CAMPAIGN: AUTOMATIC TRANSAXLE VALVE BODY ASSEMBLY. Saturn Saturn 1992

For 1990-2009 cars

# CAMPAIGN: AUTOMATIC TRANSAXLE VALVE BODY ASSEMBLY

#### SUBJECT: PRODUCT SAFETY CAMPAIGN 92-C-01, AUTOMATIC TRANSAXLE VALVE BODY ASSEMBLY

YEAR and MODEL: 1992 FOUR-DOOR SEDANS AND COUPES, EQUIPPED WITH AUTOMATIC TRANSAXLES

#### TO: ALL SATURN RETAILERS

The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a product campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to adequately repair within sixty (60) days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge, or a refund of the purchase price less a reasonable allowance for depreciation.

To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the owner letter, owners are being. instructed to contact the Saturn Assistance Center if their Retailer does not remedy the condition within five (5) days of the service date. If the condition is not remedied within a reasonable time, owners are instructed how to contact the National Highway Traffic Safety Administration.

#### DEFECT INVOLVED

Saturn has determined that a defect which relates to motor vehicle safety exists in some 1992 vehicles equipped with automatic transaxles. The valve body assemblies on some of these vehicles were improperly machined. Vehicles with this condition may not properly engage in Park. If this problem exists, the gear selector may indicate the vehicle is in Park or Neutral, even though it could be in Reverse or Drive. If this happens. the car could start in Reverse or Drive, or might move unexpectedly, which may result in a vehicle crash or injury to persons outside the vehicle without prior warning.

Most of the affected vehicles are in Retailer inventory and have not been delivered to customers. However, we are contacting owners of affected, delivered vehicles and asking them to make arrangements with a Saturn Retailer to have their vehicle transported to a retail facility for inspection and replacement of the valve body assembly if necessary.

#### VEHICLES INVOLVED

Certain 1992 SL1, SL2 and SC models equipped with automatic transaxles, as detailed on the "VIN LIST OF VEHICLES INVOLVED IN CAMPAIGN" located on pages 8 and 9 of this campaign bulletin, Will require this campaign. Refer to this list to determine if a vehicle is affected. PERFORM THE CAMPAIGN ONLY TO VEHICLES ON TMS LIST. IF A VEHICLE DOES NOT APPEAR ON THIS LIST, IT DOES NOT REQUIRE THE CAMPAIGN SERVICE. Contact the Saturn Assistance Center (1-800-828-2112, prompt 6) if you have questions concerning vehicles requiring this campaign.

#### OWNER NOTIFICATION

Owners of vehicles involved will be notified of this campaign by Saturn (refer to the owner letter included with this bulletin). The Saturn Assistance Center will also contact customers to assist in making arrangements to have the campaign completed in a manner that minimizes customer inconvenience.

#### FACILITY VIN LIST

A list of vehicles assigned to you (Facility VIN Listing), which our records indicate were sold by or shipped to you, is enclosed for your follow-up program. The Facility VIN Listing contains:

* Complete Vehicle Identification Number;

* Owner name, address and telephone number; and

* VIN's of vehicles, which according to Saturn records, are in retail stock.

The Facility VIN Listing (with owner information) is furnished to involved Retailers with the Product Campaign Bulletin. Those Retailers not involved initially in this campaign will receive a message at the top of a blank Facility VIN Listing that states: NO VEHICLES ASSIGNED AT THIS TOW FOR CAMPAIGN 92C01.

Although these vehicles are assigned to your facility, it is important to note that owners can take their vehicles to the Saturn Retail Facility of their choice to have this campaign performed.

In addition, a complete VIN list of all vehicles requiring this campaign is attached. Only those vehicles contained in this list are to have the campaign correction performed.

#### TRANSFER OF CAMPAIGN RESPONSIBILITY

Saturn vehicles that have been sold by you, which may be in closer proximity to another Saturn Retailer, will still appear on your Facility VIN Listing. If either you or the vehicle owner determines that it is more desirable for a vehicle on your Facility VIN Listing to be serviced by another Saturn Retailer, campaign responsibility may be transferred by contacting the Saturn Assistance Center (800-828-2112, prompt 6). The Assistance Center will aid in identifying the proper servicing Retailer. All changes to campaign responsibility win be reflected in your next monthly Unfixed VIN Report.

All other changes in vehicle status (e.g., scrapped, stolen, etc.) are to be made in accordance with section 4.4.3 of the Retailer Service Reference Guide (Notifying Saturn of Vehicle Status Change).

#### RETAILER RESPONSIBILITY

All unsold new vehicles in Retailers' possession and subject to this campaign must be held at the retan facility and inspected/repaired per the service procedure of this campaign bulletin before owners take possession of these vehicles.

