Optional -- A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or
    Optional -- A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent.
    Correction
    There are three distinct zones across the back window that must be checked. They are:

    the driver's side outboard of the two vertical lines
    the passenger side outboard of the two vertical lines
    the central zone that falls between the two vertical lines
    To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following:

    Caution
    Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.
    Cover the rear shelf area to prevent damage to the interior trim material.

    Start the engine and turn on the back window defogger.

    Important
    The first place to check should be the driver side segment 2 to 3 lines up from the bottom about 380-385 mm (15-15.2 in) from the buss bar.

    Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case.
    The following are provided as a alternative way to detect a non-functional grid line. If available, use in addition to the steel wool.
    Method using liquid crystal heat sensitive paper.

    Important
    The first part of the test must be completed quickly before the entire surface of the back window becomes warm.

    From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone.
    Repeat the process for the passenger side and center area zones.
    If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and therefore not heating up. More than one broken grid line may be found.
    Method using a portable infrared thermometer.
    Start the engine and turn on the rear back window defogger.
    From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings.
    Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found.
    Repeat the process for the passenger side and center area zones.
    Use Permatex Quick Grid, P/N 15067, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions.
    Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260C -- 371C (500F -- 700F). Hold the heat gun within 25 - 51 mm (1- 2 in) from the repair point for 2 to 3 minutes.
    Recheck the grid line with the heat sensitive paper or a portable infrared thermometer to ensure that the line is now functional and that the repair was successful.
    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation
    C0631
    Grid, Electric Back Window Defogger -- Repair
    0.3 hr

    Add
    To Repair Each Additional Grid
    0.1 hr

    Add
    Diagnosis Time
    0-0.3 hr

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    Driver or Passenger Seat Squeaks in Full Down Position (Trim Seat Cushion Outer Panel) #04-08-50-001 - (Jan 6, 2004)
    Driver or Passenger Seat Squeaks in Full Down Position (Trim Seat Cushion Outer Panel)
    2004 Pontiac GTO

    Condition
    Some customers may comment on a squeak from the driver or passenger seat while driving with the seat in the full down position.

    Cause
    The seat cushion outer trim panel contacting the seat track outer cover when the seat is full down may cause this noise.

    Correction
    This condition can be corrected by trimming some material off the seat cushion outer trim panel at the area of contact. Use the procedure listed below.

    Remove the seat cushion outer trim panel from the seat. Refer to the Seat Cushion Outer Trim Panel Replacement procedure in the Seats sub-section of the Service Manual (SI Document ID #1362372).

    Important
    Trimming the material on a bench grinder is the preferred method. Remove any sharp edges.

    Trim 8 mm (0.314 in) of material from the panel as shown.
    Reinstall the seat cushion outer trim panel.
    Check that the interference is eliminated.
    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation

    C6581 (Passenger)
    Cover, Reclining Seat Back Control Hinge Outer -- R&R or Replace
    Use Published Labor Time

    C6585 (Driver)
    Cover, Reclining Seat Back Control Hinge Outer -- R&R or Replace
    Use Published Labor Time

    Add:
    To Trim Material From Panel
    0. hr

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    Wind Rush Noise from Outside Rear View Mirrors (File Down Mirror Upper Mounting Boss and Hard Landing) #04-08-58-001 - (Jan 6, 2004)
    Wind Rush Noise from Outside Rear View Mirrors (File Down Mirror Upper Mounting Boss and Hard Landing)
    2004 Pontiac GTO

    Condition
    Some customers may comment on a wind rush noise coming from one or both outside rear view mirrors.

    Cause
    This noise may be caused by an excessive gap between the mirror base and the window seal.

    Correction
    This condition can be corrected by filing down the mirror upper mounting boss and hard landing using the procedure listed below.

    Determine whether wind noise emanates from the right hand or left hand side, and inspect for presence of gap between the mirror base and window seal. Proceed with repair below only if visual gap is present.
    Remove the mirror from the door. Refer to the Mirror Replacement procedure in the Doors sub-section of the Service Manual (SI Document ID #1353519).

