A/T - Temperature Sensor Fluid Leak

BULLETIN NO.: 02-T-07

ISSUE DATE: January, 2002

CATEGORY TYPE: Transaxle-01

CATEGORY: Automatic

CORPORATION NO.: 02-07-30-005

SUBJECT:
Automatic Transaxle Temperature Sensor Fluid Leak
(Replace Transaxle Temperature Sensor)

MODELS AFFECTED:

2002 Saturn S-Series equipped with MP6/MP7 automatic transaxles built between and including VINs 2Z115026 and 2Z135026

CONDITION:

Some customers may comment about an automatic transaxle fluid leak. Diagnosis may identify the leak to be coming from the automatic transaxle temperature sensor.

CAUSE:

Possible thread damage during assembly due to insufficient or improper application of thread sealer to temperature sensor threads.

CORRECTION:

Verify transaxle temperature sensor is the source of the fluid leak following the leak diagnosis procedure in this bulletin. Refer to "Leak Diagnosis Procedure" in this bulletin.





LEAK DIAGNOSIS PROCEDURE:

1. Clean any existing fluid off the transaxle case.

2. Add transaxle dye to automatic transaxle to verify source of leak. (Refer to the manufacturer's directions when using the kit.)

3. Pour the recommended amount of dye into the automatic transaxle.

4. Operate the vehicle under normal operating conditions ensuring that the transaxle fluid temperature reaches 180°F (82°C).

5. Direct the black light toward the automatic transaxle case (below the air cleaner). The dye will appear as a fluorescent green, emphasizing the leak path.

If the source of the leak is confirmed to be at the automatic transaxle temperature sensor and the vehicle was built between and including VINs 2Z115026 and 2Z135026, replace the transaxle temperature sensor following the "Temperature Sensor Installation Procedure" in this bulletin.

If the source of the leak is not the automatic transaxle temperature sensor, refer to "Fluid Leak Diagnosis" in the Automatic Transaxle System section of the 2002 S-Series Automatic Transaxle Service Manual.

TEMPERATURE SENSOR INSTALLATION PROCEDURE:

1. Apply sealant with Teflon(R) P/N 21485278 (or equivalent) to threads before installing on transaxle.

2. Install transaxle fluid temperature sensor P/N 21025106.

Torque:
Transaxle Fluid Temperature Sensor: 4-5 N.m (35-44 in-lbs)

IMPORTANT:
The installation torque in this bulletin is lower than previous publications. The reduction in torque is due to the presence of fluid and Teflon(R) sealer on the sensor threads during installation. The fluid and Teflon(R) reduce friction between the threads, therefore less torque is required for correct installation.

IMPORTANT:
When the temperature sensor is properly installed and torqued, there will be 2 - 3 threads visible on the sensor.





PARTS REQUIREMENTS:

CLAIM INFORMATION:





To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as shown.





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