FLUID LEAKS FROM AUTOMATIC TRANSAXLE END COVER ASSEMBLY

SUBJECT: Fluid Leaks from Automatic Transaxle End Cover Assembly (Torque Bolts or Replace End Cover Assembly) ---------------------------------------------------------------

MODELS AFFECTED: 1996 Saturns equipped with MP6/MP7 automatic transaxles built before and including VIN TZ305652 ------------------------------------------------------------

CONDITION:

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Transaxle fluid leak from automatic transaxle. Diagnosis identifies leak to be coming from the middle of the end cover assembly, around the input shaft hub retaining bolts.

CAUSE:

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Some automatic transaxle end cover assemblies may have been cast with a thin-walled section in the area around the input shaft hub bolts. This thin-walled section may allow automatic transaxle fluid to weep or leak through the end cover assembly over a period of time.

CORRECTION:

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Refer to the following procedure to diagnose and repair the transaxle fluid leak.

PROCEDURE

A dye and black light kit (SA9175 -NE) is available for finding leaks. (Refer to the manufacturer's directions when using the kit.)

1. Pour the specified amount of dye into the automatic transaxle.

2. Operate the vehicle under normal operating conditions.

3. Raise the vehicle on a hoist.

4. Direct the black light toward the suspected component. The dyed fluid will appear as a brightly colored fluid, leading back to the fluid path.

5. If the leak appears to be coming from the area around the input shaft hub retaining bolts in the end cover assembly, proceed to the next step.

If the leak does not appear to be coming from the area around the input shaft hub retaining bolts in the end cover assembly, proceed to "Fluid Leak Diagnosis" in the "General Information" section of the "1996 Revised Automatic Transaxle Service Manual."

6. Check the torque on the two input shaft hub retaining bolts. Torque: 12 N-m (106 in - lbs)

a. If bolts were properly torqued, remove and replace the end cover assembly. (Refer to "End Cover" removal and installation procedures in the "In-Vehicle Service" section of the "1996 Revised Automatic Transaxle Service Manual.")

b. If bolts were not properly torqued, properly torquing the bolts should repair the leak. Operate vehicle under normal operating conditions and re-test for leaks. If fluid still leaks from the area around the input shaft hub bolts in the end cover assembly, remove and replace the end cover assembly. (Refer to "End Cover" removal and installation procedures in the "In-Vehicle Service" section of the "1996 Revised Automatic Transaxle Service Manual.")

PARTS REQUIREMENTS:

21002421 Cover Asm-Trans 21001684 Gasket-Trans Conv Cvr 21002372 Gasket-Input Hub to End Cvr 21007670 Dye-Trans Oil

CLAIM INFORMATION:

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System using the appropriate Electronic Labor Time Guide and Labor Operation Code K6105 Trans Oil Leak Analysis) and K6490 (Replace Transaxle End Cover), 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.