    Cut the rubber seal back 1 mm (0.039 in) from the top of the upper screw mounting boss.

    Notice
    Do not remove too much material off the screw boss and hard landing otherwise the window operation (and seal) may be adversely affected.

    File off 1 mm (0.039 in) from the upper screw mounting boss and hard landing.
    Reinstall the mirror to the door.
    Check that the window operates correctly.

    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation

    B4155 (Right Hand Side)
    Mirror, Outside Rear View -- Replace
    Use Published Labor Time

    B4156 (Left Hand Side)
    Mirror, Outside Rear View -- Replace
    Use Published Labor Time

    Add:
    To File Mirror Upper Screw Mounting Boss and Hard Landing
    0.1 hr

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    Info - Engagement Time of Electronically Controlled Transmissions in General Motors Vehicles (Garage Shifts, Park to Reverse, Neutral to Drive, Neutral to Reverse, Park to Drive, Delayed Engagement) #03-07-30-007A - (Nov 4, 2003)
    Engagement Time of Electronically Controlled Transmissions in General Motors Vehicles (Garage Shifts, Park to Reverse, Neutral to Drive, Neutral to Reverse, Park to Drive, Delayed Engagement)
    2000-2002 Chevrolet Camaro

    2000-2004 Chevrolet Corvette

    2000-2002 Pontiac Firebird

    2004 Pontiac GTO

    2000-2004 All Light Duty Trucks

    2003-2004 HUMMER H2

    with 4L60-E (RPO M30) or 4L65-E (RPO M32) Automatic Transmission

    This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 03-07-30-007 (Section 07 - Transmission/Transaxle).

    Park/Neutral to Reverse or Drive (commonly called garage shift) engagement times may be different from what many customers might be accustomed to, especially if they have recently traded for a General Motors' vehicle.

    Normal Park/Neutral to Reverse or Drive engagement time will be in the vicinity of one (1) second if the automatic transmission fluid (ATF) is above 0C (32F) . When the ATF is colder than 0C (32F), the engagement time will become longer the colder the transmission fluid. A time limit factor cannot be placed on proper engagement times because the factors that affect transmission operation are many.

    At the moment of engine start, for economy and emission requirements, the transmission line pressure is maintained at low levels. This allows a lower cold idle engine RPM (the colder the oil is, the higher the energy level (engine torque output) required to pressurize the oil).

    When the driver moves the shift lever from "Park/Neutral" to "Reverse" or any "Drive" range, the following actions must occur for the powertrain control module (PCM) to determine at what pressure to control the transmission line pressure.

    The module will look at the following items:

    The voltage readings of the engine coolant temperature sensor (ECT).
    The voltage reading of the transmission fluid temperature sensor (TFT).
    Whether or not air conditioning is requested.
    Movement of the shift lever and controls engine RPM based on the gear position selected. The module will adjust the engine RPM in response to the torque requirements needed to increase transmission line pressure.
    When the module determines the status of the above items, the module will apply the appropriate signal to the PWM pressure control solenoid, thereby controlling the application of the required clutch(s) depending on the driver's selection.

    Controlling transmission apply pressures allows the transmission to engage in a smooth manner, thus reducing the potential of abrupt/harsh engagement of the transmission.

    All of the above actions happen very quickly; however, the resultant time interval may be approximately one second.

    When determining if shift times are excessive, the exact conditions that the vehicle was in at the time the extended garage shift occurred must be duplicated. The following are several possible conditions.

    Was the vehicle outside or in a heated garage?
    What was the temperature of the environment at the time of the occurrence?
    Length of time the vehicle sat unused, such as overnight or a weekend, etc.? A vehicle that has been driven to the service facility cannot be tested for this concern because the transmission, the engine oil and the coolant are no longer at the temperature they were when the customer experienced the condition.
    No attempts to repair should occur unless the condition can be duplicated under the conditions the customer experienced.

    Road test the vehicle following the steps below until the vehicle engine and transmission temperatures are at normal operating temperatures. This is approximately 16 km (10 mi) of driving.

