Remanufactured Automatic Transaxle (ATM) Program (96-40-015)

REMANUFACTURED AUTOMATIC TRANSAXLE (ATM) PROGRAM

TECHNICAL SERVICE BULLETIN

DESCRIPTION

The Remanufactured Automatic Transaxle Program has been updated. A new warranty policy allows for in-dealership repairs/replacements of the following components (additions to the previous allowable repairs are shown underlined):

• Axle seal leaks
• End clutch
• Front pump seal, O-ring and gaskets
• Kickdown servo
• Oil pan leaks
• Oil temperature sensor
• Pulse generator
• TCM and/or wiring
• Solenoids

However, if an internal ATM mechanical condition is diagnosed, remove and replace the ATM with a remanufactured unit. No internal disassembly of the ATM should be performed.

TRAINING

A new Automatic Transaxle Troubleshooting and Certification Course (# 451300) superseded previous classes in March, 1996. This class provides detailed instruction on how to properly diagnose, and when to repair or replace, an ATM. Regional approval is necessary when installing remanufactured units if your dealership does not currently employ a Technician who has attended this course.

AFFECTED MODELS

This program applies to all models except 1986 Excels.

SPECIAL SERVICE TOOLS

Your dealership must have on hand the following Special Service Tools/supplies:

• ATM Oil Cooler Flushing Tool, Kent-Moore part number J39463. Each remanufactured ATM comes with enough flushing fluid to service one vehicle. Additional flushing fluid may be purchased through your facing PDC, part number 00233-12100.
• Hyundai Automatic Transaxle Tester (Kent-Moore # J39853)
• HDS
• HDS Scan Tool (Kent-Moore # J41490)
• HDS Trans-Tech Module

DIAGNOSIS PROCEDURE

1. Service Advisor opens a Repair Order (RO) noting the customer's complaint. A road test by a Technician or Service Advisor may be necessary to verify the customer's description.
2. The Service Advisor carefully follows and completes the "ATM Diagnosis Questionnaire."
3. The Questionnaire and shop copy of the RO are dispatched to the Technician. (The remaining copies of the RO can be broken out and distributed according to established dealership procedures.)
4. Technician follows Diagnostic Flow Chart on the back of the Questionnaire to help complete the diagnosis of the ATM and to make a repair/replace decision.
5. If it is determined that a remanufactured unit must be ordered/installed, the technician must obtain the Service Manager's approval and signature on the Questionnaire.
6. If a remanufactured unit is necessary, the technician sends both the Questionnaire and RO to the Parts Department.
7. Parts Department orders remanufactured ATM from the facing PDC and retains RO and Questionnaire, filed by RO number.
8. Parts Department receives remanufactured ATM, shipped prepaid in a reusable box, and provides ATM, RO and Questionnaire to Technician.
   NOTE: Retain reusable box and use to return 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 to remanufacturing center
   • Bill of Lading
   • Installation Tips
9. Parts Department completes all required fields of information on the Core Return Checklist. Failure to do so will result in debit.
10. Technician completely drains all fluids, removes the ATM and torque converter from the vehicle.
    NOTE: Do not disassemble any part of the ATM.
11. Flush the transaxle Oil Cooler and hoses using the Oil Cooler Flusher (part number J39463) and Flushing Fluid (part number 00233-12100). (Flushing Fluid is shipped with each remanufactured ATM unit.)
12. Install the remanufactured ATM according to the appropriate Shop Manual. Fill the ATM fluid to the specified level using Genuine Hyundai ATF+ Type 7176.
13. Secure the removed torque converter to the removed ATM core using the torque converter retaining strap and bolts removed from the remanufactured ATM unit.
14. Install all plugs removed from the remanufactured ATM unit into the removed ATM unit before packaging to prevent residual fluid from leaking.
15. Place the Core Return Checklist into the plastic bag provided with the remanufactured ATM unit and close the envelope securely. Enclose all needed forms and ensure they are completed and fully filled out.
    NOTE: Failure to properly complete and/or return the ATM Core Checklist will result in a $50.00 reduction of the $1000.00 core credit and/or charge back of your warranty claim.
16. Place the removed ATM into the reusable shipping container provided with the remanufactured ATM (make sure that the ATM is seated in the proper direction); close lid and fasten retaining straps on the side of the container securely.
17. Using the address label provided with the remanufactured ATM unit, ship the removed ATM with the Core Return Checklist.
    NOTE: Dealership is not responsible for freight charges for returning the removed ATM to the remanufacturing center if the enclosed bill of lading is used and ATM is shipped via HMA approved carriers. DO NOT SUBMIT A WARRANTY CLAIM FOR THESE CHARGES.
    NOTE: Cores not received by the remanufacturing center within 15 days of the date the remanufactured unit was shipped by the PDC are subject to a reduction of the core deposit of up to $1000.00. Cores not returned within 60 days will NOT be accepted (at HMA's discretion) and the dealer will forfeit the $1000.00 core charge. See Core Return Checklist for details.
18. The bottom copy of the Core Return Checklist is retained in the dealership's Parts Department, filed by the repair order number indicated in the top right hand corner of the checklist.
19. The ATM Diagnosis Questionnaire must be attached/retained with the shop copy of the RO in the Dealership's VIN service files. Dealership must record the removed and remanufactured ATM serial numbers on the shop copy of the RO.
20. Remanufacturing center receives the removed ATM and Core Return Checklist.
21. Remanufacturing center checks documents and sends forms to HMA.
22. Dealer is reimbursed for core ATM.
    NOTE: Second and subsequent ATM reman replacements on the same VIN will require Regional approval/authorization prior to performance of the repair.
    NOTE: HMA may deny/chargeback all or portions of ATM claims and/or core credits on remanufactured units if:

