M/T - Gear Rattle Noise in Cold With Clutch Released
Bulletin No.: 05-07-29-004Date: May 18, 2005
TECHNICAL
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
1. Remove transaxle from vehicle.
2. Remove 5th gear synchronizer, Reverse idler gear and output shaft from transaxle.
3. Install leaf springs between Reverse gear blocker ring and Reverse gear spring ring.
4. 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.
5. Install leaf springs between the 5th gear blocking ring and the 5th gear synchronizer hub during transaxle assemble at step 42.
Parts Information
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.
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