    In a safe manner, bring the vehicle to a complete stop.
    Place the shift lever in Neutral and wait five seconds.
    Place the shift lever in Drive. A delayed engagement of approximately one (1) second will occur. THIS IS NORMAL. This time may be extended if the engine RPM is above the base idle, controlled by the driver's foot rather than the control module.
    Drive the vehicle for a distance of not less than a tenth of a mile (160 m).
    In a safe manner, bring the vehicle to a complete stop.
    Place the shift lever in Neutral and wait five seconds.
    Place the shift lever in Reverse. A delayed engagement of approximately one (1) second will occur. THIS IS NORMAL. This time may be extended if the engine RPM is above the base idle, controlled by the driver's foot rather than the control module.
    Place the shift lever in Neutral and wait five seconds.
    Place the shift lever in Drive. A delayed engagement of approximately one (1) second will occur. THIS IS NORMAL. This time may be extended if the engine RPM is above the base idle, controlled by the driver's foot rather than the control module.
    If an out of line condition (excessively long time, over two seconds, to engage a gear) is observed, the following areas within the transmission should be inspected for the cause of the concern.

    The forward clutch piston seals (delay to drive).
    The low and reverse clutch piston seals (delay to reverse).
    The reverse input clutch piston seals (delay to reverse).
    The stator shaft to reverse input drum seals (delay to reverse).

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    Info - Engagement Time of Electronically Controlled Transmissions in General Motors Vehicles (Garage Shifts, Park to Reverse, Neutral to Drive, Neutral to Reverse, Park to Drive, Delayed Engagement) #03-07-30-007A - (Nov 4, 2003)
    Engagement Time of Electronically Controlled Transmissions in General Motors Vehicles (Garage Shifts, Park to Reverse, Neutral to Drive, Neutral to Reverse, Park to Drive, Delayed Engagement)
    2000-2002 Chevrolet Camaro

    2000-2004 Chevrolet Corvette

    2000-2002 Pontiac Firebird

    2004 Pontiac GTO

    2000-2004 All Light Duty Trucks

    2003-2004 HUMMER H2

    with 4L60-E (RPO M30) or 4L65-E (RPO M32) Automatic Transmission

    This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 03-07-30-007 (Section 07 - Transmission/Transaxle).

    Park/Neutral to Reverse or Drive (commonly called garage shift) engagement times may be different from what many customers might be accustomed to, especially if they have recently traded for a General Motors' vehicle.

    Normal Park/Neutral to Reverse or Drive engagement time will be in the vicinity of one (1) second if the automatic transmission fluid (ATF) is above 0C (32F) . When the ATF is colder than 0C (32F), the engagement time will become longer the colder the transmission fluid. A time limit factor cannot be placed on proper engagement times because the factors that affect transmission operation are many.

    At the moment of engine start, for economy and emission requirements, the transmission line pressure is maintained at low levels. This allows a lower cold idle engine RPM (the colder the oil is, the higher the energy level (engine torque output) required to pressurize the oil).

    When the driver moves the shift lever from "Park/Neutral" to "Reverse" or any "Drive" range, the following actions must occur for the powertrain control module (PCM) to determine at what pressure to control the transmission line pressure.

    The module will look at the following items:

    The voltage readings of the engine coolant temperature sensor (ECT).
    The voltage reading of the transmission fluid temperature sensor (TFT).
    Whether or not air conditioning is requested.
    Movement of the shift lever and controls engine RPM based on the gear position selected. The module will adjust the engine RPM in response to the torque requirements needed to increase transmission line pressure.
    When the module determines the status of the above items, the module will apply the appropriate signal to the PWM pressure control solenoid, thereby controlling the application of the required clutch(s) depending on the driver's selection.

    Controlling transmission apply pressures allows the transmission to engage in a smooth manner, thus reducing the potential of abrupt/harsh engagement of the transmission.

    All of the above actions happen very quickly; however, the resultant time interval may be approximately one second.

    When determining if shift times are excessive, the exact conditions that the vehicle was in at the time the extended garage shift occurred must be duplicated. The following are several possible conditions.

