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Service Manual Update For 2000/2001 S-Series Automatic Transaxle Service Manuals (00-T-65)

Publication date: 2000-11-01
Reference number: 00-T-65

SERVICE MANUAL UPDATE FOR 2000/2001 S SERIES AUTOMATIC TRANSAXLE SERVICE MANUALS

SERVICE MANUAL UPDATE FOR 2000/2001 S SERIES AUTOMATIC TRANSAXLE SERVICE MANUALS

TECHNICAL SERVICE BULLETIN

Reference Number(s): 00-T-65, Date of Issue:  02/13/2003
SATURN: 2000-2001 S-Series Vehicles
SECTION: Transaxle

SUBJECT

Service Manual Update for 2000/2001 S-Series Automatic Transaxle Service Manuals.

MODELS AFFECTED

2000-2001 Saturn S-Series vehicles equipped with automatic transaxles (RPOs MP6/MP7).

PURPOSE

The purpose of this bulletin is to update all 2000/2001 S-Series Automatic Transaxle Service Manuals at your location.

Please obtain all 2000/2001 S-Series Automatic Transaxle Service Manuals and make the necessary updates as indicated below.

SERVICE MANUAL UPDATE FOR PAGE 316 OF THE 2000/2001 S-SERIES AUTOMATIC TRANSAXLE SERVICE MANUAL

Refer to Technical information Bulletin 00-T-65. November, 2000. 

  1. 18. Install new input shaft hub-to-end cover gasket in the end cover.
  2. 19. Upon installation of input shaft hub, be sure that the roll pin lines up with the slots in the input hub of the end cover.
  3. 20. On 1st design, install input shaft hub external retaining bolts to end cover.
Fig 1: First Design
G00220327

1ST DESIGN SHOWN  See Fig 1 .

Tighten  Input Shaft Pilot Hub-to-End Cover Bolts to 12 Nm (9 lb ft).

NOTE: Use new bolts due to insufficient torque retention of the old bolts. When tightening and torquing these bolts it must be done with a hand wrench or torque wrench. Using a power tool will generate excess heat in the faster causing an incorrect torque.
  1. 21. On 2nd design, install internal Torx(R) bolts inside the input shaft hub. 2nd Design Shown Fig 2 . Tighten Input Shaft Pilot Hub-to-End Cover Torx(R) Bolts to 5 Nm (44 in lb).
    Fig 2: Second Design
    G00220328
  2. 22. Lube O-ring and install the output shaft hub assembly in the end cover. Make sure seal does not bind up during installation.
  3. 23. Install the output shaft hub retaining ring.
  4. 24. Install the output shaft lip seal and retaining ring. Make sure lip seal does not bind during installation.

NEW SERVICE PROCEDURE FOR 2000/2001 S-SERIES AUTOMATIC TRANSAXLE SERVICE MANUAL

Refer to Technical information Bulletin 00-T-65. November, 2000. 

CLUTCH: 

TOOLS REQUIRED: 

DISASSEMBLY

Fig 3: Clutch Assembly
G00220331
  1. Disassembly of all clutch assemblies is similar. When disassembling the 1st clutch remove needle bearing by separating bearing from inner race, and the remove 1st gear thrust bearing and washer.
  2. Remove backing plate snap ring and remove backing plate, clutch plates and 1st clutch apply spring. See Fig 3 .
    3. IMPORTANT: To prevent possible seal damage, the following steps to remove the clutch apply piston should only be performed if previously diagnosed as being the problem, or if a thorough cleaning is required.
    Fig 4: Clutch Spring Compressor
    G00220332
  3. Install Clutch Spring Compressor SA9146T and compress spring with hydraulic press, or a long bolt, nut and washers. See Fig 4 .
  4. Use snap ring pliers to remove spring retaining snap ring.
  5. Slowly release spring tension and remove return spring assembly.
    Fig 5: Installing Air Lock Fixture
    G00220333
  6. Install air check fixture and wrap clutch housing in shop towel, Fig 5 . Apply air pressure to housing and blow piston out of its bore.
    1. 1st - SA9147T
    2. 2nd, 3rd - SA9109T
    3. 4th - SA9110T
  7. 1st clutch only. If the 1st clutch housing is being replaced, new bearing and race will have to be installed.

