M/T - Hops Out of 5TH Gear: Overview

91saturn03

NO.: 91-T-33

DATE: September, 1991

GROUP: Transaxle

CORP. NO.: 187203R


SUBJECT: Transaxle Hops out of 5th Gear (Replace Shift Control Housing, 5th/Reverse Fork Retainers and/or 5th/Reverse Synchronizer) All 1991 Saturns with MP2/MP3 Manual Transaxles


CONDITION: With the manual transaxle in 5th gear, the transaxle may occasionally hop out of gear.


CAUSE: This condition is caused by the 5th gear synchronizer sleeve lock notches not fully engaging the 5th drive gear clutching teeth due to:

^ The shift control housing does not provide adequate shift fork movement.

^ The 5th gear synchronizer sleeve with scalloped lock notches require more fork travel than a sleeve with square notches.

^ The 5th/Reverse fork retainer (when used with the current shift shaft, P/N 21001086) reduces fork movement.