Manual Transmission Linkage NOISE Mystery

[CRUX]

Original Post onRedline Forum 6/30/08
Manual Transmission Linkage Mystery

Okay, so I took my Sky into the Dealer for service today… I had the dealerships main service technician go out with me for a test drive before he got started with the diagnostics. My service tag reads: “Customer states when clutch is pressed in and or gearshift activated there is noise. Check & Advise” So we take the test-drive and every time I am in first gear and press in the clutch (after accelerating) there is a metal slapping or shuttering noise coming from the drive train (mostly from the rear). The noise is present in the other gears but most definitely in first. The technician tells me he positively hears it and it’s good that its consistence, so they can trouble shoot it easier. So we go back to the dealership and they take the car away for about 2 hours. I get the call it is ready and the service representative gives me a three page document (see attached) and tells me everything is fine and they went ahead and completed the scheduled maintenance and all is good… After reading the document, which states: [The purpose of this bulletin is to assist in identifying characteristics of manual transmissions that repair attempts will not change.] Oh, and one other note: this document/bulletin is for most all GM cars in general. I spoke to the sales manager who was a pretty down to earth guy, as I knew him when I brought the car. Now he goes out and talks to the service technician. So he comes back and tells me “basically if it isn’t causing a safety concern it’s just a design issue and you’ll just have to live with it!” Also, there is another bulletin coming out this month that specifically mentions the “SKY drive train” and the “Clutch” and apparently there is something about a “DAMPER” that makes noise when the clutch is depressed at low throttle and low speeds!! Again, they know about these issues but they are keeping it under wraps and just publishing disclaimers in the form of bulletins. So, back to my service tag: It states: “Inspected & verified test drive with customer. Rattle type sound present coming from rear when pushing in clutch. No damage or loose parts found. See Noise Doc# 03-07-29-004E for normal trans… Customer is advised” So that’s the gist of it!! Someone had said in an earlier reply “just turn up the radio”…. he must have been a used car salesman in his past as that’s what was done back in the day to hide noises!!! So bottom line…. If it’s broke GM will replace the parts but if it’s not causing a safety issue or doesn’t impede performance, you are stuck with it and you get no sympathy! So when you read reviews about the Saturn Sky and they say its all good, they just might be talking about an automatic transmission!!!
Attached Files

[coopcj7]

I had all kind of clunks and other noises when I shifted my 2.4. took it in the for recall and they replaced the whole differential. now I dont have any noise at all even on low rpm shifting. It is quiet as a mouse

[sky4me2ply]

I just purchased a 2007 used Sky 2.4 about 1 month ago. Got a really good price on it from a chevy dealer right down the street from a Saturn dealership. At any rate, I have begun noticing grinding and more specifically "clunking" noises from the rear end of my car during shifts from first gear to second gear.

I just took the car to the Saturn dealership this morning to look into the grinding and clunking and within 2 hours I received a phone call from them telling me that the entire differential would need to be replaced. However, they needed to order it and that it would be in by the end of the week. I hope to hear from them soon to get it installed but they said that all of the clunking was coming from the differential.

I would highly recommend that you take your car to a different Saturn dealership and have them take a look at it again. I would also have them check to make sure that the differential recall has been addressed on your car.

Good luck.

[CRUX]

Thanks for the feedback. I had my RL in for the recall last year when it started leaking fluid on my garage floor. It wasn’t making the noises as much then and the dealership (which was a different one) said they could not hear any sounds? I just guess from what the sales manager told me today that unless I “break it” it wouldn’t get replaced. By the way the noises are coming now more frequently, it may not be long till it breaks!!

[sky4me2ply]

Crux...

Along with the "clunking" I was also noticing a high pitched whining noise from the rear end when at speed (approximately 60 mph).

This noise along with the clunking is what really tipped me off that there might be a problem. When they checked the service records on my car (since I just purchased it) they showed also that mine had been in for the recall work. However, they said that the only work completed on mine was the installation of a new differential vent and a new seal. It is my understanding from what I have read on this forum, that there are a few other parts that need to be replaced as part of the recall and the following bulletins.

My dealer (Saturn of Avondale) seemed to be very aware of the differential problems and even told me when I dropped off the car that chances are that the differential would need to be replaced. They had to do their diagnostics first but they seemed to be already aware that it would need to be replaced.

Not sure why your dealer is being so resistant to admitting that there might be a problem with your car. You are right... you may very well have a "broken" car soon. Mine right now until they get the new differential delivered is clunking so much it sounds like the rear wheels are going to fall off. They changed the fluid in the differential until the new one comes in so that they could ensure it would be ok until then.

I had always heard that Saturn was such a customer service driven company. Was not very satisfied with their sales department (why I ended up buying mine from a chevy dealer) but the service department is top notch.

Do you have another Saturn dealer in the area that you could get a second opinion from?

Good luck!!! I will let you know the outcome of my differential swap once it is completed.

[CRUX]

Hey Brad, thanks again for the input. Yes I too have that high pitch sound when I am at high speeds and I have had it ever since I had the car. I always thought it might have been normal?? Well it will be interesting to hear how your new differential works out. It seems that is really the answer but GM doesn’t want to own up to it and many dealers play along!! Keep me posted…

Len
San Francisco Bay Area

[CRUX]

So I couldn't deal with the annoying metal sound any longer and it was getting to the point that I didn’t want to drive my baby…every time I pushed in the clutch I heard metal noises…. so I traded it back into Saturn and took a monetary beating…. I traded up to a ‘08 AUTOMATIC!! Sometimes you got to do what you got to do… I hope no one else has a similar problem, as GM won’t acknowledge it unless it becomes life threatening. There is a definite problem and at some point it will resurface.

[jus2shy]

I wouldn't think there's anything wrong with the ratcheting noise of the manual transmission. It is the same transmission as the one from the Chevy Colorado. It sounds like my dad's old F250, which clanked and clunked even louder, hell, it had a lot more drive line lash and that was all normal. Thankfully I only have the ratcheting noise, I don't have the dreaded "clunk", and my undercarriage doesn't have any grease .

[JRinKY]

If you search through this forum and the Solstice forum you will find that there are a variety of noises that emanate from the drivetrain. Some of them are normal, some are not. Some of them indicate problems, some do not.

All mechanical systems make noise. Much of the problem with the Kappas is the fact that you sit much closer to the drivetrain than in other cars, so small noises that you would not hear in other cars are quite apparent in ours.

Mine clunks during some shifts, and sometimes whines at some speeds. Neither sound is particularly loud, and neither indicates a problem.

I cannot conceive of trading a manual for an automatic to eliminate a noise that only occurs during shifting, but that's just my opinion.