Edmunds Answers

Voted Best Answer




  • avatar karjunkie 07/01/10 9:59 am PST

    There is a TSB on this condition which is caused by a bad transaxle electrical connector as follows:

    #01-T-09: Harsh Shifts, No Shifts, and/or No TCC Operation with Transaxle Releated DTCs Set - (Feb 13, 2003)





    Subject: Harsh Shifts, No shifts, and/or No TCC Operation with Transaxle Related DTCs Set (Replace Transaxle Connector and Harness)







    Models: 1994 - 2001 Saturn S-Series vehicles with automatic transaxles (RPO MP6 or MP7)



    Due to normal powertrain vibration, the transaxle wiring may flex and cause a circuit to open inside wire insulation near transaxle connector. In some cases, insulation will look distorted at point of open circuit.


    Perform procedure in this bulletin to replace transaxle connector (P/N 21024415).


  • Remove air inlet duct.




    2.1. Open clamp at throttle body





    2.2. Disconnect fresh air hose at air duct.





    2.3. Remove air cleaner housing cover and air duct.

  • Remove battery.
  • Remove battery tray.

  • Loosen transaxle electrical connector bolt and disconnect transaxle electrical connector.
  • Disconnect transaxle range switch connectors.
    Important: A sewing "seam stripper" is an excellent tool for removing tape from a wire harness. It cuts the tape without damage to the wires under the tape.

  • Remove electrical tape from wiring harness from transaxle electrical connector to main engine harness approximately 20-25 cm [8-10 in.]).


  • Important: If wires are broken inside insulation, outside of insulation may appear to be thin in one area, stretched or discolored.

  • Visually inspect circuits associated with DTC. Inspect wires for damaged or deformed insulation from transaxle electrical connector to main engine harness (up to 25 cm [10 in.] away from connector).




    If there is visual evidence of wire damage and the location of the open circuit can be identified, continue with next step.





    If there is no evidence of wire damage, physically inspect each wire by sliding fingers along entire length of wire and feel for abnormalities or depressions.





    - If wire damage is located during physical inspection, continue with next step.





    - If no wire damage is located during physical inspection, continue to step 10.






    Important: When splicing in new connector, stagger crimp-and-seal connectors so they are not all in same location. Staggering crimp-and-seal connectors will allow for a better finished look.




  • Once location of open circuit is identified, replace transaxle connector in its entirety (all ten circuits) with replacement transaxle connector (P/N 21024415).




    9.1. Cut transaxle connector circuit branch within 38 mm (1.5 in.) of main harness to ensure any other possibly affected circuits are repaired. Discard transaxle connector.





    9.2. Remove insulation from ends of cut wires and new transaxle connector harness. Recommended strip length is 4.8 mm (3/16 in.) for 12-20 gauge wire and 9.5 mm (3/8 in.) for 22 gauge wire so it can be folded in half. Care must be used when stripping wire to prevent cutting the wire strands.

    * Can be ordered through Delphi-Packard by calling 1-800-PACKARD (1-800-722-5273).

    ** Can be ordered through Saturn Special Tool Catalog. Found with J44020 Terminal Repair Kit.






    Important: For the wiring used in Saturn vehicles, it is recommended that only approved Packard Electric Crimp and Seal Splice Sleeves (or equivalent) be used.








    9.3. Using a Saturn-approved crimp and seal splice sleeve (found in terminal repair kit J44020), position stripped ends of wires in sleeve until wires hit stop.
  • 9.4.
    Hand crimp splice sleeve using correct jaws in Packard crimper (P/N 12085155) or appropriate crimping tool. Gently tug on wires to ensure they are secure before applying heat to seal sleeve.



    Caution: DO NOT USE A MATCH OR OPEN FLAME TO APPLY HEAT TO SPLICE SLEEVE.








    9.5. Apply heat using Ultratorch ® or heat gun. Heat to 175° C (347° F) until glue flows around edges of sleeve.





    9.6. Check for continuity in the wire and verify the repair.

  • Connect transaxle range switch connectors.
    Notice: Do not over-tighten or damage tot he connector plate may occur.

  • Connect transaxle electrical connector, and torque transaxle electrical connector bolt.
    Tighten
    Transaxle Electrical Connector Bolt: 3 N·m (27 in lb)

  • Clear DTC(s) and retest.




    If a DTC is reset, refer to diagnostic aids in appropriate model year Automatic Transaxle service manual and continue with next step.





    If no DTCs are rest, go to step 15.

  • Clear DTC(s) again.
  • Check for intermittent circuit fault. Wiggle harness near connector while performing diagnostic test on affected circuit.




    If DTC sets, refer to appropriate diagnostic flow chart for circuit number identification. (Refer to appropriate model year Automatic Transaxle service manual for diagnostic flow charts.) Continue with next step after diagnostics have been completed.





    If DTC does not set, refer to diagnostic aids in appropriate model year Automatic Transaxle service manual for intermittent conditions. Continue with next step after diagnostics have been completed.