Retailers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the Retailer, and arrangements made to make the required correction according to instructions contained in this bulletin.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your retail facility for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

#### PARTS INFORMATION

A pre-shipment of parts required to perform this campaign has been automatically sent to you from Saturn Service Parts Operations (SSPO). These initial shipments are to aid the Retailer in campaign preparation and ensure minimal customer inconvenience.

Should you require additional parts, please contact your parts support analyst immediately and we will expedite the shipment overnight.

Please do not enter any orders for any of the part numbers below without contacting the Parts Assistance Team.

#### Required Parts

Quantity Required Part Number Description Per Vehicle ----------- ----------- ----------------- 21001683 Gasket, Pan 1 21002390 Gasket, Spacer Plate AR* 21002691 Valve Body Assembly AR**

* It is estimated that approximately 50% of affected vehicles will require replacement of both Spacer Plate Gaskets.

** It is estimated that approximately 25% of affected vehicles will require Valve Body Assembly replacement.

#### SERVICE PROCEDURE

1. Remove the valve body cover by following the first seven (7) steps of the "Valve Body Removal" procedures in the "Automatic Transaxle In-Vehicle Repair" section of the "Automatic Transaxle Service Manual."

2. Inspect the upper valve body for the identification symbols shown in step 3 of this campaign service procedure. The outside identification symbol is located to the left of the clutch priority valve bore. The clutch priority valve bore faces the front of the vehicle and can be seen once the valve- body cover is removed.

3. Does the identification symbol on the outside of the upper valve body MATCH?

a. If the outside identification symbol MATCHES, the valve body is not defective. Reinstall the valve body cover following the procedures at the end of "Valve Body Installation." Be sure to use a new pan gasket when reinstalling the valve body cover.

b. If the outside identification symbol DOESN'T MATCH, remove the valve body by completing step eight (8) of the "Valve Body Removal" procedure and then go to step four (4) of this procedure.

c. If the outside identification symbol can't be read. proceed to step 4 of this campaign service procedure.

4. With the valve body on the bench, separate the valve body halves by removing the actuator cover to valve body bolts and then remove bolt #9 which holds the valve body halves together. (Refer to bottom illustration on page TAAT 224 of the 1991-1992 "Transaxle Service Manual" for location of bolt #9.) Also refer to Technical Information Bulletin 92-T-15. Carefully separate the two halves to ensure that the check balls are retained.

5. Inspect the inside identification symbol marked in the upper valve body passage shown below. Does the identification symbol on the upper valve body match?

a. If the identification symbol marked inside the upper valve body MATCHES replace the valve body assembly with a new one.

b. If the identification symbol marked inside the upper valve body DOESN'T the valve body is not defective. Using new spacer place gaskets, and making sure all. surfaces are clean. reassemble the valve body and install in vehicle. Be sure to use a new pan gasket when reinstall the valve body cover. Use "Valve Body Assembly" and "Valve Body Installation" procedures under the "Automatic Transaxle In-Vehicle Repair" section of the "Automatic Transaxle Service Manual." Also refer to Technical Information Bulletin 92-T-15.

c. If the identification symbol marked inside the upper valve body can't be read, replace the valve body assembly with a new one.

#### RELATED TECHNICAL INFORMATION

For Related Technical Information, refer to 92-T-15.

#### CAMPAIGN IDENTIFICATION AND VERIFICATION

All vehicles in for service at a Saturn facility will have the VIN checked for possible outstanding campaigns by the Satum Dealer System. The Saturn Dealer System compares the VIN from the vehicle in for service to a list of VIN ranges (Campaign Parameter File) that was set up for this campaign. Although the Campaign Parameter File is designed to be as discriminating as possible, it should only be used as a tool to aid the Retailer in identifying vehicles that may possibly be subject to this campaign. Check pages 8 and 9 of this campaign bulletin to verify if the vehicle requires the campaign. ONLY PERFORM THE CAMPAIGN SERVICE TO VEHICLES ON THIS LIST.

#### CAMPAIGN COMPLETION LABEL

Upon completion of the campaign. a Campaign completion Label is to be affixed on a clean, dry surface of the radiator core support in an area clearly visible when the hood is raised. Each label provides a space to print in ink (or type) the campaign number (92C01) and the five (5) digit facility code of the Retailer performing the campaign service.

As a reminder, additional labels may be obtained from your Service Support Activities Folder (provided to each facility as part of their "start-up" package) or the Saturn Assistance Center (1-800-828-2112).

#### CREDIT

To receive credit for this campaign, submit a claim as follows with one of the labor operations below based on the repair performed. All necessary vehicle information normally entered on a CSO (VIN, mileage, etc.) must be included. Refer to the Saturn Claims Processing Manual for details on Product Campaign Claim Submission.

