Saturn VUE VT25-E Transaxle Assembly Replacement Program

The purpose of this bulletin is to outline the VT25-E Transaxle Replacement program for the 2002-2003 model year Saturn VUE vehicles. The VT25-E Replacement program will be administered through April 15, 2003. Beginning in October 2002, limited on-vehicle service of the VT25-E Transaxle is scheduled to be introduced to compliment the replacement program. A service bulletin will be published to provide special details.

The VT25-E Transaxle Replacement program will be used to provide quick and reliable product feedback that product engineering will use to identify and resolve product concerns.

Important: To facilitate an effective engineering analysis, do not disassemble the removed transaxle or loosen any fasteners. Also, be sure to completely fill out the SRTA Product Feedback Form before returning any parts to the GM Warranty Parts Center (WPC).

The VT25-E Transaxle Replacement program will be administered through the Saturn Technical Assistance Center (TAC) in the United States and the 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. (For Canadian vehicles, this program will be administered by the GM of Canada Technical Assistance Center at 1-800-263-7740 for English or 1-800-263-7960 for French; Monday through Friday from 6:30 a.m. - 8:00 p.m. EST.) All VT25-E Transaxle Replacement requests must be reviewed with the appropriate Technical Assistance Center.

Currently, the only authorized repairs on the VT25-E transaxle assembly is replacement of the park/neutral position switch assembly, transaxle fluid fill lower tube assembly, and the transaxle fluid fill lower tube plug. However, there are situations that may occur where certain components are allowed to be serviced and are being stocked in SSPO. For instance, damage to or loss of a part during shipping or installation. For these cases, the technicians can explain their situation to TAC, and the TAC engineer will be able to order the part by contacting the PSA. The components that fall under these situations are:

If any internal component of the VT25-E Transaxle Assembly requires repair or replacement, the complete transaxle must be replaced.

1. Verify the fluid leak is actually DEX-CVT® fluid. Refer to "Fluid Diagnosis" in the VT25-E (M16/M75) section of the 2002-2003 VUE Transaxle Service Manual.
2. Be sure to mark the exact location of the leak(s) on the transaxle with a permanent marker.

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.

When a Saturn Retailer contacts TAC to request a VT25-E replacement transaxle, the TAC engineer will arrange to ship a new unit to the Retailer within 24 hours (72 hours in Canada).

Replacement transaxles will be shipped filled with DEX-CVT® additive, partially filled with DEX-CVT® fluid and return shipping instructions, including a WPC address label (freight collect at destination) and a partially completed Yellow Freight Bill of Lading document.

The GM WPC will be requesting the return of these cores via a "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 inquiries regarding parts return and shipment tracking for this program. The telephone number is 248-371-9901/9902. Canadian retailers may refer to the GM of Canada Service Policies & Procedures Manual, article 1.7.5 "Material Requested For Inspection" for program details. Canadian retailers requiring assistance regarding Sameday Right-O-Way shipments may call the WINS Claims Assistance Centre in Oshawa at 1-888-222-5546 (English) or 1-888-276-8746 (French).

Important: Before transaxle is removed, you must record transaxle pump pressure readings on the "SRTA Product Feedback Form" included in this bulletin. Also, be sure to completely fill out the SRTA Product Feedback Form before returning the transaxle to the WPC.

1. Check transaxle fluid line pressure and record pressure readings on the SRTA form included in this bulletin. Refer to "Line Pressure Test" procedure in the VT25-E (M16/M75) section of the 2002-2003 VUE Transaxle Service Manual.
2. Drain all DEX-CVT® fluid from transaxle and replace drain plug when finished. Torque: 16 N·m (12 ft-lbs).

Tighten
Transaxle Lower Tube Assembly 16 N·m (12 lb ft)




3. Remove transaxle assembly. Refer to "Transaxle Removal" procedure in the 2002-2003 VUE Transaxle Service Manual.
4. Remove park/neutral position switch lever nut and lever and install onto the replacement transaxle. Refer to "Park/Neutral Position Switch" installation procedure in the VT25-E (M16/M75) section of the 2002-2003 VUE Transaxle Service Manual.




Notice: All shifter cable and park lock cable clips are one time usage only. Any service repair requiring cables to be disconnected from the transaxle control cable bracket or shifter assembly will require a cable clip replacement.

5. Remove shifter cable bracket (900) and install onto replacement transaxle.

Tighten
Control Cable Bracket Bolts 23 N·m (17 lb ft)

6. Remove all plastic shipping plugs and covers from the replacement transaxle and install them onto the removed transaxle.
7. If the transaxle is being returned for a fluid leak(s) concern, mark the exact location of the leak(s) on the transaxle with a permanent marker.



