Service Information on Saturn VUE AF33-5 Automatic Transaxle Assembly and Transaxle Control Module (TCM) Exchange Program

The purpose of this bulletin is to outline the Automatic Transaxle and TCM Exchange Program for the 2002 model year Saturn VUE vehicles equipped with AF33-5 automatic transaxle assemblies. The exchange program will be administered through November 30, 2002.

The AF33-5 Automatic Transaxle and TCM Exchange program will be used to provide quick and reliable product feedback that product engineering will use to identify and resolve product concerns.

Important: For effective engineering analysis do not disassemble the removed unit or loosen any fasteners other than those listed on the Authorized AF33-5 automatic transaxle component repairs list

The AF33-5 Automatic Transaxle and TCM are considered separate exchange units and are not required to be serviced together. Replace only the defective unit.

The AF33-5 Automatic Transaxle and TCM Exchange program will be administered through the Saturn Technical Assistance Center (TAC) and the GM Warranty Parts Center (WPC). Saturn Technical Assistance Center can be contacted at 1-800-828-2112, prompt 1; Monday from 9:30 a.m. - 6:30 p.m. CST; Tuesday through Friday from 7:30 a.m. - 6:30 p.m. CST.

Certain repairs can be performed on the AF33-5 Automatic Transaxle Assembly that do not require the complete assembly to be exchanged. During the AF33-5 Automatic Transaxle and TCM Exchange Program period, Retailers may replace any of the components listed below without having to replace the AF33-5 Automatic Transaxle or TCM assembly:

Fluid leaks coming from any component(s) listed in the table above should be repaired at the Retailer without requesting an exchange unit from TAC

1. Verify the fluid leak is actually automatic transaxle fluid (ATF) by using the appropriate method outlined in the 2002 VUE Transaxle Service Manual.
2. Once the leak is verified as ATF, determine if the leak(s) is coming from one of the components listed in the Authorized AF33-5 Automatic Transaxle Component Repairs Table.

•	If a leak is coming from one of the components in the table, refer to the appropriate service procedure in the 2002 Saturn VUE Transaxle Service Manual.

•	the leak is not coming from a component listed in the table, the unit must be replaced. Contact TAC to request an exchange unit.

If any internal components of the AF33-5 Automatic Transaxle Assembly require repair or replacement, the complete unit must be exchanged. Assembly components in the Authorized AF33-5 Automatic Transaxle Component Repairs table must be serviced according to the repair procedures in the 2002 Saturn VUE Transaxle Service Manual.

Important: Do not remove any unauthorized components from the transaxle assembly. Do not remove/replace any unauthorized fasteners from the transaxle assembly, as the torque may assist in determining the cause of an oil leak.

The new exchange transaxle will arrive as an assembly including Torque Converter, Valve Body, Park/Neutral Position Switch assembly (75), Output Speed Sensor (62), Input Speed Sensor (73), Vent Assembly (812 - 815, 822), Fluid Pressure Test Hole Plugs (66), Transaxle Oil Cooler Line Seals (87), Axle Seals (80, 800), Drain Plug (819), and Lube Fill Plug (70). All of these components must be assembled to the removed unit prior to shipment if they have been removed. For effective engineering analysis, please do not remove any components from the transaxle assembly.

Caution: Any components that are reinstalled on the failed automatic transaxle must BE TORQUED to specification to avoid operator injury during pre-teardown testing.

Refer to the 2002 VUE service manuals for proper torque specifications. Retail facilities that return partially disassembled automatic transaxle will be billed for all materials furnished.

When a Saturn Retailer contacts TAC to request an Automatic Transaxle exchange unit, the TAC engineer will arrange to ship a new unit to the retailer overnight at no charge. The automatic transaxle exchange unit will be shipped with a residual amount of ATF fluid.

Notice: A full volume fill of Saturn T-IV fluid P/N 22689186 must be added to the unit. Add approximately 3.3 qts (3.1L) of Saturn T-IV fluid to the transaxle.

Follow the transaxle fluid level checking procedure in the 2002 Saturn VUE Transaxle Service Manual when adding fluid. Incorrect fluid level may result in transaxle damage. The 1.0 quart containers of Saturn T-IV fluid may be ordered from SSPO.

Notice: Use of any other fluid other than Saturn T-IV will cause internal transaxle damage.

Exchange units will be shipped with return shipping instructions, including a WPC address label (freight collect at destination) and a partially completed Yellow Freight Bill of Lading document.

When a Saturn Retailer contacts TAC to request a TCM exchange unit, the TAC engineer will arrange to ship a new unit to the Retailer overnight at no charge. The TCM will be shipped with return shipping instructions including a UPS/ARS label for return to the WPC.

The GM WPC will be requesting the return of these cores via an Exchange Program Special Part Request form which will be faxed to the attention of the Retailer's Parts Manager for processing. The WPC Customer Assistance office is available to answer inquires regarding parts return and shipment tracking for this program. Telephone number 248-371-9901/9902.

Important: Do not ship a component to the WPC without an official request.

Important: Before transaxle is removed you must record transaxle pump pressure readings on the "SRTA Product Feedback Form" included in this bulletin.

1. Check transaxle fluid line pressure and record pressure readings on the SRTA form included in this bulletin. Refer to "Line Pressure Test (AF33-5)" procedure in the AF33-5 (M45) section of the 2002 VUE Transaxle Service Manual.
2. For automatic transaxle assembly exchange, continue with procedure in this bulletin. If replacing only TCM proceed to step 10.
3. Drain all ATF from the automatic transaxle.



4. Remove transaxle assembly. Refer to "Transaxle Removal" starting on page 386 in the 2002 Saturn VUE Transaxle Service Manual.
5. Retorque all fasteners that were loosened and/or removed to their original torque specification.
6. Remove all plastic shipping plugs and covers from the exchange unit and install them onto the removed unit.
7. Remove fluid level indicator from removed unit.
8. Install new O-ring on fluid level indicator and install fluid level indicator on exchange unit. New O-ring is provided in the exchange packet.
9. Install new transaxle assembly. Refer to "Transaxle Installation" procedure starting on page 748 in the 2002 Saturn VUE Transaxle Service Manual.
10. If the unit is being returned for a fluid leak(s) concern, mark the exact location of the leak(s) on the unit with a permanent marker.
11. The component ID tag must be completed and attached to the part being returned.
12. Place the removed transaxle assembly and/or TCM into the original shipping containers.
13. Place a copy of the service order and completed SRTA feedback form contained with the exchange unit in the envelope provided and attach the envelope to the return unit.
14. Make sure that the Retailer address (return address) and the TAC case number are clearly visible on the outside of the shipping container.
15. Write the WPC return number in permanent marker on the outside of the container.

If the envelope containing the shipping information which came with the exchange unit is lost, contact the Saturn Service Parts Assistance Center at 1-800-828-2112, prompt 2.

To receive credit for replacing the AF33-5 automatic transaxle or TCM during the unit exchange program time frame, submit a claim with the following information.

Important: Applicable miscellaneous parts, such as transaxle fluid, are to be sold to the customer service order (CSO) following standard CSO preparation procedures.

* Unit exchange program administrative allowance.

** This is the exchange unit part allowance.

Refer to Paper version of this bulletin for the original form "Attachment 1"