Failed Parts Sale Case Labor Labor Add Repair Performed Part Allow. Type Type 0P Hours Hrs.* ---------------- ------ ------ ---- ---- ----- ----- ---- Outside Valve Body Inspection 21001683 ** WC VC V7610 1.4*** 0.1 Remove/Replace Inside Valve Body Inspection 21002390 ** WC VC V7611 2.1*** 0.1 Reassemble/Replace Valve Body Inspection 21002691 ** WC VC V7612 1.9*** 0.1 Replace Defective Valve Body

* Campaign Administrative Allowance

** The Parts Allowance should be the sum total of the current SSPO Retailer Net price plus 30% of all parts required for the repair.

*** Add 0.2 hrs for vehicles equipped with antilock brakes (ABS).

(Involved)

Dear Saturn Owner,

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Saturn has determined that a defect which relates to motor vehicle safety exists in some 1992 cars equipped with automatic transaxles. First of all we want you to understand that we regret that this happened and we want to assure you that you will receive the special care and service you expect as a valued Saturn owner.

Unfortunately. we have recently discovered that the valve body assemblies on some of these cars were improperly machined. This problem affects about five Saturn owners. Cars with this condition may not properly engage in Park. If this problem exists in your car, the gear selector may indicate the car is in Park or Neutral, even though it could be in Reverse or Drive. If this happens, your car could start in Reverse or Drive. or might move unexpectedly, which may result in a vehicle crash or injury to persons outside the car, without prior warning.

Naturally, we want to minimize any inconvenience to you and correct the problem as quickly as possible. First. however. there are some precautions you should follow if you must operate your car before we have the opportunity to inspect and complete any necessary repairs. Please be sure to apply your parking brake whenever your car is parked. Also, before starting your car make sure the parking brake is set and you firmly apply the service brake while starting the engine. If you are parking on a hill that has a curb, you can do one more thing, tum your front wheels so they contact the curb ... please look at your Owner's Handbook page 209-211 for more information.

Our goal is to make sure your ownership experience is the best it can be. We understand how important your time is, so we will make every effort to minimize any inconvenience to you. With that goal in mind, we have decided to do the following:

What Saturn Will Do: o We will arrange to have your car picked up and delivered to your Saturn Retailer to be inspected and. if necessary, to replace the valve body in the transaxle.

o If you prefer, you may choose to exchange your car for another new Saturn under our Moneyback Guarantee Program.

o Since you will be without your car for a short period of time, we will deliver a loaner vehicle to you if you need one.

o After we have finished servicing your car. we will deliver it back to you. Of course, there will be no charge to you for these services.

o We have arranged for a Saturn Assistance Center Advisor to contact you to schedule a mutually convenient time for us to pick up your car.

What You Should Do: o Please be sure to follow the precautionary measures above if you decide to use your car prior to it being serviced.

o Please think about a time when your car can be made available for service. It Will take about 2.5 hours for your Retailer to complete the service at the Retailer's facility.

Your Saturn Retailer is best equipped to obtain parts and provide service to ensure your car is corrected as promptly as possible. However, if your car is provided to the Retailer on the agreed service date and they do not remedy this condition on that date, or within five days, please contact the Saturn Assistance Center at 1-800-553-6000. Our advisors will assist you and the Retailer in getting your car corrected.

If, after contacting your Retailer and the Assistance Center you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator. National Highway Traffic Safety Administration, 400 Seventh St., S.W.. Washington, D.C. 20590, or call 1-800-424-9393 (Washington, D.C.. residents use 426-0123).

Again, we sincerely regret any inconvenience or concern this situation causes you. We have taken this action in the interest of your safety. Naturally, we want to do whatever we can to make you completely satisfied with your new Saturn and ownership experience. If you have any questions. please give us a call on our toll-free number, 1-800-553-6000.

(Non-Involved)

Dear Saturn Owner,

Chances are, you've already heard about a Saturn "recall" involving a small number of 1992 Saturn cars equipped with automatic transaxles. We're writing to let you know what this is all about and especially to let you know that your car is not involved.

Recently. we discovered that the transaxle valve body assemblies on about five Saturn cars, that have been delivered to owners, may have been improperly machined. This means that these cars may not properly engage in Park. Although the gear selector may indicate the car is in Park or Neutral, the car could be in Reverse or Drive. If this happens, the car could start in Reverse or Drive, or might move unexpectedly.

Owners of these few cars have already been notified and are being taken care of. As we hope you know, we place the highest priority on the safety of our owners, in addition to providing the unparalleled service and care that every Saturn owner expects. That's why we will pick up and deliver each owner's car to their Saturn Retailer for inspection and any servicing required. To e any inconvenience, these owners will be given a loaner car during this service.

Our goal is to make sure that all of our owners feel comfortable with the Saturn they're driving and that every ownership experience is the best that it can be.

Again, we want to assure you that your car is not affected. And we want you to know that we will always do whatever we can to make sure you are completely satisfied not just with your car, but with us as a company.

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.