    Was the vehicle outside or in a heated garage?
    What was the temperature of the environment at the time of the occurrence?
    Length of time the vehicle sat unused, such as overnight or a weekend, etc.? A vehicle that has been driven to the service facility cannot be tested for this concern because the transmission, the engine oil and the coolant are no longer at the temperature they were when the customer experienced the condition.
    No attempts to repair should occur unless the condition can be duplicated under the conditions the customer experienced.

    Road test the vehicle following the steps below until the vehicle engine and transmission temperatures are at normal operating temperatures. This is approximately 16 km (10 mi) of driving.

    In a safe manner, bring the vehicle to a complete stop.
    Place the shift lever in Neutral and wait five seconds.
    Place the shift lever in Drive. A delayed engagement of approximately one (1) second will occur. THIS IS NORMAL. This time may be extended if the engine RPM is above the base idle, controlled by the driver's foot rather than the control module.
    Drive the vehicle for a distance of not less than a tenth of a mile (160 m).
    In a safe manner, bring the vehicle to a complete stop.
    Place the shift lever in Neutral and wait five seconds.
    Place the shift lever in Reverse. A delayed engagement of approximately one (1) second will occur. THIS IS NORMAL. This time may be extended if the engine RPM is above the base idle, controlled by the driver's foot rather than the control module.
    Place the shift lever in Neutral and wait five seconds.
    Place the shift lever in Drive. A delayed engagement of approximately one (1) second will occur. THIS IS NORMAL. This time may be extended if the engine RPM is above the base idle, controlled by the driver's foot rather than the control module.
    If an out of line condition (excessively long time, over two seconds, to engage a gear) is observed, the following areas within the transmission should be inspected for the cause of the concern.

    The forward clutch piston seals (delay to drive).
    The low and reverse clutch piston seals (delay to reverse).
    The reverse input clutch piston seals (delay to reverse).
    The stator shaft to reverse input drum seals (delay to reverse).

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    DTC P0757 Set, SES Lamp Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) #01-07-30-038B - (Jan 26, 2004)
    DTC P0757 Set, SES Lamp Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris)

    with 4L60-E/4L65-E Automatic Transmission (RPOs M30/M32)

    Condition
    Some customers may comment on any of the following conditions:

    The SES lamp is illuminated.
    No 3rd and 4th gear.
    The transmission does not shift correctly.
    The transmission feels like it shifts to Neutral or a loss of drive occurs.
    The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling.

    Cause
    The most likely cause is chips or debris plugging the bleed orifice of the 2-3 shift solenoid. This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded.

    DTC P0757 may also be set if the 2-3 shift valve or 2-3 shuttle valve were stuck, restricted and/or hung-up in its bore.

    Correction
    Inspect / Clean the 2-3 shift valve, the 2-3 shuttle valve and the valve bore of debris / metal chips.
    Inspect / Clean the 2-3 shift solenoid opening of debris / metal chips. While inspecting the 2-3 shift solenoid, look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid with P/N 10478131 that does have a screen over the solenoid opening.
    Refer to the appropriate Service Manual for additional diagnostic information and service procedures.

    Parts Information
    Part Number
    Description
    Qty

    10478131
    Valve, 2-3 Shift Solenoid
    1

    Parts are currently available from GMSPO.

    Info - Remote Keyless Entry (RKE) Normal Operating Characteristics #04-08-52-006 - (Jun 22, 2004)
    Remote Keyless Entry (RKE) Normal Operating Characteristics

    2004 Pontiac GTO

    This bulletin is being published to advise dealers of two normal operational characteristics of the RKE system that may lead customers to believe the system is faulty.

    In the first instance, if a driver exits the vehicle and locks it with the remote, and the passenger door is open, the vehicle will not lock. The horn will chirp three times to indicate that the doors are not properly locked and this warning signal will occur again on each successive press of the lock button on the key fob. To reset the system, press and hold the door unlock button for five seconds. Both doors can now be locked. In order to bypass this condition, the personalization settings must be changed. Refer to Vehicle Personalization in the Owner's Manual.