ASSEMBLY

Fig 6: Clutch Piston Installation Tools
G00220334
  1. Clean clutch housing with solvent and air dry.
  2. Inspect clutch piston lip seals for cracks or damage, replace as necessary.
  3. Clutch pistons are installed using Piston Driver SA9117T-1 (1) and Piston Replacer SA9117T-4 (4). See Fig 6 .
    • On 1st clutch, install Seal Protector SA9117T-3 (3) to clutch housing. See Fig 6 .
    • 2nd, 3rd, and 4th clutches require installing Step Plate SA9117T-2 (2) to housing before installing seal protector SA9117T-3 (3). See Fig 6 .

      CLUTCH - SPECIAL TOOLS REQUIRED Fig 6

      1. 1 - SA9117T-1, SA9117T-3, SA9117T-4
      2. 2 - SA9117T-1, SA9117T-2, SA9117T-3, SA9117T-4
      3. 3 - SA9117T-1, SA9117T-2, SA9117T-3, SA9117T-4
      4. 4 - SA9117T-1, SA9117T-2, SA9117T-3, SA9117T-4.
      NOTE: Prior to using clutch piston replacer SA9117T-4 (Fig 6 ), inspect the tool and the clutch housing for any nicks or burns that could damage the clutch piston.
      Fig 7: Piston Replacer
      G00220335
  4. Lube clutch seals with petroleum jelly and place in Piston Replacer SA9117T-4 (4). One side is used for 1st while the other side is for 2nd, 3rd, and 4th. See Fig 7 .
    Fig 8: Positioning Installer n Clutch Housing
    G00220336
  5. Using Piston Driver SA9117T-1 (Fig 6 ), position installer in clutch housing (Fig 8 ) and install piston.
    Fig 9: Piston Assembly
    G00220337
  6. Inspect piston seals for correct installation.
    NOTE: The piston return spring assembly for 1st clutch is different than the piston return spring assembly for 2nd, 3rd, and 4th clutch.
  7. Install piston return spring assembly to clutch housing.
  8. Install Clutch Spring Compressor SA9146T (Fig 4 ) and compress spring.
  9. Use snap ring pliers to install retaining snap ring.
    Fig 10: First Clutch Assembly
    G00220338
  10. On 1st clutch assembly, install 1st clutch apply spring as shown Fig 10 .
    11. IMPORTANT:
    • When installing the 1st clutch apply spring the convex side must be installed towards the clutch piston, and the concave side should be installed towards the clutch pack.
    • To determine the convex side, lay the 1st clutch apply spring on a flat metal surface. If the surface near the inside diameter is in not contact with the flat metal surface, the convex side is pointed upwards. If the surface near the outside diameter is not in contact with the flat surface, the convex side is pointed downwards and is in contact with the flat metal surface.
      NOTE: Clutch plates and apply plates must be presoaked for ten minutes in Saturn Transaxle Fluid otherwise damage to the friction material may occur.
      Fig 11: Clutch Plate Housing Assembly
      G00220339
  11. Install apply plate to clutch housing with fiber side up on 2nd, 3rd, and 4th clutch.
  12. Install 1st clutch plates, starting with an external plate with fiber side up after installing the 1st clutch apply spring.
  13. Install 2nd, 3rd, and 4th clutch plates starting with a internal tang, alternate plates with fiber side up.
    1. 1st clutch: 3 - internal 3 - external
    2. 2nd clutch: 5 - internal 4 - external
    3. 3rd clutch: 4 - internal 3 - external
    4. 4th clutch: 3 - internal 2 - external
  14. Install clutch backing plate, and install selective retaining ring.
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