Grinding/Rattle Type Noise Coming From Transaxle

Some customers may comment on a grinding or rattle type noise coming from the transaxle area. This noise usually occurs with the transaxle in first or second gear at low engine RPMs and can be intermittent.

This condition may be caused by natural harmonics of the engine that leads to a vibration in the transaxle.

There are two separate noises that can occur. Refer to the diagnostic procedure listed in this bulletin to determine which noise the vehicle has and to perform the outlined repair.

Diagnosis for Type 1 Noise

This is a very distinct noise that is usually much louder than Noise #2. If the vehicle is not making any noise when trying to verify the customer complaint, it can sometimes be induced by making several tight left-hand circles with the vehicle at normal operating temperature. Making a sharp right-hand turn will usually stop the noise. In order to distinguish between the two noises, you can press lightly on the clutch pedal while the noise is occurring without releasing the clutch and this noise (Noise #1) will NOT go away or change while Noise #2 will be reduced or eliminated. As a second diagnostic aid, while the vehicle is making the noise, shift to third gear and the noise will stop.

A design change was made to prevent this noise from occurring on transaxles with serial number 01 285828 and higher. The transaxle serial number is located on a label at the rear of the transaxle above the rear powertrain mount. The '01' in the serial number previously listed indicates 2001 build year. All transaxles built with a year indicator of '02' (2002 build year) were built with the design change and will not exhibit noise #1.

Repair for Type 1 Noise

Replace the transaxle fluid with Saturn® Manual Transaxle Lubricant, P/N 21018899. Overfill to a total capacity of 2.4 L (2.6 qts.). A possible side effect of this repair may be a slightly higher shift effort.

1. Raise and support the vehicle. Refer to "Lifting and Jacking the Vehicle" in the General Information section of the 2002 Saturn VUE Service Manual.
2. Place a suitable container under the transaxle assembly.
3. Remove the drain plug located on the bottom of the transaxle and completely drain the fluid.
4. Install the drain plug.

Tighten
Tighten the drain plug to 38 N·m (28 lb ft)

5. Lower the vehicle.
6. Remove the fill plug located on the top/middle of the transaxle on the driver side, near the red vent cap. If you use the check level plug on the side of the transaxle, you will not be able to overfill the transaxle.

Notice: Fill the transaxle to the amount specified. Too much fluid will result in a leak from the vent cap. Not enough fluid will defeat the purpose of this bulletin.

Important: Do not use the red vent cap to fill.

7. Fill the transaxle with 2.4 L (2.6 qts) of Saturn® Manual Transaxle Fluid P/N 21018899.
8. Install the fill plug.

Tighten
Tighten the fill plug to 38 N·m (28 ld ft)

Diagnosis for Type 2 Noise

This noise, commonly referred to as gear rattle, can be induced by lugging the engine in any gear, but it is usually most noticeable in first or second gear. While the noise is occurring, if you press lightly on the clutch pedal without releasing the clutch, the noise will be reduced or eliminated.

Repair for Type 2 Noise

Do not attempt to repair this noise. This noise is characteristic of the vehicle and any vehicle with a manual transaxle can be made to make a similar noise. Driving at slightly higher engine RPM levels will reduce this noise.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for K3950 (Transmission Fluid Drain and Fill), or if another procedure is performed refer to the appropriate electronic labor time guide.