INTERMITTENT HOP OUT OF 5TH GEAR OR NO 5TH GEAR

SUBJECT: Intermittent Hop Out of 5th Gear or No 5th Gear or Stuck in 5th Gear (Replace Missing/Damaged 5th/Reverse Actuator Retainer Clip or 5th Shift Fork Retainer Clip)

MODELS AFFECTED: 1996-1997 Saturns equipped with MP2/MP3 manual transaxles

CONDITION: The transaxle hops out of 5th gear or there is no 5th gear or the transaxle is stuck in 5th gear. These conditions may be intermittent.

CAUSE: These conditions may be caused by a 5th/Reverse actuator retainer clip or 5th shift fork retainer clip that has been damaged or has become disconnected from the shift shaft.

CORRECTION: When diagnosing an intermittent hop out of 5th gear or no 5th gear or stuck in 5th gear condition, refer to the following procedures.

PROCEDURE: 1. Test drive the vehicle to verify condition.

2. If condition is verified, refer to "5th/Reverse Actuator Retainer Clip" procedure in this bulletin.

5th/Reverse Actuator Retainer Clip ----------------------------------

Remove the shift control housing according to procedures in the appropriate year "Manual Transaxle & Clutch Service Manual" and inspect for proper installation of the 5th/Reverse actuator retaining clip.

- If the 5th/Reverse actuator retainer clip is properly secured to the shift fork shaft, re-install the shift control housing according to procedures in the appropriate year "Manual Transaxle & Clutch Service Manual," and proceed to "5th Shift Fork Retainer Clip" procedure in this bulletin.

NOTICE: Make sure the shift control housing is completely down on the transaxle case before installing bolts. Torquing bolts on a misaligned shift control housing will damage the transaxle case.

- If the 5th/Reverse actuator retainer clip is off location (not properly secured to shift fork shaft):

a. Remove the transaxle according to procedures in the appropriate year "Manual Transaxle & Clutch Service Manual," and remove the manual transaxle case.

b. Remove the 5th/Reverse actuator retainer clip and replace with a new 5th/Reverse actuator retainer clip.

c. Re-install manual transaxle case and transaxle according to procedures in the appropriate year "Manual Transaxle & Clutch Service Manual."

- If the 5th/Reverse actuator retainer clip is missing, it must be retrieved to prevent possible damage to other transaxle components.

a. Remove the transaxle according to procedures in the appropriate year "Manual Transaxle & Clutch Service Manual."

b. Retrieve the 5th/Reverse actuator retainer clip.

c. Inspect transaxle components for damage from the 5th/Reverse actuator retainer clip and replace any damaged components as necessary.

d. Replace 5th/Reverse actuator retainer clip.

e. Re-install the transaxle according to procedures in the appropriate year "Manual Transaxle & Clutch Service Manual."

5th Shift Fork Retainer Clip

1. If the 5th/Reverse actuator retainer clip is properly secured to the shift fork shaft, perform the following procedures to inspect, and replace if necessary, the 5th shift fork retainer clip.

2. Remove the transaxle end cover assembly according to procedures in the appropriate year "Manual Transaxle & Clutch Service Manual" and inspect for proper installation of the 5th shift fork retainer clip.

- If the 5th shift fork retainer clip is properly secured to the shift fork shaft, re-install the end cover assembly according to procedures in the appropriate year "Manual Transaxle & Clutch Service Manual." After end cover assembly has been installed, refer to appropriate complaint/condition chart in the service manual to diagnose and repair the condition.

- If the 5th shift fork retainer clip is not properly secured to the shift fork shaft:

a. remove the 5th shift fork retainer clip.

b. Replace with a new 5th shift fork retainer clip according to procedures in the appropriate year "Manual Transaxle & Clutch Service Manual."

c. Re-install the transaxle end cover assembly according to procedures in the appropriate year "Manual Transaxle & Clutch Service Manual."

- If the 5th shift fork retainer clip is missing, it must be retrieved to prevent possible damage to other transaxle components.

a. Retrieve the 5th shift fork retainer clip.

b. Inspect transaxle components for damage from the 5th shift fork retainer clip and replace any damaged components as necessary.

c. Re-install the transaxle end cover assembly according to procedures in the appropriate year "Manual Transaxle & Clutch Service Manual."

PARTS REQUIREMENTS: 21001346 Clip-5th/Rev Actuator Ret 21001346 Clip-5th Shift Fork Ret

CLAIM INFORMATION: To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:

Labor Case Operation Type Description Code Time ---- ------------------------------ ----- ---------- VW Inspect/Replace 5th Shift Fork T9733 1.4 hrs Retainer Clip

VW Inspect/Replace 5th/Reverse T9734 5.2 hrs Actuator Retainer Clip

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.