M/T - Whine Noise in 3rd Gear Only

BULLETIN NO.: 99-T-19

ISSUE DATE: July, 1999

GROUP/SEQ. NO.: Transaxle - 04

CORPORATION NO.: 99-07-29-002

SUBJECT:
Manual Transaxle Whine Noise in 3rd Gear Only Between 2500-4000 RPM (Replace 3rd Drive Gear)

MODELS AFFECTED:
1999 Saturn S-Series vehicles equipped with MP2 manual transaxles built up to and including VIN XZ284995

CONDITION:

Customers may comment about an excessive whine noise or a "turbine-like" noise in 3rd gear only. The noise is present at about 2500 rpm and increases in pitch or sharpness as engine rpm reaches 4000 rpm.

CAUSE:
Improperly machined gear surface on the 3rd drive gear.

CORRECTION:
Disassemble transaxle and replace 3rd drive gear assembly (P/N 21120332).

PROCEDURE:

1. Verify that VIN is less than or equal to XZ284995.

2. Drive the vehicle to verify transaxle noise increases in pitch and/or produces a "turbine-like" noise that is prominent in 3rd gear between 2500-4000 rpm as described above.

^ If the whine noise is present in other gears besides 3rd gear, refer to the Diagnostics section of the 98-99 Manual Transaxle Service Manual.

^ If the whine noise is present in 3rd gear only, continue with step 3.

3. Remove transaxle from vehicle. (Refer to "Transaxle Removal" procedure in the Out-Vehicle Service section of the 98-99 Manual Transaxle Service Manual.)

4. Remove input and output shafts from transaxle. (Refer to "Transaxle Disassembly" procedure in the Out-Vehicle Service section of the 98-99 Manual Transaxle Service Manual.)

5. Disassemble input shaft. (Refer to "Input Shaft Disassembly" procedure in the Out-Vehicle Service section of the 98-99 Manual Transaxle Service Manual.)

6. Remove 3rd drive gear assembly from input shaft.

7. Obtain replacement 3rd drive gear assembly (P/N 21120332) and install on input shaft.

8. Assemble input shaft. (Refer to "Input Shaft Assembly" procedure in the Out-Vehicle Service section of the 98-99 Manual Transaxle Service Manual.)

9. Install input and output shafts in transaxle. (Refer to "Transaxle - Assembly" procedures in the Out-Vehicle Service section of the 98-99 Manual Transaxle Service Manual.)

10. Install transaxle into vehicle. (Refer to "Transaxle Installation" procedure in the Out-Vehicle Service section of the 98-99 Manual Transaxle Service Manual.)

11. Drive vehicle to verify that condition has been repaired.

PARTS REQUIREMENTS:

21120332 Gear Asm-3rd drive





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