FixVault
Home › Saturn › 2000 › LS2 Automatic › Repair and Diagnosis › Transmission › Automatic Trans › Servicing - A/T › Removal & Installation › Transaxle Case Side Cover › Installation

Transaxle Case Side Cover: Installation

  1. Inspect case side cover for cracks or damage to seal grooves and mounting bosses. Inspect side cover seals for damage. Side cover seals are reusable, if not damaged. Thoroughly clean side cover and side cover seals. Clean and dry seal grooves and axle seal bore. Install case side cover gaskets into grooves on side cover. See Fig 1. Retain seals with petroleum jelly.
    Fig 1: Installing Side Cover Gaskets
    G00078035Courtesy of GENERAL MOTORS CORP.
    2. CAUTION: Axle Seal Protector (J41102) must be used on output shaft of transaxle to protect axle seal from damage when installing case side cover. If axle seal protector is not used, damage to seal may result.
  2. Install side cover to driven sprocket thrust washer onto side cover. Retain with petroleum jelly. Install axle seal protector on output shaft of transaxle, and install side cover assembly onto transaxle case. Install and hand start lower side cover-to-transaxle case bolts and tighten to specification. See TORQUE SPECIFICATIONS .
  3. Install left transaxle mount bracket to transaxle. Tighten transaxle mount bracket-to-transaxle bolts to specification. See TORQUE SPECIFICATIONS . Install power steering lines to left transaxle mount bracket. Tighten power steering lines-to-left transaxle mount bracket bolts to specification.
    4. CAUTION: In order to prevent damage to axle shaft splines during vehicle operation, add grease to axle shaft splines prior to axle shaft installation.
  4. Install a new axle retaining clip on output shaft of transaxle. Untie left axle shaft and install axle shaft into transaxle. Install frame assembly. See appropriate REMOVAL & INSTALLATION article. Lower vehicle. Install left transaxle mount to engine compartment rail. Tighten left transaxle mount-to-engine compartment rail bolts to specification.
    5. CAUTION: If powertrain mount is not reinstalled in its original position, it could lead to premature mount wear.
  5. Reference alignment marks made during disassembly and install left transaxle mount bolts. Tighten transaxle mount-to-transaxle mount bracket bolts to specification. See TORQUE SPECIFICATIONS . Remove engine support bar assembly. Install upper transaxle side cover fasteners. Tighten side cover-to-transaxle case bolts to specification.
  6. Install wire harness to transaxle case side cover. Tighten wiring harness attachment fasteners to specification. See TORQUE SPECIFICATIONS . Make sure transaxle manual shaft is in Neutral position. Align flats on transaxle shift shaft with flats on transaxle range switch and install switch. Loosely install transaxle range switch bolts.
    7. NOTE: After adjusting switch, verify engine starts only in Park or Neutral. If engine starts in any other position, readjust switch.
  7. Adjust transaxle range switch. See TRANSAXLE RANGE SWITCH  under ADJUSTMENTS. Install transaxle range switch lever and nut. Tighten transaxle range switch lever nut to specification. See TORQUE SPECIFICATIONS . Connect transaxle range switch harness connectors.
  8. Install shift control cable to transaxle range switch lever and verify proper operation. Install battery tray and battery tray fasteners. Tighten battery tray bolts to specification. Install underhood fuse block case to battery tray and install bolt. Tighten underhood fuse block case bolts to specification. See TORQUE SPECIFICATIONS .
  9. Install wire harnesses to fuse block case. Wire harness grommets have retaining tabs that lock into case (3) when engine (A), forward lamp (B) and instrument panel (C) harnesses are fully installed. See Figure. Snap fuse block onto fuse block case hinges. Install the following connectors to underhood fuse block:
    • Engine 68 pin (1).
    • Forward lamp 68 pin (2).
    • Instrument panel 68 pin (3).
    • Forward lamp 2 pin (White) (4).
    • Instrument panel 2 pin (Black) (5).
    • Instrument panel 2 pin (Green) (6).
    • Instrument panel 2 pin (Brown) (7).

    For identification of harness connectors, refer to illustrations. See Figure and Figure .

  10. Secure underhood fuse block to fuse block case by rotating down and snapping into place. Install underhood fuse block cover. Secure coolant hose into place on fuse block cover. Install battery feed cable to underhood fuse block. Tighten battery feed cable-to-underhood fuse block bolt to specification. See TORQUE SPECIFICATIONS .
    11. CAUTION: Positive battery terminal must be connected first to prevent arcing.
  11. Install battery. Install battery into battery tray. Install battery hold down bracket. Tighten battery hold down bracket bolt to specification. Install fan control module by sliding down onto battery hold down bracket. Install battery cables (positive first, negative second). Tighten battery cables to specification. See TORQUE SPECIFICATIONS .
  12. Start engine, warm up transaxle, and check for leaks. Check for proper fluid level. See CHECKING FLUID LEVELS  under LUBRICATION.
About FixVault