8. Disconnect transaxle oil cooler line assembly from transaxle oil cooler.

8.1.	Flush transaxle oil cooler line assembly. Refer to "Transaxle Cooler Flushing Procedure" in the VT25-E (M16/M75) section of the 2002-2003 VUE Transaxle Service Manual.

8.2.	Flush transaxle oil cooler. Refer to "Transaxle Cooler Flushing Procedure" in the VT25-E (M16/M75) section of the 2002-2003 VUE Transaxle Service Manual.

9. Connect transaxle oil cooler line assembly to transaxle oil cooler.

Tighten
Transaxle Oil Cooler Line Assembly Nut 8 N·m (71 lb in)

10. Install new transaxle assembly. Refer to "Transaxle Installation" procedure in the 2002-2003 VUE Transaxle Service Manual.
11. Add approximately 4.0 qts (3.8L) of DEX-CVT® fluid to transaxle and proceed to next step to inspect transaxle fluid level.

Notice: Use DEX-CVT® fluid P/N 22688912 only. Use of any fluid other than DEX-CVT® will cause internal transaxle damage.

Caution: Make sure vehicle is properly supported and squarely positioned on hoist. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed.

12. Install Scan tool.
13. Start vehicle.
14. Perform the following:

14.1.

Shift transaxle from (P) Park to (R) Reverse for 10 seconds.

14.2.

Shift transaxle from (R) Reverse to (D) Drive for 10 seconds.

14.3.

Shift transaxle back to (P) Park. The engine should remain running.

15. Set transaxle to the following conditions:

15.1.

Engine Speed at idle or 800 rpm.

15.2.

Shift selector in (P) Park.

16. Raise vehicle. Vehicle must be level, with engine running.



17. Place a clean container under the drain hole to capture fluid. This fluid will be added back into the transaxle during step 20. Remove lower tube plug and discard.

•	If fluid drains down at a steady stream from the opening, wait for it to stop. Go to step 18

•	If no or very little fluid drains down from opening, add fluid to transaxle until it starts to drain at a steady stream (1/4 inch in diameter). Then stop adding immediately. Allow fluid to drain until fluid stream stops.

Notice: Saturn Automatic Transaxle Fluid (ATF) (P/N 21005966 and P/N 21019223) is not compatible with this transaxle. If Saturn ATF is used, transaxle damage will result. This transaxle uses DEX-CVT® Fluid (P/N 22688912).

18. Replace with new plug and wipe away any excess fluid from transaxle. Torque: 11 N·m (8 ft-lbs).

Tighten
Transaxle Lower Tube Plug 11 N·m (8 lb ft)

19. Lower vehicle.
20. On Scan tool, record the Trans. Fluid Temp.

•	If the Trans. Fluid Temp. is 20°C (68°F) or below, add 0.5 qt. (0.47 liter) of fluid to transaxle using captured fluid first. Do not remove plug.

•	If the Trans. Fluid Temp. is 40°C (104°F) add 0.75 qt. (0.71 liter) of fluid to the transaxle using captured fluid first. Do not remove plug.

•	If the Trans. Fluid Temp. is 60°C (140°F) add 1.0 qt. (0.95 liter) of fluid to the transaxle using captured fluid first. Do not remove plug.

•	If the Trans. Fluid Temp. is 80°C (176°F) or above, add 1.25 qt. (1.2 liter) of fluid to the transaxle using captured fluid first. Do not remove plug.

21. Turn off vehicle.

Important: Retail facilities that return a partially disassembled transaxle will be billed for all materials furnished.

1. Complete and attach component ID tag to transaxle being returned.
2. Place removed transaxle assembly into original shipping container. Be sure transaxle has been drained.
3. Place a copy of service order and completed SRTA feedback form contained with the replacement transaxle in envelope provided and attach envelope to the returned transaxle.
4. Make sure that the Retailer address (return address) and the TAC case number are clearly visible on the outside of the shipping container.
5. Write the WPC return number in permanent marker on the outside of the container.

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

To make arrangements to have the VT25-E automatic transaxle core picked up, contact Yellow Freight System Inc. at 1-800-610-6500. Canadian Retailers contact Same DAY Right-O-Way at 1-800-387-2727 ext. 3889. Remove the original shipping label and attach the WPC address label to the crate. The bill of lading which is provided with the replacement transaxle is the only shipping document required to return the removed transaxle. After the bill of lading has been dated and signed by the carrier, retain a copy with your service order. This copy is your only proof that the removed transaxle was returned.

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

Contact the appropriate Saturn Technical Assistance Center (TAC) for specific transaxle assembly part number information. The following part numbers are considered common replacement parts and are available through Saturn Service Parts (SSPO).

To receive credit for replacing the VT25-E transaxle during the transaxle replacement 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 replacement program administrative allowance.