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Hoot Noise During Light Throttle Deceleration with Engine Speed Between 3000 and 4000 RPM

Subject:"Hoot" Noise during Light Throttle Deceleration with Engine Speeds Between 3000 and 4000 RPM (Install Damper to Right - Hand Drive Axle)

Models:1992 Saturn SL and SL1 sedans equipped with SOHC (LKO) engines built before, and including VIN NZ221871



Condition

A noise, similar to a "Hoot," is heard from inside some vehicles during very light throttle deceleration conditions with engine speeds between 3000 and 4000 rpm. Because of the strict drivetrain torque conditions required for this noise to occur, it is usually only noticeable on vehicles equipped with manual transaxles.

Cause

The noise is caused by a vibration, that occurs under certain driving conditions, causing the drive axle to resonate.

Correction

A dynamic damper has been developed to correct this condition. Refer tot he following procedure for installation of he damper tot he right - hand drive axle. Saturn L and SL1 Sedans equipped with SOHC (LKO) engine and manual transaxles (MP2) beginning with, and including VIN NZ221872 have this damper already installed.

Procedure:

Important: Some vehicles built before, and including VIN NZ221871 have been retrofitted with the damper. Visually check for presence of a damper on the right -- hand drive axle. If the damper is present, the condition and service procedure described in this bulletin does not apply.

  1. Remove right - hand drive axle assembly. Refer to "Drive Axle Removal" in the "1991 - 1992 Drive Axle Service Manual."
  2. Remove outer CV joint from drive axle assembly. Refer to "Drive Axle Removal" in the "1991 - 1992 Drive Axle Service Manual."
  3. Thoroughly clean and degrease the drive shaft.
  4. Important: Drive shaft must be clean and free of grease to ensure the friction fit damper is secure to the drive shaft after installation.


    Object Number: 878542  Size: SH
  5. Measure 182 mm (7.15 in.) from the outboard end of the drive shaft for location of where damper will be installed. Mark this location with a piece of masking tape.
  6. Wrap the drive shaft splines and grooves tightly with vinyl tape to prevent damage tot he damper during installation. wind the tape in the direction of the CV joint end of the shaft.

  7. Object Number: 878536  Size: SH

    Notice: When installing the damper, make sure that the pipe used for installation presses on the inner damper ring. Pressing on the outer damper ring will damage the damper.

  8. Obtain an appropriate type and size of installation pipe.
  9. Material required: Steel or Schedule 40 or higher PVC

    Steel (ID): 25.4 mm (1 in.)

    Length: 160 mm (6.3 in.)

    Good Advice: Lubricate shaft with a liquid detergent (example, liquid dishwashing detergent) to aid in damper installation.

  10. Place drive shaft in a vice with brass jaws and start damper onto the drive shaft by hand. Using this installation pipe, obtained in Step 6, and a hammer, tap damper into position aligning inboard edge of damper with masking tape installed in Step 4.
  11. Important: If more than light-to-moderate tapping is required to move the damper, shaft splines or grooves are improperly taped or not enough liquid detergent has been applied.

  12. Remove masking tape and vinyl tape from drive shaft.
  13. Assembly outer CV joint to drive axle. Refer to "Drive Axle Assembly" in the "1991 - 1992 Dive Axle Service Manual."
  14. Install drive axle assembly using new drive shaft nut, included in kit. Refer to "Drive Axle Installation" in the "1991-1992 Drive Axle Service Manual."

PARTS REQUIREMENT:

21011999 -- Damper Kit - Right - Hand Drive Axle

CLAIM INFORMATION:

To receive credit for this repair, submit a claim through the Saturn Dealer Systems as follows:

Case Type

Description

Labor Operation Code

Time

VW

Damper, RH Drive Axle - Install

T9578

1.4 hrs