Recall - Shift Cable Retaining Clip Installation
SI M25 01 02Gear Shift Mechanism
August 2002
Service Engineering
This Service Information bulletin supersedes S.I. M25 01 02 dated July 2002.
PERFORM THE PROCEDURE OUTLINED IN THIS SERVICE INFORMATION ON ALL AFFECTED VEHICLES BEFORE CUSTOMER DELIVERY OR THE NEXT TIME THEY ARE IN THE SHOP FOR MAINTENANCE OR REPAIRS.
Under the National Traffic and Motor Vehicle Safety Act of 1966, as amended, if there has been a recall campaign, dealers must assure that all new vehicles and new items of replacement equipment are free of safety defects and comply with all applicable Federal Motor Vehicle Safety Standards at the time of delivery to the consumer. This means that dealers may not deliver new motor vehicles or new items of replacement equipment to consumers unless the safety defect or noncompliance has been remedied before delivery.
[NEW] designates changes to this revision
SUBJECT
[NEW] Recall Campaign No. 02V-201: Shift Cable Retaining Clip
MODEL
R50 Cooper with W10 engine and manual transmission
SITUATION
The potential defect involves the transmission shift cable. The cable connects the gearshift lever in the vehicle interior to the shift linkage on the transmission. It is possible, in some cases, for the shift cable to detach from the transmission shift linkage while the driver is attempting to change gears.
If the cable detaches from the shift linkage, gear changes will no longer be possible and the transmission will remain in the last gear selected. However, the engine will continue to run, the vehicle can still be steered and braked with power assist, and all electrical functions, including lighting, are retained.
If shift cable detachment occurs and the transmission remains in any forward gear, the vehicle can still be driven in that gear only. However, if the transmission moves into neutral and remains there, the vehicle would no longer have the ability to accelerate or maintain speed. Depending on traffic conditions and the driver's reactions, this could lead to a crash.
BMW is conducting a Recall Campaign to check the shift cable end and install a shift cable retaining clip.
The letter will be mailed to owners of affected vehicles.
While a repair is inconvenient for the customers, it is also an opportunity for you to ask them about their MINI motoring experience, answer questions about their cars, and show them the latest MINI accessories. Customers will be impressed when you return their cars cleaned inside and out and with a full tank of gas. Reimbursement information for the fueling costs can be found in the Warranty portion of this bulletin.
AFFECTED VEHICLES
[NEW] This Recall involves R50 Cooper vehicles with W10 engines and manual transmissions produced from 12/01 5/02.
[NEW] In order to determine if a specific vehicle is affected by this Recall, it will be necessary to utilize the "Service Menu" of the DCS (Dealer Communication System). Based on the response of the system, either proceed with the corrective action or take no further action.
The Chassis Number Ranges listed below are only for informational purposes and are not to be considered as the only deciding factor.
CORRECTION
Check and install a shift cable retaining clip and check and adjust the gap between the wiring harness and shift cable end, if necessary, on all affected vehicles.
PROCEDURE
1. Remove the vehicle battery and battery box as outlined in repair manual, group 61, section 61 21 020.
Note:
Ensure that the battery positive cable moves freely after installation of the battery box.
2. Check the transmission shift cable end (see arrow) mounted on the transmission shift lever.
3. If the shift cable end looks like illustration (1) without the inertia absorber, no further action is required. Reinstall the battery box and battery. If the shift cable end looks like illustration (2) with the inertia absorber, a shift cable retainer clip must be installed.
Installation of shift cable retainer clip:
4. Carefully unfasten the wire clip for shift cable housing (1) and remove the cable from the transmission bracket. Note: Wire clip should be reused. If wire clip is damaged upon removal, replace it with PN 25 11 7 515 461.
5. Remove the shift cable end (2) from the lever ball joint.
Note:
If the ball cup separates from the inertia absorber when removing the cable end from the ball joint, it should be reinserted into the inertia absorber (aligning as shown see arrows).
6. Before clip installation apply a thin coating of engine oil (1 drop) on the inertia absorber (1) and the retaining clip (2).
7. Install retaining clip on inertia absorber (steps 1 and 2 in illustration) and then reconnect the shift cable to the transmission shift lever ball joint (step 3).
Reinstall the shift cable housing on the transmission bracket assuring that the wire clip locks the cable housing securely into the bracket.
Check gap between the transmission shift cable (inertia end) and steering system wire harness:
8. With the transmission in second gear, check the gap (1) between the transmission shift cable (inertia end) and steering system wire harness. The gap (1) must be at least 10 mm. If the gap is 10 mm or greater no further action is required. Reinstall the battery box and battery.
9. If the gap described above is less than 10mm, readjust the steering system wire harness as follows:
^ Remove wire ties from harness (see arrows)
^ Shift wire harness until gap (1) shown above is at least 10 mm. Reattach the wire harness with new ties as shown.
Caution:
The wire harness must not come in contact with any sharp edges.
10. Reinstall the battery box and battery.
11. Fill up fuel tank.
PARTS INFORMATION
Orders for the following part numbers can only be placed using the vehicle VIN number. If the VIN is within the range indicated on DCS, the order will be released automatically. Please check your vehicle's VIN against the DCS before entering your orders. When placing your VIN specific order, please place the last seven digits of the YIN in the text field.
NON-VIN SPECIFIC ORDERS WILL BE CANCELLED. ORDERS FAXED IN TO DIRECT SHIPMENT WILL NOT BE ENTERED. IT IS THE DEALERS RESPONSIBILITY TO ENTER THE ORDERS THROUGH DCS WITH A VIN NUMBER.
LABEL INSTRUCTIONS
This Recall has been assigned code number 2. After the vehicle has been checked, and corrected if necessary, obtain a label (MD 20-013) and:
a. emboss your BMW dealer warranty number in the middle of the label (1);
b. punch out code number 2 printed on the label
and,
c. affix the label to the B pillar as shown.
If the vehicle already has a label from a previous Service Action/Recall Campaign, affix the new label next to the old one. Do not affix one label on top of another one because a number from an underlying label could appear in the punched-out hole of the new label.
WARRANTY INFORMATION
[NEW] Reimbursement for this Recall will be provided through Campaign Entry. Reimbursement for topping off the fuel tank will be provided through normal claim entry. See details listed below.
ATTACHMENTS
view PDF attachment M250102Letter.