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Home › Chevrolet › 2005 › Malibu Base › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transaxle - Introduction & Repair Instructions › Repair Instructions › Transmission Replacement › Installation Procedure

Installation Procedure

  1. Install the PNP switch.
  2. Install the torque converter clutch (TCC) lock up clutch O-ring.
  3. Install the torque converter.
  4. Transfer the transaxle from the bench fixture to transmission jack.
  5. Install the side cover transmission mount bracket to the transmission.
  6. Install the rear transmission mount bracket to the transmission.
  7. Position the transaxle in the vehicle.
    8. Fig 1: Identifying Lower Transmission To Engine Bolts And Stud
    GM104580Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the lower transmission to engine bolts and nuts.

    Tighten:  Tighten the bolts and nuts to 90 N.m (66 lb ft).

  9. Install the front transmission mount bracket to the transmission.
  10. Connect the wheel drive shafts to the transmission. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
    11. Fig 2: View Of VSS Wiring Harness
    GM414901Courtesy of GENERAL MOTORS CORP.
  11. Connect the VSS wiring harness to the VSS.
    12. Fig 3: View Of Flywheel To Torque Converter Bolts
    GM475919Courtesy of GENERAL MOTORS CORP.
  12. Install the torque converter to flywheel bolts.

    Tighten:  Tighten the torque converter bolts to 62 N.m (46 lb ft).

    13. Fig 4: View Of Flywheel Inspection Cover Bolts
    GM510441Courtesy of GENERAL MOTORS CORP.
  13. Install the starter. Refer to Starter Motor Replacement (L61) or Starter Motor Replacement (LX9) in Engine Electrical.
  14. Install the flywheel inspection cover bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

  15. Connect the transaxle cooler pipes to the transaxle.

    Tighten:  Tighten the cooler pipes to 8 N.m (71 lb in).

  16. Install the oil pan to bell housing bracket (3 bolts).

    Tighten:  Tighten to 72 N.m (53 lb ft).

  17. Install the 3 bolts to the transmission brace at final area and tighten.
  18. Remove the transmission jack.
  19. Install the frame. Refer to Frame Replacement (W/L61) or Frame Replacement (W/LX9) Frame and Underbody.
  20. Install the engine splash shields.
  21. Install the front wheel and tire assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  22. Lower the vehicle.
  23. Remove the radiator and condenser support, and the engine support fixture
  24. Install the upper transmission to engine bolts and stud.

    Tighten:  Tighten the bolts to 90 N.m (66 lb ft).

    25. Fig 5: Installing Shift Cable Bracket
    GM1239109Courtesy of GENERAL MOTORS CORP.
  25. Install the shift cable bracket and shift cable to the lever.
  26. Install the exhaust pipe upper bolts and heat shield.
    27. Fig 6: Identifying Shift Control Cable, Lever & Electrical Connector At Transaxle Range (TR) Switch
    GM1233683Courtesy of GENERAL MOTORS CORP.
  27. Connect the electrical connectors to the PNP switch and transaxle.
  28. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  29. Install the battery cover.
  30. Install the air intake duct to the throttle body and air cleaner assembly.
  31. Add automatic transmission fluid (ATF) and verify the proper fluid level of transaxle.
  32. Road test the vehicle.
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