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Transmission Fluid Leak, Slipping Clutch or Broken Axle Shaft - keywords crack housing shift slip

Subject:Transmission Fluid Leak, Slipping Clutch or Broken Axle Shaft

Models:2005-2008 Chevrolet Cobalt SS
2004-2007 Saturn Ion Redline
Equipped with a 5-Speed Manual Transmission (RPO MU3)



This PI was superceded to remove models. Please discard PIP3932A.


The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:

Some customers have commented about transmission oil in the clutch housing, slipping clutches or broken axle shafts on this model. An analysis of several of these failures has revealed that the problem is due to excessive front wheel hop during WOT acceleration events.

Excessive wheel hop transmits a torsional shock load into the transmission case. This causes the case to crack and transmission fluid to leak into the clutch housing. See photos below.


Object Number: 1864859  Size: SH

Object Number: 1864860  Size: SH

Object Number: 1864862  Size: SH

Recommendation/Instructions:

Stiffer axle shafts and hardware will change the system harmonics and help prevent wheel hop. These planned changes will not be available until the 2008 model year.

Note: Be advised that failures of this nature are abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by the dealer and Area Vehicle Manager. A product report should be submitted on each.

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.