Transaxle Gear Rattle Noise in Cold Ambient Temperatures

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



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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
Remove transaxle from vehicle. Refer to "Transmission Replacement" (SI Document ID #1386881).
Remove 5th gear synchronizer, Reverse idler gear and output shaft from transaxle. Refer to "Transaxle Disassemble" and follow procedure through step 37 (SI Document ID #1408030).
Install leaf springs between Reverse gear blocker ring and Reverse gear spring ring. Refer to "Reverse Idler Gear Disassemble" (SI Document ID #1408111) and "Reverse Idler Gear Assemble" (SI Document ID #1640966).
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. Refer to "Input Shaft Disassemble" (SI Document ID #1349208) and "Input Shaft Assemble" (SI Document ID #1640967).
Install leaf springs between the 5th gear blocking ring and the 5th gear synchronizer hub during transaxle assemble at step 42. Refer to "Transaxle Assemble" (SI Document ID #1349227) and follow procedure starting from step 9 through the end of the procedure.
Parts Information
Part Number
Description
Qty

90541193
Retainer-main shaft RR Bearing (O-ring)
1

55352125
Spacer 3rd and 4th Gear
1

90490868
Bearing Assembly - Input Shaft
1

90511077
Ring - Input Shaft Retainer
1

90490860 (Saab P/N)
Leaf Spring 3rd and 4th gears
6

12791537 (Saab P/N)
Leaf Spring 5th gear
3

90511081 (Saab P/N)
Spring Ring 5th gear
1

12791541 (Saab P/N)
Leaf Spring Reverse
3

90511116 (Saab P/N)
Spring Ring Reverse
1

90511224
Nut 5th Gear
1

21005993*

(in Canada, 10953466)
*Sealer - 515 Anaerobic or equivalent
see below*

21485278**

(in Canada, 10953480)
**Sealant - Teflon Pipe, Anaerobic or equivalent
see below**

#05-07-29-004: Transaxle Gear Rattle Noise in Cold Ambient Temperatures with Clutch Pedal Released (Up) at 1500-2500 RPM (Install Leaf Springs Between Blocker Ring/Synchronizer Hub for 3rd, 4th, 5th, Reverse Gears) - (May 18, 2005)

i believe this is what my car is doing, but gm says they won't warrenty it cause its a different transmission cause this is for two trannys in the car and my tranny code isn't one of them.

04_redline wrote:i believe this is what my car is doing, but gm says they won't warrenty it cause its a different transmission cause this is for two trannys in the car and my tranny code isn't one of them.

Print that out and take it to sherwood.

they pulled up the same thing. but my tranny vin number doesn't match the one that is on the two things. its a rank rattle. loud. and when i put my clutch in it goes away.

I had this done on my 04 redline.... I'd strongly advise against doing this after seeing how baffled the guys at Saturn were doing them. I can only imagine how great they would be at sherwood now. It took them a month to get it back together in that car.... Really wish I could just do my own warranty work.

did they do the exact same thing, they told me isn't under warranty and they couldn't hear the noise even thought i got power train until march 7/10 but they won't do anything about it, but i hear it daily, every time i start it. and its loud.

I took in the TSB cause they were denying everything.... Threw the printout down on the service desk and told them to take care of it. The shims made it harder to shift into 5th as well so I wouldnt advise doing it. It's not going to cause any damage if you don't.

is there any other way to get reid of it, like putting a different clutch in.