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Transaxle Case Side Cover: Removal

  1. Position vehicle on hoist. Remove battery. Disconnect battery cables (negative first, positive second). Move fan control module. Leave wiring connected, lift module up and away from bracket, and position out of way. Remove battery hold-down bracket.
  2. Remove battery. See Fig 1. Disconnect battery feed to underhood fuse block. Disconnect coolant hose from underhood fuse block. Release retaining tabs on underhood fuse block cover and remove.
    Fig 1: Removing Battery Hold Down
    G00078023Courtesy of GENERAL MOTORS CORP.
  3. Release retaining tabs (2) on underhood fuse block and roll fuse block back (1) to access harness connectors. See Fig 2. Remove the following connectors from underhood fuse block and lift fuse block off case:
    • 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 Fig 3 and Fig 4 .

    Fig 2: Identifying Retaining Tabs
    G00078026Courtesy of GENERAL MOTORS CORP.
    Fig 3: Identifying Underhood Fuse Block Harness Connectors (1 Of 2)
    G00078024Courtesy of GENERAL MOTORS CORP.
    Fig 4: Identifying Underhood Fuse Block Harness Connectors (2 Of 2)
    G00078025Courtesy of GENERAL MOTORS CORP.
    4. NOTE: There are 2 tabs that hold hard shell grommets in place at bottom of grommet. Disengage tabs to remove grommet from case.
  4. Remove harnesses from underhood fuse block case by releasing retaining tabs on bottom of hard shell grommets for engine (A), forward lamp (B) and instrument panel (C) harnesses. See Fig 3. Remove underhood fuse block case fastener, and remove case from battery tray.
  5. Remove battery tray fasteners and battery tray. See Fig 5. Remove wire harness from transaxle case side cover. Remove clamp from A.I.R. hose behind cooling fan. Separate A.I.R. tube from hose and push tube back toward transaxle. See Figure. Note original position of A.I.R. components. Apply parking brake and place control assembly in Neutral position. Transaxle manual shaft must be in Neutral position prior to re-installing transaxle range switch.
    Fig 5: Removing & Installing Battery Tray
    G00078027Courtesy of GENERAL MOTORS CORP.
  6. Remove shift control cable from transaxle range switch lever. Disconnect harness connectors from transaxle range switch. See Fig 6. Remove transaxle range switch lever nut and lever. Remove transaxle range switch bolts and remove switch. Remove upper transaxle case side cover fasteners. See Fig 7.
    Fig 6: Removing & Installing Shift Control Cable
    G00078028Courtesy of GENERAL MOTORS CORP.
    Fig 7: Removing & Installing Upper Transaxle Case Bolts
    G00078029Courtesy of GENERAL MOTORS CORP.
  7. On vehicles equipped with 2.2L engine, install Engine Support Bar Assembly (SA9105E) with Engine Support Fixture Adapter (743405). On vehicles equipped with 3.0L engine, install engine support fixture assembly with engine Support Fixture Adapter (J-43405). See Fig 8 and Fig 9 . Mark position of, and then remove left transaxle mount bolts. See Fig 10.
    Fig 8: Identifying Engine Support (2.2L)
    G00078030Courtesy of GENERAL MOTORS CORP.
    Fig 9: Identifying Engine Support (3.0L)
    G00078031Courtesy of GENERAL MOTORS CORP.
    Fig 10: Removing & Installing Left Transaxle Mount Bolts
    G00078032Courtesy of GENERAL MOTORS CORP.
    8. CAUTION: To prevent damage to CV joint boots, be careful not to allow them to contact other parts during removal/installation process. Also, never pull on shaft assembly.
  8. Remove left transaxle mount from engine compartment rail. Remove frame assembly. See appropriate REMOVAL & INSTALLATION article. Remove left drive axle from transaxle using a pry bar. Remove axle retaining ring from output shaft of transaxle and discard. Axle can be left in steering knuckle. Tie axle up and out of the way.
    9. CAUTION: Pry on side cover near locating dowel pins to prevent damage to sealing surfaces.
  9. Remove power steering lines from left transaxle mount bracket. Remove transaxle mount bracket fasteners and remove bracket. Remove remaining transaxle case side cover bolts and remove case side cover. See Fig 11. Remove 2 case side cover gaskets and side cover to driven support thrust washer, if they did not remain with side cover assembly when it was removed. See Fig 12.
Fig 11: Removing & Installing Lower Transaxle Side Cover Bolts
G00078033Courtesy of GENERAL MOTORS CORP.
Fig 12: Removing Side Cover Gaskets
G00078034Courtesy of GENERAL MOTORS CORP.
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