    The second issue is when the customer presses the lock and/or unlock button multiple times. This will cause the key fob to become out of sequence with the RKE receiver. When this occurs, the key fob will not operate until it is re-sequenced.

    In order to correct a key fob that is out-of-sequence, follow these steps:

    While seated in the vehicle, press and hold the unlock button on the key fob.
    While still pressing the unlock key on the fob, insert the ignition key into the ignition switch and turn the key to the ON position.
    Once the Driver Information Center (DIC) cycles, release the unlock button.
    Turn the key to the OFF position and remove the key.
    The key fob should now operate both doors.

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    Information on Intermittent Loss of Radio Speakers/Sound When Played at Very High Volume - Normal Condition/Design Intent #04-08-44-002 - (Feb 3, 2004)
    Information on Intermittent Loss of Radio Speakers/Sound When Played At Very High Volume

    2004 Pontiac GTO

    Some customers may comment that the radio audio or speakers may turn off intermittently resulting in no sound. This may occur when the radio is played at very high or full volume for an extended period. The radio is designed to shut itself off to protect the amplifier from overheating under such severe usage. When the amplifier cools down, the radio will reset and function normally. This characteristic is NOT a failure of any component. Do not replace the radio for this condition; it is the designed and intended function of the protection circuit.

    Important
    This characteristic is NOT a failure of any component. Do not replace the radio for this condition, it is the designed and intended function of the protection circuit.

    Recommendation
    The radio has a built in function that limits distortion. Distortion is the main generator that causes heat buildup in the amplifier. This is a user selectable function that is accessible in the Personalization Programming Menu available through the I/P display. The Dynamic Distortion selection must be turned ON to activate this function. The Dynamic Distortion circuit will limit the radio volume and dynamic range to control distortion at high sound levels. The Dynamic Distortion feature will slightly limit volume and will reduce the heat generated in the amplifier, however, continued operation even with the Dynamic Distortion turned on can result in overheat and radio shut down. Refer to the Owner's Manual for specific instructions to enable this feature. Additionally, you should instruct your customer to keep the Dynamic Distortion feature ON.

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    Info - Pre-Delivery and Service Guide #03-00-89-041 - (Nov 19, 2003)
    PRE-DELIVERY AND SERVICE GUIDE
    2004 Pontiac GTO

    FLUIDS AND LUBRICANTS:
    Many of the fluids and lubricants specified for the GTO may differ from those used in other GM products. The following chart summarizes some of the most critical fluids/lubricants. Please refer to Service Manual (Document #1318760) and Owner manual for a complete list.

    Location
    Fluid/Lubricant
    Quantity

    Fuel
    Premium unleaded with a posted octane of 91 or higher
    18.5 gallons

    Engine Oil
    GM Goodwrench Motor Oil SAE 5W-30, GM P/N 12345610, or the equivalent engine oil SAE 5W-30 SJ ILSAC GF-3
    6.2 L (6.5 q) with filter change

    Engine Coolant
    A 50/50 mixture of water and GM Vehicle Care DEX-COOL Antifreeze, (GM6277M), GM P/N 12346290, or the equivalent DEX-COOL Antifreeze
    14.3L (15.1 q)

    Auto Trans Oil
    GM Goodwrench Automatic Transmission Fluid -- DEXRON III, GM P/N 12378470, or the equivalent DEXRON III Automatic Transmission Fluid
    5.0L (5.3 q) service refill

    Manual Trans Oil
    GM Goodwrench Automatic Transmission Fluid -- DEXRON III GM P/N 12378470, or the equivalent DEXRON III Automatic Transmission Fluid
    4.4L (4.6 q)

    Rear Axle
    GM Vehicle Care Synthetic Gear Oil GM P/N 89021809

    AND GM Vehicle Care Limited Slip Differential Friction Modifier GM P/N 89021958
    1.575L (1.664 q)

    0.025L (0.026 q)

    Brakes
    GM Vehicle Care Brake and Clutch Fluid Super DOT-4, GM P/N 88958860, or the equivalent DOT-4 brake fluid


    Power Steering
    GM Goodwrench Automatic Transmission Fluid -- DEXRON III, GM P/N 12378470, or the equivalent DEXRON III Automatic Transmission Fluid


