Vehicle Does Not Shift or Move After Running for a Period of Time and/or Check Engine Light is ON, DTC P0741 Set (Replace Torque Converter, Valve Body, Clean Out Transaxle, Install New Flex Plate Bolt

This bulletin is being revised to add the 2004 model year ION and additional diagnostics information. Please discard Corporate Bulletin Number 03-07-30-023A (Section 07 -- Transmission/Transaxle).

On low mileage vehicles or after a recent engine or transmission replacement, some customers may comment that after the vehicle has run for a period of time, the vehicle may not shift or launch from a stopped position. The Check Engine Light may also be ON with DTC P0741 displayed on the Tech 2 Scan Tool.

The transaxle may have been installed with either incorrect length flex plate-to-torque converter bolt(s) or correct bolts with missing captive washers. The torque converter clutch apply surface within the torque converter may be damaged if either incorrect length bolts (excessive length) or bolts with missing captive washers have been installed. This localized damage can result in the torque converter clutch friction material overheating and may generate debris causing an inoperative torque converter clutch and potential loss of fluid pressure as the sump filter becomes plugged with clutch fibers.

Remove and disassemble transaxle, making sure to thoroughly clean out all visible debris. Flush transaxle oil cooler lines. Install new fluid filter, torque converter, transaxle oil cooler lines, control valve body, wiring harness (as required), and correct flex plate bolts with captive washers.

1. Using Tech 2 Scan Tool, check and record diagnostic trouble codes.
2. Perform line pressure test using the "Line Pressure Test" procedure in the appropriate Saturn Service Manual.

•	If pressures are normal, run engine at idle for 10 minutes.

•	Recheck line pressures after 10 minutes of idle operation. If pressures are within specification, verify condition.

-	If condition is present and transaxle has normal pressures, follow the appropriate Diagnostic Trouble Code or symptom diagnostics in the corresponding Saturn Service Manual.

-	If condition is not present and transaxle pressures are within specification, follow diagnostics for intermittent condition.

•	If pressures are low, proceed to next step.

3. Disconnect negative battery cable.

3.1.	Record all of the customer's radio station presets.

3.2.	Turn off all lamps and accessories.

3.3.	Turn the ignition OFF.





3.4.	Remove the battery ground (negative) cable and bolt from the battery.

4. Raise vehicle on a hoist. Refer to "Lifting and Jacking the Vehicle" procedure (SI Document ID #878849 [ION], 995301 [VUE]) in the appropriate Saturn Service Manual.
5. Disconnect electrical connections to starter motor.
6. Remove starter motor.

6.1.	Remove the B+ battery cable nut at starter.

6.2.	Remove the S-terminal nut.

6.3.	Remove the lower starter assembly to engine block bolt.

6.4.	Remove the upper starter assembly to engine block bolt.

6.5.	Move the starter right, clearing the engine block, then left and out of the engine block (flywheel housing).




7. Turn the crankshaft clockwise to gain access to the flex plate-to-torque converter bolts.



8. Inspect the three flex plate-to-torque converter bolts for the correct bolt and the presence of a captured washer under the head of each bolt.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

•	If captured washers are present on bolts, tighten bolts and proceed to next step.

Tighten
Tighten flex plate-to-torque converter bolts to 60 N·m(44 ft-lbs).

•	If any captured washer is missing or an incorrect bolt was used, the transaxle requires removal and disassembly. The following repairs of the transaxle are necessary. Use the appropriate service manual procedure for the replacement and repairs.

-	Replace the torque converter

-	Replace the control valve assembly

-	Inspect the fluid pump and if faulty or damaged replace

-	Replace the fluid filter

-	Clean the transaxle of any debris and inspect for damage

-	Install transaxle in vehicle using new flex plate-to-torque converter bolts. Refer to "Transaxle Installation" procedure (SI Document ID #875670 [ION], 1232480 [VUE]) in the appropriate Saturn Service Manual or SI.

9. Install starter motor and tighten starter motor bolts.

Tighten
Tighten starter-to-engine bolts to 40 N·m(30 ft-lbs).

10. Install starter motor electrical connectors.

10.1.

Install the B+ cable and nut.

Tighten
Tighten B+ cable-to-starter nut to 10 N·m(89 in-lbs).

10.2.

Install the S-terminal wire and nut.

Tighten
Tighten the S-terminal nut to 5 N·m(44 in-lbs).

11. Lower vehicle.




Important: Clean any existing corrosion from the battery terminal bolt flange and the battery cable end.

12. Connect negative battery cable.

12.1.

Install the battery ground (negative) cable and bolt to the battery.

Tighten
Tighten battery terminal bolt to 17 N·m(13 ft-lbs).

12.2.

Program all of the customer's radio station presets and set the radio clock to the current time.

13. Drive vehicle to verify condition has been repaired.

Important: Not all parts listed below are needed for procedure. Refer to SI and the appropriate Parts and Illustration catalog to ensure correct and current parts are being used for each model transaxle.

* One tube will service two vehicles.

** Check transmission part number per parts catalog prior to ordering control valve body assembly and gasket kit.

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