Transaxle Gear Rattle Noise in Cold Ambient Temperatures with Clutch Pedal Released (Up) at 1500-2500 RPM (Install Leaf Springs Between Blocker Ring/Synchronizer Hub for 3rd, 4th, 5th, Reverse Gears)
| Subject: | Transaxle Gear Rattle Noise in Cold Ambient Temperatures with Clutch Pedal Released (Up) at 1500-2500 RPM (Install Leaf Springs between Blocker Ring and Synchronizer Hub for 3rd, 4th, 5th and Reverse Gears) |
| Models: | 2004-2005 Saturn ION Red Line Vehicles with 5-speed Manual Transaxle (RPO MU3) |
| Built Prior To and Including VIN Breakpoint 5Z145882 |
| Attention: | Fixed Operations Manager and Technician |
Condition
Some customers may comment on a gear rattle type noise coming from the manual transaxle when engine speed is between 1500-2500 revolutions per minute (RPM) during the first 3 to 5 miles of driving. The rattle noise may be more pronounced after cold soak conditions with temperatures below 10° C (50° F) and may be misinterpreted as coming from the throw-out bearing.
Cause
The noise may be caused by the 3rd, 4th, 5th and/or Reverse gear blocker rings rattling within the transaxle. The transaxle and transaxle fluid temperature may also contribute to the rattling blocker rings.
Correction
To correct this condition, install leaf springs between the blocker rings and synchronizer hub on 3rd, 4th, 5th and Reverse gears. Follow the procedures in this bulletin and the referenced 2005 model year SI documents to complete this repair.
Service Procedure
- Remove transaxle from vehicle. Refer to "Transmission Replacement" (SI Document ID #1386881).
- Remove 5th gear synchronizer, Reverse idler gear and output shaft from transaxle. Refer to "Transaxle Disassemble" and follow procedure through step 37 (SI Document ID #1408030).
- Install leaf springs between Reverse gear blocker ring and Reverse gear spring ring. Refer to "Reverse Idler Gear Disassemble" (SI Document ID #1408111) and "Reverse Idler Gear Assemble" (SI Document ID #1640966).
- Install leaf springs between the 3rd gear blocking ring and the 3rd/4th synchronizer hub and between the 4th gear blocking ring and the 3rd/4th synchronizer hub. Refer to "Input Shaft Disassemble" (SI Document ID #1349208) and "Input Shaft Assemble" (SI Document ID #1640967).
- Install leaf springs between the 5th gear blocking ring and the 5th gear synchronizer hub during transaxle assemble at step 42. Refer to "Transaxle Assemble" (SI Document ID #1349227) and follow procedure starting from step 9 through the end of the procedure.
Parts Information
Part Number | Description | Qty |
|---|---|---|
90541193 | Retainer-main shaft RR Bearing (O-ring) | 1 |
55352125 | Spacer 3rd and 4th Gear | 1 |
90490868 | Bearing Assembly - Input Shaft | 1 |
90511077 | Ring - Input Shaft Retainer | 1 |
90490860 (Saab P/N) | Leaf Spring 3rd and 4th gears | 6 |
12791537 (Saab P/N) | Leaf Spring 5th gear | 3 |
90511081 (Saab P/N) | Spring Ring 5th gear | 1 |
12791541 (Saab P/N) | Leaf Spring Reverse | 3 |
90511116 (Saab P/N) | Spring Ring Reverse | 1 |
90511224 | Nut 5th Gear | 1 |
21005993* (in Canada, 10953466) | *Sealer - 515 Anaerobic or equivalent | see below* |
21485278** (in Canada, 10953480) | **Sealant - Teflon Pipe, Anaerobic or equivalent | see below** |
U.S. Retailers:
* 1 tube (10 mL) will service 1.5 vehicles; material allowance = $9.27 per vehicle
** 1 tube (50 mL) will service 10 vehicles; material allowance = $2.09 per vehicle
*** Total material allowance = $11.36 per vehicle
Canadian Retailers:
* 1 tube (6 ml) will service 1 vehicle; material allowance = $5.18 per vehicle
** 1 tube (50 ml) will service 10 vehicles; material allowance = $1.43 per vehicle
*** Total material allowance = $6.61 per vehicle
Claim Information
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for K3161 (Synchronizers, 3rd-4th - R&R or Replace). An add time of 0.2 hours to install leaf springs on reverse synchronizer is provided.
U.S. Retailers:
*** It will be necessary to sell these materials to the CSO as "material" using net item code "M". Claims received in the amount of $11.36 will be accepted. Claims exceeding the amount of $11.36 will be returned with return reason 143 - material amount greater than maximum allowed.
Canadian Retailers:
*** Applicable miscellaneous items, such as sealers and sealants, should be added to the part allowance amount and claimed in the Parts Cost column and not included in the Net Amount (DMN) column of the warranty claim.
