A/T - No Shift/No Gear Engagement/MIL ON/DTC P0741
File in Section: 07 - Transmission/TransaxleBulletin No.: 03-07-30-023
Issue Date: November, 2003
TECHNICAL INFORMATION BULLETIN
Subject:
Vehicle Does Not Shift or Move After Running For a Period of Time
and/or Check Engine Light is ON and DTC P0741 is Set (Replace Torque
Converter, Valve Body, Clean Out Transaxle and Install New Flex Plate
Bolts and Washers)
Models Affected:
2002-2003 Saturn VUE Vehicles with Aisin AF33-5 Automatic Transaxle (RPOs M09 and M45)
Attention:
Fixed Operations Manager and Technician
Condition:
Some customers may comment that after the vehicle has run for a period of time, the vehicle may not shift or launch from a stopped position. The Check Engine Light may also be ON with DTC P0741 displayed on the Tech 2 Scan Tool.
Cause:
The transaxle may have been installed with a missing washer on the flex plate-to-torque converter bolt(s). The missing washer may allow the bolt to engage deeper than intended, which may cause damage to the torque converter clutch apply surface. This localized damage may cause the torque converter clutch friction material to overheat and generate debris resulting in an inoperative torque converter clutch and potential loss of fluid pressure as the sump filter becomes plugged with clutch fibers.
Correction:
Remove and disassemble transaxle, making sure to thoroughly clean out all visible debris. Flush transaxle oil cooler lines (refer to Bulletin 03-07-30-022 for oil cooler flushing procedure, which applies to all 2002-2003 Saturn VUE vehicles, regardless of transaxle in vehicle). Install new fluid filter, torque converter, transaxle oil cooler lines, control valve body, wiring harness, and flex plate bolts with washers.
Service Procedure:
1. Using Tech 2 Scan Tool, check and record codes.
2. Perform line pressure test using the "Line Pressure Test (AF33-5)" procedure in the 2002-2003 Saturn VUE Transaxle Service Manual, Vol.1.
^ If pressures are normal, run engine at idle for 10 minutes and recheck.
^ If pressures are normal after running engine at idle for 10 minutes, verify that condition stated in this bulletin is present.
- If condition is present and transaxle has normal pressures, follow the appropriate code diagnostics in the 2002-2003 Saturn VUE Transaxle Service Manual, Vol.1.
- If condition is not present and transaxle pressures are normal, follow code diagnostics for an intermittent condition.
^ If pressures are low, proceed to next step.
Caution:
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF unless instructed otherwise in these procedures. If there is potential for a tool or equipment to come into contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
3. Disconnect negative battery cable.
3.1. Record all of the customer's radio station presets.
3.2. Turn off all lamps and accessories.
3.3. Turn the ignition OFF.
3.4. Remove the battery ground (negative) cable and bolt from the battery.
4. Raise vehicle on a hoist. Refer to "Lifting and Jacking the Vehicle" procedure in the 2002-2003 Saturn VUE Service Manual, Vol.1.
5. Disconnect electrical connections to starter motor.
6. Remove starter motor.
6.1. Remove the B+ battery cable nut at starter.
6.2. Remove the S-terminal nut.
6.3. Remove the lower starter assembly to engine block bolt.
6.4. Remove the upper starter assembly to engine block bolt.
6.5. Move the starter right, clearing the engine block, then left and out of the engine block (flywheel housing).
7. Turn the crankshaft clockwise to gain access to the flex plate-to-torque converter bolts.
8. Inspect flex plate-to-torque converter bolts for the presence of a washer under the head of each bolt.
Notice:
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
^ If washers are present on bolts, tighten bolts and proceed to next step.
Tighten
Tighten flex plate-to-torque converter bolts to 60 N.m (44 ft-lbs).
^ If any washer is missing, remove the transaxle from vehicle. Refer to "Transaxle Removal (AF33-5)" procedure in the 2002-2003 Saturn VUE Transaxle Service Manual, Vol.1.
- Disassemble the transaxle and thoroughly clean out all debris. Refer to the appropriate procedures in the 2002-2003 Saturn VUE Transaxle Service Manual, Vol.1.
- Flush the transaxle oil cooler lines. Refer to Bulletin 03-07-30-022 for oil cooler flushing procedure.
- Install new pump filter, torque converter, transaxle oil cooler lines, and flex plate-to-torque converter bolts. Refer to the appropriate procedures in the 2002-2003 Saturn VUE Transaxle Service Manual, Vol.1.
- Disassemble and inspect the fluid pump and control valve body. Refer to the appropriate procedures in the 2002-2003 Saturn VUE Transaxle Service Manual, Vol.1. Replace necessary components if any damage to fluid pump or control valve body is present. If new control valve body (P/N 24226260) is installed, a new wiring harness (P/N 24226258) must be used.
- Install transaxle in vehicle. Refer to "Transaxle Installation (AF3~5)" procedure in the 2002-2003 Saturn VUE Transaxle Service Manual, Vol.1.
9. Install starter motor and tighten starter motor bolts.
Tighten
Tighten starter-to-engine bolts to 40 N.m (30 ft-lbs).
10. Install starter motor electrical connectors.
10.1. Install the B+ cable and nut.
Tighten
Tighten B+ cable-to-starter nut to 10 N.m (89 in-lbs).
10.2. Install the S-terminal wire and nut.
Tighten
Tighten the S-terminal nut to 5 N.m (44 in-lbs).
11. Lower vehicle.
Important:
Clean any existing corrosion from the battery terminal bolt flange and the battery cable end.
12. Connect negative battery cable.
12.1. Install the battery ground (negative) cable and bolt to the battery.
Tighten
Tighten battery terminal bolt to 17 N.m (13 ft-lbs).
12.2. Program all of the customer's radio station presets and set the radio clock to the current time.
13. Proceed to standard transaxle diagnostics.
Parts Information:
Important:
If new control valve body (P/N 24226260) is installed, a new wiring harness (P/N 24226258) must be used.
Claim Information:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:
^ For vehicles that have normal pressure readings, and the condition is or is not present:
Claim K6400 (Oil Pressure Test), and relate any diagnostics and/or labor operations for replaced parts.
^ For vehicles that have low pressure readings, but all flex plate washers are present:
Claim K6400 (Oil Pressure Test) and J4640 (Motor Assembly, Starter - R&R or Replace). An "add time" condition is provided to inspect flex plate bolts and washers. Relate any further diagnostics and/or labor operations for replaced parts.
^ For vehicles that have to be repaired due to missing flex plate washer(s):
K7800 (Transaxie Case - R&R or Replace).
An "add time" condition is provided to check transaxle line pressure testing.
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