TRANS HOPS OUT OF 5TH GEAR REPLACE SHIFT CONTROL HOUSING. Saturn Saturn 1991

For 1990-2009 cars

# TRANS HOPS OUT OF 5TH GEAR REPLACE SHIFT CONTROL HOUSING

#### 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:

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

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

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

#### CORRECTIVE ACTION:

Determine the vehicle identification number (VIN) and refer to the following chart before proceeding to the procedures in this bulletin.

#### PROCEDURES:

------------

#### SHIFT CONTROL HOUSING

Removal

#### CAUTION:

THE NEGATIVE TERMINAL MUST BE DISCONNECTED FIRST TO PREVENT ARCING WHEN REMOVING THE POSITIVE CABLE.

1. Disconnect battery terminals. 2. Remove battery shield. 3. Remove battery. 4. Remove battery tray.

#### IMPORTANT: Two bolts are located in the fender well.

5. Disconnect back-up light electrical connector. 6. Place transaxle in neutral. 7. Remove shift control housing retaining bolts.

Installation

1. Clean gasket surfaces and install the shift housing gasket to case. 2. Install the shifter housing assembly on case.

#### NOTICE: Clean and lubricate fastener with ATF (DEXRON-II or equivalent). Wipe off excess fluid and install.

Torque: 28 N.m (21 lbs. in.)

#### NOTICE: Make sure the shift housing is completely down on case before installing bolts. Torquing bolts on a misaligned housing will damage the case.

3. Connect back-up light switch electrical connector. 4. Install battery tray. 5. Torque battery tray bolts. Torque: 7 N.m (62 lbs. in.) 6. Install battery. 7. Install battery shield. 8. Torque battery shield bolts. Torque: 7 N.m (62 lbs. in.)

#### CAUTION:

THE POSITIVE TERMINAL MUST BE CONNECTED FIRST TO PREVENT ARCING.

9. Connect battery terminals.

#### 5TH GEAR AND 5TH REVERSE SYNCHRONIZER

Removal and Inspection

#### CAUTION:

MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

1. Position car on hoist. 2. Place transaxle in any gear except 5th or reverse. 3. Raise car. 4. Remove driver's side wheel. 5. Drain transaxle fluid. 6. Remove left inner splash shield. 7. Remove rear cover bolts and rear cover, and discard gasket. 8. Remove 5th/Reverse fork retainer(s) and push the fork forward to engage 5th gear with the synchronizer sleeve to lock transaxle into two gears. 9. Remove the input shaft nut. 10. Remove the reverse cone, thrust washer and blocking ring. 11. Remove the 5th/Reverse synchronizer and fork as an assembly. Inspect the notches in the lock notches in the synchronizer sleeve. If notches are square-cut as shown in Figure A at the beginning of the bulletin, the synchronizer can be re-installed. If the lock notches are not square, replace the synchronizer assembly.

#### NOTICE: Synchronizer hubs and sleeves must be kept together as matched sets. Hubs and sleeves are etched to show proper alignment.

#### 5TH GEAR AND 5TH REVERSE SYNCHRONIZER INSTALLATION

1. Install the 5th gear synchronizer blocker ring to 5th gear. 2. Install the 5th gear synchronizer spring to 5th synchronizer. 3. Slide the 5th/Reverse fork over the 5th/Reverse synchronizer sleeve and install the sleeve to the hub and fork to the shift fork shaft at the same time.

#### IMPORTANT: Always use new retainers.

4. Install the synchronizer spring to the reverse blocker and install the assembly to the 5th/Reverse sleeve. 5. Install the reverse cone and thrust washer. 6. Move 5th/Reverse fork and synchronizer sleeve to engage 5th gear to lock transaxle into two gears at the same time. 7. Install shaft nut and torque.

#### IMPORTANT: Make sure that the threads on the shaft are clean and free of oil. A wire brush may be used to clean the threads of the shaft.

Torque: 150 N-m (110 lbs. ft.)

8. Unlock the shafts by moving 5th fork to the neutral gate. 9. Install the 5th/Reverse fork retaining rings using P/N 21120014. Two retainers are required. 10. Turn the reverse cone so one of the slots is facing the top of the transaxle (align cone to rear cover). 11. Install rear cover gasket.

#### NOTICE: Clean and lubricate fasteners with ATF (DEXRON-II or equivalent) wipe off excess fluid and install.

12. Install rear cover and install bolts and torque using a crisscross pattern.

Torque: 14 N.m (124 lbs. in.)

13. Install inner splash shield.

#### NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel lug nuts to loosen in service.

14. Position wheel onto hub. 15. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to be sure torque is correct.

Torque: 140 N.m (103 lbs. ft.)

16. Fill transaxle with fluid.

#### PARTS REQUIREMENTS:

21001360 1-Housing Asm-Shift Cont 21001244 1-Gasket-Shift Hsg Asm 21120014 2-Ring-5th/Rev Shift Fork Ret 21001375 1-Syncronizer Asm-5th/Rev Brk 21001232 1-Gasket-Rear Cover

#### CLAIM INFORMATION:

To receive credit for this repair, submit a claim through the Saturn Dealer System as follows: Labor Case Operation Type Description Code Time ----- -------------------------- ------- ------- VW 5th-Reverse Synchronizer R&R or K3160 1.0 hrs Replace

VW Housing Assembly and/or Gasket K2240 1.3 hrs Transaxle Shift R&R or Replace

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.