Grinding / Rattle Type Noise from Manual Transmission M86 M94 - 5sp first fluid gear information lubrication plug second shift vibration

When servicing the vehicle with the VIN you entered, the following diagnosis might be helpful if the vehicle exhibits the described symptoms.

Repeat grinding or rattle type noise coming from the transmission after performing TSB 02-07-29-001. The noise usually occurs with the transmission in first or second gear at low RPM's and can be intermittent and should be greatly reduced after performing the bulletin procedure.

The diagnostic procedure for TSB 02-07-29-001 MUST be followed exactly.

If the noise characteristics match Noise #2 as described in the bulletin, DO NOT ATTEMPT TO REPAIR THE VEHICLE. This is a characteristic of the vehicle and can not be corrected.

If the noise characteristics match "Noise #1" as described in the bulletin after the overfill procedure has been performed, follow the procedure listed below for the installation of the wavy washers.

The noise in question is found in first and second gears while driving. However, the fix is implemented in the third and fourth gears.

1. Please refer to the published service information for the assembly and disassembly of the transmission. There are no other changes required for this installation.
2. Remove the input shaft followed by the third and fourth speed gears and respective blocker rings per the service information. Refer to DOC ID number 901674 of the 2003 Unit Repair Manual.
3. The wavy washers are installed between the blocker ring and the third speed gear and between the blocker ring and the fourth speed gear with the tabs on the washer snapping into the grooves at the base of the gear cone. The tabs on the washer MUST face the speed gear. Refer to DOC ID number 901676 of the 2003 Unit Repair Manual.
4. The blocker rings and gear sets are then re-assembled per the published service information.

Note: The Saturn fluid and overfill is not necessary once the wavy washers have been installed.

Parts and Labor operation information:

Part number: 12577493. Part number shown is the most current at the time of this information.

Part numbers are subject to change.

Quantity needed: 2

Labor Operation: K3161 3-4 synchronizer

Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. This diagnostic approach was developed for the vehicle with the VIN you entered and should not be automatically be used for other vehicles with similar symptoms.