    Wheel Nut Torque
    140 Nm (100 lb ft)

    SERVICE SUPPORT:

    Instrument Cluster
    Clusters are not repairable and must be replaced as an assembly. Should a new cluster be required, a replacement part should be ordered from AJR International Inc. AJR will send a pre-exchange unit to the dealership and the dealership will need to return the original cluster. AJR International Inc is located at:

    951 North Larch Ave.
    Elmhurst, IL 60126
    Ph: 800-232-3965 or 630-832-0222
    Fax: 630-832-0333

    Audio System
    Support for the audio system is handled through AJR International Inc. The audio system will be handled on an exchange basis. Use the contact information for AJR indicated above.

    BCM
    The vehicle Body Control Module has security data recorded during vehicle production. The radio PIN and ignition key code can be accessed from the BCM via the Tech 2.

    **QUALITY PRE-DELIVERY INSPECTION (PDI)**
    Performing a quality pre-delivery inspection is one of the most important functions your dealership can do for the customer. Most customers consider the condition of their new vehicle during delivery as a direct reflection of your dealership and your service department. A quality PDI is essential to improving a customer's perception of your dealership and increasing his/her satisfaction with their new vehicle.

    Paint Protection
    A plastic film known as [lsquo ]Rapguard[rsquo ] is applied to external horizontal painted surfaces to provide protection from ultra violet light, fallout and chemical attack from bird droppings etc. This covering is to be removed within 6 months of the vehicle build date.

    Underhood Transit Corrosion Protection
    This protection is provided by a urethane coating on all surfaces. This is colorless and does not need to be removed.

    Underbody Transit Corrosion Protection
    This is a light color spray wax which does not need to be removed, but should this require removal from visible components, dissolve by using " Prepsol" or a similar product.

    Loose Parts
    A "loose parts" package is provided in the vehicle trunk. This package includes the following components:

    Wheel nut caps and wheel covers
    Floor mats and retainers
    Spare ignition and glovebox compartment keys
    License plate attaching bracket and screws
    Security data card
    Wheel Nut Caps
    The wheel nut caps are NOT threaded. Push the wheel nut caps onto the wheel nuts. Use the wheel nut cap removal tool in order to remove the wheel nut caps. The wheel nut cap removal tool stores with the spare tire service equipment in the rear compartment.

    Customer Information CD
    This CD is shipped with the vehicle and is loaded into the audio CD player. It is important that the CD remain in the CD player until the customer removes it. The cover for the CD should remain in the glovebox. The CD should be explained to the customer during the delivery process.

    Security Data Card

    Important
    The security card includes security data relevant to the security of the vehicle, including radio PIN, key cutting codes and remote key reprogramming code. Please request that the owner keep this card in a safe place, preferably not in the vehicle.

    The vehicle security data card is shipped in the loose parts package in the vehicle trunk. It includes critical data for the vehicle including key codes, BCM Security Code, and radio PIN. This should be provided to the customer during the delivery process, and the customer advised to keep it in a safe place. The selling dealership must make a copy of the security card and retain a copy in the sales file. The security information is required any time the battery is disconnected, for instance, during vehicle servicing or repair, the radio PIN will need to be re-entered. The security card is of the same size as a credit card.

    Rapgard Removal

    Notice
    Rapgard may become brittle and difficult to remove if left on the painted surfaces for periods in excess of 6 months. If the vehicle is to be stored for a period greater than this, it is recommended that the Rapgard be removed or paint damage could occur.

    Under normal circumstances, the Rapgard film should easily peel away from the surface, and leaves no residue.

    Door Edge Protection
    The foam blocks are designed to protect the vehicle while in storage or on display. The foam blocks should not be removed until the vehicle is delivered to the owner.

    Interior Protection Removal
    Within 6 months of the vehicle build date, and prior to vehicle retail delivery, remove all of the components of the interior protection package.