    • Cooler not properly flushed, causing remanufactured ATM to fail
    • Remanufactured ATM damaged due to:
      • Abuse
      • Improper installation/removal
      • Improper packaging
    • No trouble found/incorrect diagnosis
    • Comeback repair/incorrect diagnosis
    • Incomplete Core Return Checklist
    NOTE: Lost packaging and paperwork must be ordered through the PDC at the dealer's expense.
    NOTE: Dealer Parts Department accepts full responsibility for insuring that transaxles sold over the counter:

    • Have an ATM Diagnosis Questionnaire that is completely and accurately filled out
    • That the ATM cooler is flushed to HMA specifications using the proper Special Service Tool and fluid
    • Genuine Hyundai Transmission fluid (ATF+ Type 7176) is used to refill the ATM
    • All time limitations related to the return of the core remain in full effect

WARRANTY INFORMATION

Op. Code	Operation Description	Op. Time	Op. QTY.	Causal Part	Nature/Cause Codes
45000R00	Replace automatic transaxle assembly and torque converter	Current labor time standard (LTS) hours apply	1	Part number of reman ATM installed	Applicable nature/cause codes
45000RTM	*Flush oil cooler and lines, basic diagnosis, admin work	0.8	1

** 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, Scan Tool, and/or HDS.

Op. Code	Operation Description	Op. Time	Op. QTY.	Causal Part	Nature/Cause Codes
45000RP0	Perform scan tool/ATM tester	0.4	1	-	-
45000RW0	Perform HDS	0.5 - 0.9 (See LTS)	1

* The ATM oil cooler and hoses must be flushed prior to installation of the replacement remanufactured ATM. If thorough flushing is not performed, the remanufactured ATM can be contaminated by residue left in the cooler and hoses, resulting in shop comebacks and possible claim chargeback.

** Diagnostic before and after readings/measurements must be recorded on the ATM Diagnosis Questionnaire whenever the ATM Tester, Scan Tool, or HDS is used. The Questionnaire must be retained with the shop copy of the RO. In addition, if the HDS is used, a printout of the readings must also be retained with the shop copy of the RO.