  • Using high quality electrical tape, re-wrap transaxle connector circuit branch from main harness breakout to connector.
  • Install battery tray.
    Tighten
    Battery Tray-to-Vehicle Bolts: 10 N·m (89 in lbs)

  • Install battery
    Tighten
    Battery Terminal Bolts: 17 N·m (13 lb ft)

Answers




  • karjunkie 07/01/10 9:59 am PST

    There is a TSB on this condition which is caused by a bad transaxle electrical connector as follows:

    #01-T-09: Harsh Shifts, No Shifts, and/or No TCC Operation with Transaxle Releated DTCs Set - (Feb 13, 2003)





    Subject: Harsh Shifts, No shifts, and/or No TCC Operation with Transaxle Related DTCs Set (Replace Transaxle Connector and Harness)







    Models: 1994 - 2001 Saturn S-Series vehicles with automatic transaxles (RPO MP6 or MP7)



    Due to normal powertrain vibration, the transaxle wiring may flex and cause a circuit to open inside wire insulation near transaxle connector. In some cases, insulation will look distorted at point of open circuit.


    Perform procedure in this bulletin to replace transaxle connector (P/N 21024415).


  • Remove air inlet duct.




    2.1. Open clamp at throttle body





    2.2. Disconnect fresh air hose at air duct.





    2.3. Remove air cleaner housing cover and air duct.

  • Remove battery.
  • Remove battery tray.

  • Loosen transaxle electrical connector bolt and disconnect transaxle electrical connector.
  • Disconnect transaxle range switch connectors.
    Important: A sewing "seam stripper" is an excellent tool for removing tape from a wire harness. It cuts the tape without damage to the wires under the tape.

  • Remove electrical tape from wiring harness from transaxle electrical connector to main engine harness approximately 20-25 cm [8-10 in.]).


  • Important: If wires are broken inside insulation, outside of insulation may appear to be thin in one area, stretched or discolored.

  • Visually inspect circuits associated with DTC. Inspect wires for damaged or deformed insulation from transaxle electrical connector to main engine harness (up to 25 cm [10 in.] away from connector).




    If there is visual evidence of wire damage and the location of the open circuit can be identified, continue with next step.





    If there is no evidence of wire damage, physically inspect each wire by sliding fingers along entire length of wire and feel for abnormalities or depressions.





    - If wire damage is located during physical inspection, continue with next step.





    - If no wire damage is located during physical inspection, continue to step 10.






    Important: When splicing in new connector, stagger crimp-and-seal connectors so they are not all in same location. Staggering crimp-and-seal connectors will allow for a better finished look.




  • Once location of open circuit is identified, replace transaxle connector in its entirety (all ten circuits) with replacement transaxle connector (P/N 21024415).




    9.1. Cut transaxle connector circuit branch within 38 mm (1.5 in.) of main harness to ensure any other possibly affected circuits are repaired. Discard transaxle connector.





    9.2. Remove insulation from ends of cut wires and new transaxle connector harness. Recommended strip length is 4.8 mm (3/16 in.) for 12-20 gauge wire and 9.5 mm (3/8 in.) for 22 gauge wire so it can be folded in half. Care must be used when stripping wire to prevent cutting the wire strands.

    * Can be ordered through Delphi-Packard by calling 1-800-PACKARD (1-800-722-5273).

    ** Can be ordered through Saturn Special Tool Catalog. Found with J44020 Terminal Repair Kit.






    Important: For the wiring used in Saturn vehicles, it is recommended that only approved Packard Electric Crimp and Seal Splice Sleeves (or equivalent) be used.








    9.3. Using a Saturn-approved crimp and seal splice sleeve (found in terminal repair kit J44020), position stripped ends of wires in sleeve until wires hit stop.
  • 9.4.
    Hand crimp splice sleeve using correct jaws in Packard crimper (P/N 12085155) or appropriate crimping tool. Gently tug on wires to ensure they are secure before applying heat to seal sleeve.



    Caution: DO NOT USE A MATCH OR OPEN FLAME TO APPLY HEAT TO SPLICE SLEEVE.








    9.5. Apply heat using Ultratorch ® or heat gun. Heat to 175° C (347° F) until glue flows around edges of sleeve.





    9.6. Check for continuity in the wire and verify the repair.

  • Connect transaxle range switch connectors.
    Notice: Do not over-tighten or damage tot he connector plate may occur.

  • Connect transaxle electrical connector, and torque transaxle electrical connector bolt.
    Tighten
    Transaxle Electrical Connector Bolt: 3 N·m (27 in lb)

  • Clear DTC(s) and retest.




    If a DTC is reset, refer to diagnostic aids in appropriate model year Automatic Transaxle service manual and continue with next step.





    If no DTCs are rest, go to step 15.

  • Clear DTC(s) again.
  • Check for intermittent circuit fault. Wiggle harness near connector while performing diagnostic test on affected circuit.




    If DTC sets, refer to appropriate diagnostic flow chart for circuit number identification. (Refer to appropriate model year Automatic Transaxle service manual for diagnostic flow charts.) Continue with next step after diagnostics have been completed.





    If DTC does not set, refer to diagnostic aids in appropriate model year Automatic Transaxle service manual for intermittent conditions. Continue with next step after diagnostics have been completed.

  • Using high quality electrical tape, re-wrap transaxle connector circuit branch from main harness breakout to connector.
  • Install battery tray.
    Tighten
    Battery Tray-to-Vehicle Bolts: 10 N·m (89 in lbs)

  • Install battery
    Tighten
    Battery Terminal Bolts: 17 N·m (13 lb ft)
ADVERTISEMENT

Top Transmission Shifting Experts View More

Rank Leader Points
1. karjunkie 2285
2. MrShift@Edmunds 1720
3. snowball2 455
4. zaken1 445
5. texases 240
6. mcdawgg 205
7. laltazan 195
ADVERTISEMENT