    Brake Disc Protection Covers
    These impregnated paper covers which are fitted to the brake discs behind the wheels, can be removed by tearing them away from the brake disc area. There is no need to remove the wheels.
    Description of covers -- The covers are manufactured from a high strength plastic material with vapor emitting paper attached to the inner surface. They are designed to provide surface corrosion protection and are intended to prevent tearing during vehicle movement in shipping.

    License Plate Installation
    Certain State laws require the use of a front license plate. A front license plate bracket and instructions are supplied with every vehicle in the loose ship parts box in the trunk.

    Set Time Display on Radio

    To set the correct time, press the [lsquo ]Time[rsquo ] button on the radio to reveal time display. Hold for two seconds. The display will show [lsquo ]TIME ADJ[rsquo ] and the time will flash.
    To adjust hours, press SEEK/TRACK button.
    To adjust minutes, press the TUNE button.
    Front Suspension Chocks
    The chocks are fitted to both the front suspension springs to raise the suspension height during new vehicle shipment. These must be removed before the vehicle is driven on public roads. While the vehicle is on a hoist for the under body inspection, remove the front suspension chocks. Once the vehicle[rsquo ]s weight is removed from the wheels and the wheel is hanging, the chock can be grasped and twisted out for removal.

    Tire Pressure
    Tires are inflated to 60 psi at the Assembly Plant for transportation. This will also prevent flat spotting of tires when left in storage for prolonged periods, but is not suitable for normal driving. Ensure this pressure is maintained while the car is kept in storage. Deflate tires to pressures indicated on the placard on the rear face of the driver's side door prior to retail delivery.

    **PDI Checklist**


    Remove the paint film protection -- ensure door edge foam blocks remain in place

    Inspect the following contents of the "loose items" pack, and fit components to vehicle

    Wheel nut caps and wheel covers
    Floor mats and retainers
    Spare keys
    Security data card
    License plate bracket and screws

    Copy the security data card and retain security data in a safe place

    Remove all interior protection

    Remove the brake rotor protective covers

    Remove the front suspension shipping chocks

    Ensure customer information CD is in the audio CD player

    Set the clock time on the radio

    Set tire pressures.
    **Important**
    The maximum specifications are found on the tire placard located on the rear face of the driver's side door. For best ride quality, GM recommends the tire pressures be set to 30 psi.

    Inspect fluid levels. Add the following fluids if necessary:

    Coolant
    Engine Oil
    Brake Fluid
    Clutch Fluid
    Automatic Transmission Fluid
    Power Steering Fluid
    Windshield Washer Fluid

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    Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrumend Cluster Inoperative (Replace Ignition Switch) #01-07-30-002D - (Oct 19, 2004)
    Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Replace Ignition Switch)

    2004-2005 Pontiac GTO

    with 4L60-E or 4L65-E Automatic Transmission

    This bulletin is being revised to update model years, add additional models and 4L80/85 Transmission Information. Please discard Corporate Bulletin Number 01-07-30-002C (Section 07 -- Transmission/Transaxle).

    Condition
    Some customers may comment on one or more of the following conditions:

    The Malfunction Indicator Lamp (MIL) is ON.
    The transmission is defaulted to second gear (4L80/85-E).
    The transmission is defaulted to third gear (4L60/65-E).
    The instrument cluster is inoperative.
    Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle.

    Cause
    The most likely cause of this condition may be a loss of voltage to the transmission on circuit 1020. This loss of power may be caused by an open in the ignition switch. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system.

    Correction
    With the ignition switch in the RUN position, test for battery voltage at the appropriate fuse listed below.

    2004-2005
    Pontiac GTO
    AUTO TRANS

    If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. If battery voltage is not present at the fuse, replace the ignition switch using the Ignition Switch Replacement procedure in the Steering Wheel and Column sub-section of the applicable Service Manual. Refer to group number 2.188 of the parts catalog for part description and usage.

    If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse listed above is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections.

    Parts are currently available from GMSPO.

    Warranty Information
    For vehicles repaired under warranty, use:

    Labor Operation

    N2328
    Switch, Ignition Key/Key Warning - Replace
    Use published labor operation time

    N6630
    Wiring and/or Connector, Transmission – Repair

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