HARSH/ERRATIC SHIFTS/NO START IN FIRST-REPAIR ACTUATOR TERM.. Saturn Saturn 1993

For 1990-2009 cars

# HARSH/ERRATIC SHIFTS/NO START IN FIRST-REPAIR ACTUATOR TERM.

#### SUBJECT: Harsh/Erratic Shifts and/or Vehicle Does Not Start Out In First Gear From a Stop or Malfunction Indicator Lamp (SERVICE ENGINE SOON Telltale Lamp) Comes On Intermittently (Repair Transaxle Actuator Terminal)

Due to revisions in the affected model years, this bulletin supersedes bulletin 92-T-04, which should be discarded.

#### MODELS AFFECTED: 1991 -1994 Saturns equipped with Automatic Transaxles (MP6/MP7)

CONDITION: The transaxle may have harsh or erratic shifts or may not start out in first gear from a stop. In some cases, the malfunction indicator lamp (SERVICE ENGINE SOON telltale lamp) may come on intermittently or an actuator electrical flag is stored in the PCM/TC.

CAUSE: The transaxle actuator connector terminals may have been damaged during the manufacturing process causing the female terminal to have insufficient clamping ability.

CORRECTION: Remove transaxle actuator connector and visually inspect terminals for damage. If damage is not apparent, use a male terminal and check each female terminal in the connector.

#### PROCEDURE

#### NOTICE: To prevent damage to electrical components, always disconnect the battery ground cable before making any electrical repairs.

Perform the following steps:

1. Remove the 10 mm bolt from the transaxle top connector and carefully pull the connector up to a position for inspection of the terminals.

2. Using a male terminal, check each female terminal in the connector for damage. A small force should be felt when inserting the male terminal into the female terminal. As shown in the illustration, the top of the terminal should bend upwards into the connector cavity.

#### IMPORTANT: The difference in insertion force will be significant, between a good terminal and a bad terminal.

If no damage is found, install connector and refer to the "Automatic Transaxle Service Manual" for additional diagnostic procedures.

3. If terminal damage is found, proceed with the following:

a. Remove the air cleaner and battery to fully expose the connector.

b. Disconnect the wiring harness from the selector switch and bring the wiring harness upward to gain access for splicing.

#### IMPORTANT: The Saturn Electrical Kit SA9183Z must be used for splicing. For information on connector repair, refer to "Connector Repair Procedures" in the "Electrical Trouble Shooting Service Manual."

c. Using a new cut-lead connector kit (P/N 12116563), attach the first splice sleeve 25mm (1 in.) from the connector body. Next, start the second splice sleeve 13mm (1/2 in.) below the first splice sleeve. Continue to install the remaining splice sleeves 13mm (1/2 in.) apart until they are all attached to the new connector.

#### IMPORTANT: The wire splice sleeves must be staggered to prevent the wiring harness from becoming too large and contacting components in the immediate area.

d. Using the old connector as a guide, cut and splice each wire to the proper wire in the harness. Continue to match and splice the remaining wires.

4. After splicing and sealing all of the splice sleeves, install the connector wire cover, then wrap the wires and splice sleeves with electrical tape for protection.

5. Route the wiring harness and connect all the electrical connectors. Tighten the 10mm bolt to fasten the transaxle connector.

Torque: 2.5 N-m (22 lbs. in.)

6. Install the battery, battery shield and tighten bolts.

Torque: Battery - 17 N-m (62 lbs. in.)

Torque: Shield - 9 N-m (80 lbs. in.)

7. Install air inlet duct assembly.

Torque: 1.7 N-m (15 lbs. in.)

8. After the repair is complete, it is important the repair is verified before returning the vehicle to the customer. The vehicle must be driven so that each upshift and downshift is accomplished at least twice, and then the PCM/TC checked for diagnostic trouble codes and information flags. Not all faults will illuminate the indicator lamp and the memory must be checked using a Scan tool or by flashing codes.

PARTS REQUIREMENTS: 12116563 Connector Kit-Engine Wiring Harness. Transaxle Solenoid

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 Inspect terminals (Includes T9514 1.4 hrs replacement of transaxle actuator assembly)

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.