INTERMITTENT GEAR HOP-OUT MEASURE SHIFT CONTROL HOUSING. Saturn Saturn 1992

For 1990-2009 cars

# INTERMITTENT GEAR HOP-OUT MEASURE SHIFT CONTROL HOUSING

#### SUBJECT: Intermittent Gear Hop-Out (Measure Shift Control Housing for Correct Shift Paddle Travel)

#### MODELS AFFECTED: All 1991 and 1992 Saturns with MP2/MP3 manual transaxles.

#### CONDITION:

Transaxle may intermittently hop-out of any gear under normal driving conditions.

#### CAUSE:

Condition could be caused by the owner not fully shifting into gear or by insufficient travel of the shift paddle on the shift control housing.

CORRECTIVE ACTION: Test drive the vehicle to verify the condition. If the condition is not verified, review proper shifting procedures with the owner and return the vehicle.

If the condition is verified, remove the shift control housing and measure for proper shift paddle travel with the enclosed shift housing gage. Note: The gage tool does not have a service tool number; however, it is stamped with "SHFT HSG GAGE" for identification and should be stored in Tool Storage Location 4.

#### PROCEDURE:

Test drive the vehicle, simulating the conditions the owner stated the hop-out occurred. If the hop-out condition is not verified, proceed to "Proper Shifting Procedure" in this bulletin.

If the hop-out condition is verified, proceed to the "Shift Paddle Measuring Procedure" in this bulletin.

Proper Shifting Procedure

Review the following shifting procedures with the owner:

1. Press the clutch pedal completely to the floor.

2. Move the gearshift lever into the desired gear until a hard stop is felt.

3. Slowly let up on the clutch while pressing on the accelerator pedal.

#### NOTE: There are two forces that will be felt when properly shifting into gear. The first is the force of synchronization which can vary in magnitude with speed. The second is the force developed from hitting the hard stop. Always move the gearshift lever to the hard stop to insure proper gear engagement. With proper gear engagement, the transaxle cannot be pulled out of gear under torque, either accelerating or decelerating, without releasing the clutch.

Shift Paddle Measuring Procedure

To check shift paddle travel, perform the following procedures.

Removal

1. Remove the shift control housing. Refer to "Shift Control Housing" in the "Manual Transaxle In-Vehicle Service" section of the "Manual Transaxle Service Manual."

Inspection

1. Move the shift lever on the shift control housing into the 3rd gear position.

#### NOTE: The shift pattern cast into the shift control housing indicates the direction the shift lever should be moved.

2. Place the shift control housing gage on the shift control housing. Align the shift housing gage with the shift interlock and shift paddle as shown.

#### NOTE: A shift control housing has enough shift pedal travel when the shift housing gage rocks on the shift paddle between the shift interlock (refer to Figure 1). If the shift housing gage sits against the shift interlock without rocking on the shift paddle (refer to Figure 1), the shift control housing does not have enough shift paddle travel and requires replacement.

3. Repeat the shift paddle measuring procedure in Step 2 with the shift lever moved into the 4th gear position.

#### NOTE: The shift control housing requires replacement if their is not enough travel in either direction. Before installing a new shift control housing, always check the shift paddle travel using the procedures provided. NOTE: In case the shift housing gage provided with this bulletin is misplaced or lost, another tool can be made from a rigid material such as aluminum, acrylic plastic, etc. Refer to Figure 2 for dimensions of shift housing gage tool.

Installation

1. Install the shift control housing. Refer to "Shift Control Housing" in the "Manual Transaxle In-Vehicle Service" section of the "Manual Transaxle Service Manual."

2. Test drive the vehicle to verify that condition has been repaired. If the hop-out problem continues to occur after the shift control housing has been replaced or the shift control housing paddle travel has been verified to be within specification, inspect the following components and repair as necessary.

#### NOTE: Refer to the appropriate section of the "Manual Transaxle Service Manual" for instructions on how to access, inspect, remove and install the following components.

o Shift Controls - Inspect the shift/cable and shifter assembly for free and unbinding operation.

Refer to procedures in the "Manual Transaxle In-Vehicle Service" section of the "Manual Transaxle Service Manual" and remove the console for access to the shifter assembly and the select cable end. Without removing the shifter assembly, remove the select cable end from the select lever bellcrank pin. If the rod end rotates more than 10 degrees after removing the cable from the select lever bellcrank pin, adjust the rod end using the following procedure.

#### NOTE: Do not bend the select cable pushrod when adjusting the rod end. If the select cable pushrod is damaged or bent, the shift/select cable must be replaced.

a. Using a pair of pliers, grip the select cable pushrod next to the plastic rod end. Using a 13mm or 1/2 in. open end wrench, rotate the rod end until it is aligned with the select lever bellcrank pin. Refer to Figure 3.

b. After checking the select cable rod end, if necessary, lubricate the shifter assembly pivot with white lithium grease and install the console. Refer to Figure 4.

c. Install console. Refer to procedures in the "Manual Transaxle In-Vehicle Service" section of the "Manual Transaxle Service Manual."

d. Make sure that the shift/select cables are routed correctly and not twisted. Verify that the shift/select cable retainers are properly installed at the shift control housing. If there is still binding, replace the shift/select cables and/or shifter assembly and check select cable rod end alignment.

#### NOTE: Binding of the shift/select cables and/or shifter assembly can also cause high-shift efforts.

o Internal Transaxle Components - Replace the synchronizer assembly and the shift fork on the affected gear. Make sure that the shift fork pads and bushings are properly installed. Also, replace the block rings if they show any indications of gouging or wear. Inspect the clutching teeth on the affected gear. The gear should be replaced if clutching teeth show any scoring, galling, cracks, rounded corners, or any signs of wear.

PARTS REQUIREMENTS: 21001360 1 - Housing Asm - Shift Cont 21001244 1 - Gasket - Shift Hsg Asm

#### NOTE: Refer to the "1991-1992 Parts Illustration Catalog" for the part numbers of additional parts, if required.

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 Housing Assembly and/or Gasket T9552 0.8 hrs Transaxle Shift R&R or Replace (includes time to inspect shift control housing

VW Select Cable Rod End Adjustment T9574 0.5 hrs (includes time to remove console, inspect and adjust select cable rod end)

#### NOTE: Refer to the "Labor Time Guide" for labor operation codes and times on any additional repairs, if required.

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.