Service Manual Update for all the 2000 L Series Manual Transaxle Service Manuals
| Subject: | Service Manual Update for All the 2000 L-Series Manual Transaxle Service Manuals |
| Models: | 2000 Saturn L-Series Sedans and Wagons |
Purpose
The purpose of this bulletin is to update all the 2000 L-Series Manual Transaxle Service Manuals at your location.
On page 25, the Block Ring Clearances table needs to be updated.
| • | Cross out "5th Gear" from row 2 and add a third row for 5th Gear . |
| • | Check and update all specifications as provided below. |
| Important: Only highlighted areas in table below require changes. |
MEASUREMENT | STANDARD METRIC ENGLISH | SERVICE LIMIT METRIC ENGLISH | ||
|---|---|---|---|---|
1st and 2nd Gears | 1.2-14 mm | 0.047 - 0.055 in. | 0.8 mm (min) | 0.032 in. (min) |
3rd, 4th, and Rev Gears | 0.9- 1.2 mm | 0.035 - 0.047 in. | 0.5 mm (min) | 0.20 in. (min) |
5th Gear | 0.7 - 1.1 mm | 0.028 - 0.043 in. | 0.5 mm (min) | 0.020 in. (min) |
On page 112, write in the following caution statement above step 5.
Caution: THE SYNCHRONIZER DETENT INSERTS MAY BE FORCED OUT BY SPRING PRESSURE AND COULD INJURE SOMEONE. TO HELP AVOID INJURY, ALWAYS COVER THE SYNCHRONIZER HUB DETENT OPENINGS DURING DISASSEMBLY.
On page 141, above step 44, write in the following important statement.
Important: The measurement taken in this step must be taken in millimeters. If the measurement is taken in inches, multiply the inch measurements by 25.4 to convert to millimeters.
On page 141, write in the following sentence at the end of step 44.
Convert inch measurment to millimeters if necessary.
On page 143, under step 51 in the first Correction sentence, cross out the words "two numbers" and write in the words "two lines." When corrected the sentence should be read. "Tighten output shaft nut by two lines on tool 87-92-061."
On page 181, under step 13 of Clutch Removal and Inspection procedure, write in the words "and discard" after the word "Remove" at the beginning of sentence. When corrected the sentence should read. "13. Remove and discard flywheel-to-crankshaft bolts and remove flywheel."
On page 181, above step 1 of Clutch Removal and Inspection procedure, write in the words "and discard" after the word "Remove and discard flywheel-to-crankshaft bolts and remove flywheel."
On page 181, above step 1 of Clutch Installation procedure, write in the following notice:
NOTICE: Flywheel and flexplate bolts are not interchangeable. Ensue that flywheel bolts are used or powertrain damage may result.
On page 181, change step 1 of Clutch Installation procedure to read as follows:
1. Install flywheel onto crankshaft with new flywheel bolts and hand start bolts.
Make a photo copy of page 3 of this bulletin. Cross out complete step 46 on page 142 and insert phot copy between pages 142 and 143.
On page 142, cross out step 46 and place a copy of this page between pages 142 and 143.
46. Tighten output shaft nut.
a. Install tool 87-92-061 on output shaft nut.
b. Calculate number of lines that tool 87-92-061 must be turned to tighten output shaft nut.
1. Add mesured value determined in step 44 to nominal value from chart below. Ensure that measurment taken in step 44 is in millimeters or has been converted to millimeters.
Transaxle Conditition | Nominal Value |
Old clutch housing, > 31,000 miles Old output shaft bearing, > 31,000 miles | 0.0 mm |
Old clutch housing, < 31,000" output" shaft" bearing,"> 31,000 miles | 0.03 |
Old clutch housing, < 31,000" output" shaft" bearing | 0.08 |
New clutch housing. New output shaft bearing | 0.15 |
2. Multiply this sum by 100.
3. With a marker, place a mark on the grear tooth corresponding to line on socket that matches number calculated above. This the number of lines that tool 87-92-061 must be turned.
Example:
- Reading from step 44 is 0.38 mm + Nominal value 0.08 mm = 0.46 mm
- 0.46 mm (just calculated) is multiplied by 100 = 46
- 46 is the number of lines too 87-92-061 must be turned.
