Procedure
Since the powertrain damper kit is designed to correct a very specific vibration, it is important that all other possible causes of vehicle vibration be eliminated before installing the kit. Since a road test is necessary, it is important that the following checks are performed.IMPORTANT:
Perform all of the following checks before road testing vehicle.
^ Check for debris build-up on the tires and/or road wheels.
^ Check tires for tread distortions, separations, bulges from impact, and abnormal or excessive wear.
^ Check for bent and/or damaged road wheels.
^ Check for missing or loose road wheel weights.
^ Check for loose or missing road wheel lug nuts.
^ Check for proper tire bead seating on rim of road wheel.
^ Make sure the road wheel and tire assemblies are within specification for radial and lateral runout.
^ Make sure the road wheel and tire assemblies are correctly balanced to the nearest 0.10 oz.
^ Check front suspension components for excessive wear and/or damage:
1. Check if cradle is bent.
2. Check tension strut bushings for wear or damage.
3. Check lower control arms for worn ball studs, worn bushings, or bent arms.
4. Check steering gear for wear or damage.
5. Check inner and outer tie rod ends for wear or damage.
6. Check strut assemblies for wear, binding and to make sure they are not bent.
^ Check rear suspension components for excessive wear and/or damage:
1. Check components for wear or damage.
2. Check if the cross support is bent.
3. Check trailing arms to see if the bushings are worn or if the arms are bent.
4. Check lateral links to see if the bushings are worn or if the arms are bent.
5. Check stabilizer bar on vehicles so equipped for worn or missing bushings, and to verify that the stabilizer bar is not bent.
After checking the above items, road test the vehicle on a smooth road surface while very gradually accelerating the vehicle from 77 to 87 km/h (48 to 54 mph). If the vehicle is equipped with cruise control, it is convenient to use it to accelerate the vehicle at 2 km/h (1 mph) increments.
A vibration may start between 77 and 87 km/h (48 to 54 mph). It may grow more pronounced as the vehicle maintains a steady speed within the 77 to 87 km/h (48 to 54 mph) speed range on a smooth surface. Any rough areas in the road such as expansion joints or any irregularities in the road surface will interrupt the vibration, causing a need to restart the road test.
Install the powertrain damper kit under these circumstances only:
^ When all other possible causes for vehicle's vibration have been eliminated.
^ When a continuous vibration occurs only between 77 and 87 km/h (48 and 54 mph) and the vibration is most pronounced in the vehicle's floorboards and seat cushions.
Install P/N 21012637 for vehicle's equipped with automatic transaxles.
Install P/N 21012638 for vehicle's equipped with manual transaxles.
The powertrain damper kit comes with the damper installed to the upper bracket. The powertrain damper kit has two steel washers and two rubber grommets attached to the damper's shaft. One M8 x 20 mm bolt and one M8 nut (used for second design vehicles), and one M6 nut are included in each kit. Each kit contains a lower bracket. There are two lower bracket designs, one for automatic transaxies and one for manual transaxles.
The powertrain damper kit installs between the left midrail and the transaxle. Utilizing the forward battery tray fastener(s), the upper bracket attaches to the midrail, underneath the battery tray. The lower bracket (a modified transaxle strut bracket) attaches to the transaxle at the same location as the transaxle strut bracket. The damper itself attaches to the upper bracket with an M10 x 40 mm bolt and to the lower bracket with steel washers and the rubber grommets held in place with an M6 nut.
The following procedures are separated into four procedures:
1. Damper Bench Assembly to Lower Bracket (Required for all vehicles)
2. Battery and Battery Tray Removal (Required for all vehicles)
3. Powertrain Damper Kit Installation-First Design Vehicles (First Design - 1994 and early 1995 Saturns built before and including VIN SZ154030)
4. Powertrain Damper Kit Installation-Second Design Vehicles (Second Design - 1995 vehicles built after and including VIN SZ154031 and 1996-1999 vehicles)
IMPORTANT:
All 1994 and early 1995 Saturns used two vertical and two horizontal fasteners to secure the battery tray to the vehicle. (This is called the First design.) In September 1994, the front horizontal battery tray fastener was removed; all vehicles built after and including VIN SZ154031 have only the rearward horizontal battery tray fastener. (This is called the Second design.)
On 1995 vehicles built after and including VIN SZ154031 and 1996-1999 vehicles, a reinforcing bracket attached to the rear horizontal battery tray fastener helps support the battery tray. The procedure to install the powertrain damper kit differs if the vehicle has one or two horizontal battery tray fasteners.