TSB: LNF,LSJ Cracked Transmission Case

[rukkee]

#09-07-29-003: Transmission Fluid Leak, Slipping Clutch or Broken Axle Shaft (Replace Trans Assembly/Front/Rear Mounts and Both Axle Shafts-Contact District Svc Mgr (Warranty Mgr in Canada) for Repair Approval) - (Jun 12, 2009)


Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval)


Models: 2005-2009 Chevrolet Cobalt SS

2008-2009 Chevrolet HHR SS

2004-2007 Saturn ION Redline

Equipped with 5-Speed Manual Transmission (RPO MU3)

Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos)



Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted.



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Condition
Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing.

Cause
This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing.










Correction
Important: Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval.

For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline
If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts.

For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS
If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires):

• Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area.

• Inspect the upper right side mount for fluid leaks or (rubber) structural failure.

• Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts).

Important: Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2® scan tool.

Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2® is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI.

Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286)
•Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
•Remove the cover from the underhood electrical center.




•Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement.




Note: Rotate the hose to stop brake fluid from running out of it.

•Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1).
•Install the clutch actuator pipe elbow assembly, GM P/N 24252286.
•Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2).
•Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding.
•Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement.
•Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
Parts Information
Part Number
Description
Qty

24252286
Elbow Asm - Clu Actr Cyl Pipe
1

20814994
(Front) Transmission Mount
1

20814995
(Rear) Transmission Mount
1

Warranty Information
Use labor operation and time that is approved by the District Service Manager/Warranty Manager.

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.

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[sloancallaway]

Wish I would have known about this a few months ago, the local saturn dealership told me My axles were my own problem lol