Exchange Program - Limited Service Repair Program for the 5AT Automatic Transaxle Assembly (RPO MJ7/MJ8)

This bulletin is being revised to add the 2007 model year. Please discard Corporate Bulletin Number 03-07-30-040B (Section 07 -- Transmission/Transaxle).

The purpose of this bulletin is to outline the Limited Service Repair Program for 2004, 2005, 2006 and 2007 Saturn VUE vehicles equipped with the 5AT automatic transaxle assembly (RPO MJ7/MJ8) during the vehicle warranty period.

The Limited Service Repair Program will be used to provide quick and reliable product feedback that product engineering will use to identify and resolve product concerns.

5AT (RPO MJ7 OR MJ8) AUTOMATIC TRANSAXLE ASSEMBLY REPLACEMENT PROGRAM PROCESS OVERVIEW

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

Important: To facilitate effective engineering analysis, do not disassemble the removed transaxle assembly or loosen any supporting fasteners. Also, be sure to completely fill out the Automatic Transmission Core Return Form before returning any parts to the SSPO Core Return Center (in Canada, use the normal core return process to return to your servicing PDC). Retailers will NOT receive credit for returned transaxle cores if the Automatic Transaxle Core Return Form has not been completed.

AUTHORIZED AUTOMATIC TRANSAXLE REPAIRS

The Limited Service Repair Program will be in place for the first 3 years/36,000 miles (in Canada, 3 years/60,000 kilometers) of the powertrain warranty. For repairs outside of the 3 years/36,000 miles (in Canada, 3 years/60,000 kilometers), all repair parts will be available. The RPO MJ7/MJ8 Automatic Transaxle Replacement Program will be administered through the GM Technical Assistance Center (TAC) in the United States and the SSPO Core Return Center. GM TAC can be contacted at 1-877-446-8227, prompt 3, from 8:00 a.m. - 5:00 p.m. (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.)

Important: All transaxle replacement requests must be reviewed with and approved by the Technical Assistance Center (TAC). Technicians should be prepared to discuss diagnostic information such as line pressures, complaint description information, and related diagnostic trouble code (DTC) information with a TAC engineer. The information captured in this process will enable TAC to provide engineering with product feedback.

Currently, authorized repairs on the RPO MJ7/MJ8 automatic transaxle assembly include all externally mounted or externally serviceable components identified in the illustrations provided in this bulletin. If, for any reason, the repair requires the separation of the case halves (gears, bearings, clutch assemblies, case, housing, valve body, or any internal valve body control component), the RPO MJ7/MJ8 automatic transaxle assembly must be replaced with a remanufactured assembly.

FLUID LEAK(S)

1. Verify the fluid leak is actually ATF oil. (Refer to "Leak Diagnosis" in Transaxle section of the 2004, 2005, 2006 or 2007 Saturn VUE Service Manual or SI.)
2. Be sure to mark the exact location of the leak(s) on the transaxle assembly with a permanent marker or paint stick.

Refer to the 5AT (MJ7/MJ8) transaxle removal and installation procedures (SI Document ID #1412018) in the 2004, 2005, 2006 or 2007 Saturn VUE Service Manual.

Notice: Flush transaxle oil cooler and transaxle oil cooler lines before installing a new replacement transaxle assembly. Failure to properly flush the transaxle oil cooler and transaxle oil cooler lines may damage the new replacement transaxle assembly. Fill transaxle with Saturn/GM ATF Z-1 fluid, P/N 22717466.

SHIPPING PREPARATION

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

1. Place removed transaxle assembly into original shipping container. Ensure transaxle has been drained.

Important: A return envelope and shipping instructions are included with replacement transaxles. If the envelope or the shipping instructions are lost, contact the Saturn Service Parts Assistance Center at 1-800-828-2112, prompt #2 (in Canada, contact the Technical Assistance Center).

2. Place a copy of the service order and completed Automatic Transaxle Core Return Form in the return envelope and attach the envelope to the transaxle you will return to Saturn.
3. Transaxle core part content should match service part transaxle content.
4. Do not ship loose parts in the transaxle container. Disassembled components must be reattached to the transaxle core.
5. Make sure that the Retailer return address and the TAC case numbers are clearly visible on the outside of the shipping container.

Important: Retailers will NOT receive credit for returned transaxle cores if the Automatic Transaxle Core Return Form has not been completed. (U.S. retailers, please refer to Parts and Accessories Bulletin 03-PA-02 for more information.) NO credit will be provided for incorrect, incomplete, or disassembled transaxle cores. Transaxle core damage caused as the result of collision, fire, flood, or misuse are not eligible to participate in this program.

SHIPPING INSTRUCTIONS

1. Core returns are to be shipped to the SSPO Core Return Center in Spring Hill, TN (in Canada, use the normal core return process to return to your servicing PDC) upon completion of the repair. U.S. retailers, please refer to "Special Transactions" in the Saturn Parts Policies and Procedures Manual for an overview of the core return process.
2. Using the Automatic Transaxle Core Return Form, completely fill in the following information: part description, core part, service part number, retailer code, CSO number, and the last eight (8) digits of the vehicle identification number (VIN). Transaxle cores received without a completed Automatic Transaxle Core Return Form will result in the loss of a $1200 core credit to the Saturn retailer. (U.S. retailers, please refer to Parts and Accessories Bulletin 03-PA-02 for additional information.)

FAULTY TRANSAXLE SERIAL NUMBER

In order to provide engineering with quick product feedback, the faulty transaxle serial number needs to be recorded on the automatic transaxle core return form. The transaxle serial number can provide valuable manufacturing and testing information for engineering the use during root cause investigation analysis. The transaxle serial number is located below the vehicle battery on the upper right-hand side of the transaxle case.

The transaxle serial number contains 11 characters. The first four (4) digits indicate transaxle type and the fifth (5) digit indicates model year usage. One (1) equals 2004, two (2) equals 2005, three (3) equals 2006, (4) equals 2007. Refer to the transaxle serial number below:

MDRA1000001

(M) Manufacturing Factory

(DRA) Transaxle Model Type (DRA is FWD / DPA is AWD)

(1) First model year of production for this transaxle type (2004 Saturn equals 1)

(2) (2005 Saturn equals 2)

To receive credit for any repairs during the warranty coverage period, submit a claim through the Saturn Dealer System, or if another procedure is performed, refer to the appropriate Electronic Labor Time Guide for the correct Labor Operation Code and Time.