For 1990-2009 cars

# Design Changes to the Automatic Transaxle Valvebody Cover Gasket, Valvebody Cover, Valvebody Cover Bolts and Transaxle Case

Subject: | Service Information on Design Changes to automatic Transaxle Valvebody Cover Gasket, Valvebody Cover, Valvebody Cover Bolts and Transaxle Case. Due to revisions in the VIN breakpoint and a printing error, this bulletin supercedes bulletins 96-T-42 and 96-T-42A, which should be discarded.

Models: | The following Saturns equipped with MP6/MP7 automatic transaxles:

| 1992 vehicles built between VINs NZ200100 and those built after VIN NZ205625

| 1993-1995 vehicles

| 1996 vehicles built before and including VIN TZ392191

### Purpose

The purpose of this bulletin is to provide service information on changes to the:

• | Valvebody cover

• | Valvebody cover gasket

• | Valvebody cover bolts

• | Transaxle case

A controlled compression valvebody cover gasket has been implemented on vehicles equipped with automatic transaxles to reduce the chance of transaxle fluid leaks at the valvebody cover-to-transaxle case joint. These gaskets are not designed to be reused, and must be replaced whenever cover and the transaxle case have also changed to allow the use of new gasket.

In this bulletin, new valvebody covers, valvebody cover gaskets, valvebody cover bolts and transaxle cases will be referred to as second design. Valvebody covers, valvebody cover gaskets, valvebody cover bolts and transaxle cases, built before and including VIN TZ392191, will be referred to as first design.

The new illustration at the top of this page, illustrate the differences between the first and second design valvebody cover gaskets. The transaxle case and valvebody cover have also been changed to reflect the reduction in fasteners.

The second design parts are not compatible with the first design parts. First design valvebody covers, valvebody gaskets and valvebody bolts will continue to be available for servicing vehicles listed under "Models Affected" in this bulletin. If a transaxle case requires replacement, only a second design transaxle case is available from Saturn service parts. When replacing a first design transaxle case, a second design valvebody cover, valvebody cover gasket and valvebody bolts must be used.

Important: 1991 vehicles, and 1992 vehicles not listed under "Models affected" in this bulletin, continue to be serviced with parts specific for these vehicles. Refer to Saturn Parts Catalog for correct part numbers.

Due to the differences between the first design and second design parts, when installing a second design valvebody cover, perform the following procedure.

Important: The following procedure is included in the "1997 Automatic Transaxle Service Manual."

1. Clean transaxle case and valvebody cover sealing surfaces with Saturn Brake Choke Cleaner (P/N 21007432) or equivalent with a clean shop towel.
2. Position valvebody cover gasket on to transaxle case.
3. Align valvebody cover gasket and transaxle case and install valvebody cover to transaxle case.

Notice: When installing the valvebody cover, it is important to clean and lubricate fasteners with Saturn Transaxle Fluid (or equivalent), or sufficient clamp load of the gasket will not be achieved.

4. Clean and lubricate transaxle cover bolts with Saturn Transaxle Fluid (or equivalent). Wipe off excess fluid and install valvebody cover bolts.
5. Torque transaxle cover bolts according to the torque sequence shown in the illustration.

Tighten
Torque 12 N·m (106 in lbs)

6. Re-torque valvebody cover bolts, using the torque sequence shown in illustration to account for gasket relaxation.

Tighten
Tighten nut to 12 N·m (106 in lbs)

### Parts Information

P/N | Description | Usage
21001683 | Gasket - C/VLV Body CVR | 1st Design
11508885 | Bolt - C/VLV Body CVR | 1st Design
21001584 | Cover - C/VLV Body | 1st Design
21003202 | Gasket -C/VLV Body CVR | 2nd Design
21006445 | Bolt - C/VLV Body CVR | 2nd Design (8 Required)
21003201 | Cover - C/VLV Body | 2nd Design
21003309 | Case - Automatic Transaxle | 2nd Design
21007432 | Cleaner - Brake and Choke | N/A