Low Speed Grind Noise and/or Hesitation While Driving (Install New Transmission Control Module (TCM) Calibration and Add New Transmission Fluid and Additive)

Condition #1: Some customers may comment on a low speed grind noise that occurs at approximately 5-12 mph (8-19 km/h) during a vehicle coast down, during which the driver’s foot is off the accelerator. The customer may hear the same noise, for a short duration, when lightly applying the accelerator pedal within the same vehicle speed range.

Condition #2: Some customers may comment that while driving on rough or slippery road surfaces such as bumps, railroad tracks, or while turning a corner, the maneuver may result in vehicle hesitation.

Cause #1: The belt drive system is commanded to a ratio that causes a unique load on the drive belt, which generates belt noise during vehicle coast down and light pedal apply transitions.

Cause #2: A fluctuating wheel speed may be recognized by the TCM as wheel slip. The TCM may inadvertently invoke a protection algorithm to minimize the wheel slip and result in a temporary lack of power or perceived hesitation.

Install the appropriate new TCM calibration (refer to Calibration Information table in this bulletin). Drain and re-fill transaxle fluid two times using DEX-CVT® fluid, P/N 15250985 - gallon, P/N 15234609 - quart. After the second consecutive drain and fill, add one unit (10 mL [0.33 fluid oz] syringe) of DEX-CVT® additive, P/N 15231847.

The new calibration will not correct a grinding noise condition unless the new DEX-CVT® Fluid, P/N 15234609, and additive, P/N 15231847, is incorporated in the repair process.

1. Determine current TCM calibration I.D. number.

1.1.	Connect Tech 2® scan tool to the vehicle.

1.2.	Navigate to the 2.2L (VIN F) Powertrain Menu.

1.3.	Select ID information.

1.4.	Select TRANSMISSION INFORMATION.

1.5.	Read Calibration I.D. and record this number for use in step 3.

Important: Before installing new TCM calibration, make sure the Saturn Service Stall System (SSS) version is TIS 2.5 2005 or later.

2. Program the TCM with new calibration. Refer to the calibration information table in this bulletin and select the appropriate TCM calibration for the application. Use Saturn Service Stall (SSS) software release TIS 2.5 2005 or higher data CD. For reprogramming procedures, refer to the Service Programming System (SPS) in the SSS Users Guide.
3. Raise and support the vehicle. Refer to "Lifting and Jacking the Vehicle" in the General Information section of the appropriate Service Manual or SI (SI Document ID #878849).
4. Drain and fill transaxle. Refer to steps 5-14 in this bulletin.



5. Vehicle transaxle fluid should be above ambient air temperatures after performing step 2 of service procedure. With transaxle fluid temperature above ambient air temperature, remove the lower tube assembly from the transmission. Refer to illustration. Allow the fluid to completely drain. A normal amount of fluid drained in this manner should be approximately 3.79 L (4.0 qt, 1 gal).
6. Install the lower tube assembly and add approximately 3.79 L (4.0 qt, 1 gal) of new fluid, P/N 15250985 - gallon, P/N 15234609 - quart, to the transmission.

Important: If vehicle is equipped with traction control, turn traction control off.

7. Start the vehicle and perform the following drive cycle on the hoist. The drive cycle will ensure that the added fluid is properly circulated throughout the transmission.

7.1.	Operate the vehicle in REVERSE (R) at 30 mph (48 km/h) for 15 seconds.

7.2.	Operate the vehicle in DRIVE (D) at 60 mph (97 km/h) for 15 seconds.

7.3.	Operate the vehicle in REVERSE (R) at 30 mph (48 km/h) for 15 seconds.

7.4.	Operate the vehicle in DRIVE (D) at 60 mph (97 km/h) for 15 seconds.





Important: The method of draining and filling the transmission fluid a total of 2 times, and performing a drive cycle in between, helps to ensure that the majority of residual factory fill DEX-CVT® fluid in the transaxle will be removed.

8. Remove the lower tube assembly from the transmission and allow the fluid to completely drain. Refer to illustration.
9. Install the lower tube assembly, ensuring all residual transaxle fluid is cleaned from surrounding area.

Tighten
Tighten the lower tube assembly to 20 N·m (15 lb-ft).

10. Temporarily install the original lower tube assembly drain plug. Do not tighten.
11. Add approximately 3.79 L (4.0 qt, 1 gal) of new fluid, P/N 15250985 - gallon, P/N 15234609 - quart, to the transmission.
12. Lower vehicle. Refer to "Lifting and Jacking the Vehicle" in the General Information section of the appropriate Service Manual or SI (SI Document ID #878849).
13. Connect Tech 2® scan tool to vehicle.
14. With the vehicle on a flat and level surface, start the vehicle and circulate the fluid through the transmission using the following procedure:

14.1.

With the brake applied, shift the transmission into REVERSE (R) for 10 seconds.

14.2.

Shift the transmission into DRIVE (D) for 10 seconds.

14.3.

Shift the transmission into PARK (P), allowing the engine to remain running.

15. Raise and support the vehicle. Refer to "Lifting and Jacking the Vehicle" in the General Information section of the appropriate Service Manual or SI (SI Document ID #878849).
16. Remove the lower tube assembly drain plug. If plug is damaged in any way, discard plug.
17. Perform the following procedure to assure proper fluid level:

•	If the fluid drains down at a steady stream from the opening, allow the fluid to drain until it stops.

•	If no fluid or a very small amount of fluid drains, add fluid to the transmission until a steady stream starts to drain. Stop adding fluid immediately. Allow the fluid to drain until it stops.

18. Install lower tube assembly drain plug, P/N 24220892, and clean any excess fluid from the transmission. Use a new plug if original plug is damaged in any way.

Tighten
Tighten the plug to 11 N·m (97 lb-in).

19. Lower the vehicle. Refer to "Lifting and Jacking the Vehicle" in the General Information section of the appropriate Service Manual or SI (SI Document ID #878849).

Important: Do not remove the lower tube assembly drain plug.

20. With the Tech 2® scan tool, record the TRANS FLUID TEMP.

•	If the TRANS FLUID TEMP is 20° C (68° F) or less, add 0.47 L (0.5 qt) of fluid to the transmission.

•	If the TRANS FLUID TEMP is between 20° C-40° C (68° F-104° F), add 0.71 L (0.75 qt) of fluid to the transmission.

•	If the TRANS FLUID TEMP is between 40° C-60° C (104° F-140° F), add 0.95 L (1.0 qt) of fluid to the transmission.

•	If the TRANS FLUID TEMP is between 60° C-80° C (140° F-176° F), add 1.2 L (1.25 qt) of fluid to the transmission.

21. Turn OFF the ignition.

Important: The additive, P/N 15231847, should only be injected directly into the transaxle. The use of a funnel may prevent some of the chemicals within the additive from reaching the transaxle.

22. Add DEX-CVT® additive, P/N 15231847, to the transmission using the provided applicator. Inject the entire contents into the transmission.
23. Verify repair. Drive the vehicle for 8 km (5 miles) to ensure new oil has blended with DEX-CVT® additive and confirm that customer concern has been eliminated.

Select the appropriate calibration from the table based on the application and VIN of the vehicle.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for K9504 (Transaxle Fluid Change and Reprogram TCM).