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Home › Saturn › 2005 › L300 › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transaxle - Introduction & Repair Instructions › Repair Instructions › Case Side Cover Replacement › Installation Procedure

Installation Procedure

    Fig 1: Identifying Transaxle Case Side Cover Gasket & Driven Sprocket Thrust Washer
    GM892802Courtesy of GENERAL MOTORS CORP.
  1. Inspect the case side cover for cracks or damage to the seal grooves and the mounting bosses.
  2. Inspect the side cover seals for damage. The side cover seals are reusable if not damaged.
  3. Thoroughly clean the side cover and side cover seals. Clean and dry the seal grooves and axle seal bore.
  4. Install the case side cover gaskets into grooves on the side cover. Retain seals with petroleum jelly.
  5. Install the side cover to driven sprocket thrust washer onto the side cover. Retain with petroleum jelly.
    6. Fig 2: Removing & Installing Lower Transaxle Case Side Cover Bolts
    GM893279Courtesy of GENERAL MOTORS CORP.
    NOTE: J 41102 must be used on the output shaft of the transaxle to protect the axle seal from damage when installing the case side cover. If J 41102 is not used, damage to the seal may result.
  6. Install the J 41102 on the output shaft of transaxle, and install the side cover assembly onto the transaxle case.
    7. NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Install and hand start the lower side cover-to-transaxle case bolts and tighten.

    Tighten:  Tighten the side cover-to-transaxle case bolt to 20 N.m (15 lb ft).

    8. Fig 3: Removing & Installing Left Transaxle Mount Bracket At Transaxle
    GM891647Courtesy of GENERAL MOTORS CORP.
  8. Install the left transaxle mount bracket to transaxle.

    Tighten:  Tighten the left transaxle mount bracket-to-transaxle bolts to 90 N.m (66 lb ft).

  9. Install the power steering lines to the left transaxle mount bracket.

    Tighten:  Tighten power steering lines-to-left transaxle mount bracket to 10 N.m (89 lb in).

    10. NOTE: In order to prevent damage to shaft splines during vehicle operation, add grease P/N 7847638 to the splines on the stub shaft.
  10. Install a new axle retaining clip on the output shaft of transaxle. Untie the left axle shaft and install the axle shaft into the transaxle.
  11. Install the frame assembly. Refer to Frame Replacement in Frame and Underbody.
    12. Fig 4: Removing & Installing Rear Transaxle Mount
    GM891641Courtesy of GENERAL MOTORS CORP.
  12. Install the left transaxle mount to the engine compartment rail.

    Tighten:  Tighten the transaxle mount (left)-to-engine compartment rail bolts to 20 N.m (15 lb ft).

    13. Fig 5: Locating Transmission Mount-To-Transmission Bolts
    GM891639Courtesy of GENERAL MOTORS CORP.
    NOTE: If the powertrain mount is not reinstalled in its original position, it could lead to premature mount wear.
  13. Reference the alignment marks made during disassembly and install the left transaxle mount bolts.

    Tighten:  Tighten the transaxle mount (left)-to-transaxle mount bracket bolts to 55 N.m (41 lb ft).

  14. Remove the engine support bar assembly.
    15. Fig 6: Removing & Installing Lower Transaxle Case Side Cover Bolts
    GM893279Courtesy of GENERAL MOTORS CORP.
  15. Install the upper transaxle side cover fasteners.

    Tighten:  Tighten the side cover-to-transaxle case bolts to 20 N.m (15 lb ft).

  16. Install the wire harness to the transaxle case side cover.

    Tighten:  Tighten wiring harness attachment fasteners to 20 N.m (15 lb ft).

    17. Fig 7: Locating Transaxle Range Switch Bolts
    GM893832Courtesy of GENERAL MOTORS CORP.
  17. Make sure the transaxle manual shaft is in the NEUTRAL (N) position.
  18. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch.
  19. Loosely install the transaxle range switch bolts.
    20. Fig 8: Identifying J 41545
    GM893833Courtesy of GENERAL MOTORS CORP.
  20. Insert the J 41545  as shown and rotate the switch until the tool drops into position. See Special Tools .
  21. Tighten the transaxle range switch bolts.

    Tighten:  Tighten transaxle range switch bolts to 20 N.m (15 lb ft).

  22. Remove the alignment tool.
    23. Fig 9: Removing/Installing Transaxle Range Switch Lever & Nut
    GM893829Courtesy of GENERAL MOTORS CORP.
  23. Install the transaxle range switch lever and nut.

    Tighten:  Tighten the transaxle range switch lever nut to 35 N.m (26 lb ft).

    24. Fig 10: Identifying Automatic Transmission Cable & Selector Lever
    GM893831Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: After adjusting the switch, verify the engine only starts in PARK or NEUTRAL. If the engine starts in any other position, readjust the switch.
  24. Connect the transaxle range switch electrical connectors.
  25. Install the shift control cable to the transaxle range switch lever and verify proper operation.
    26. Fig 11: Removing & Installing Battery Tray
    GM886646Courtesy of GENERAL MOTORS CORP.
  26. Install the battery tray and the battery tray fasteners.

    Tighten:  Tighten the battery bolts to 15 N.m (11 lb ft).

    27. Fig 12: Removing & Installing Underhood Electrical Center Or Junction Block
    GM886877Courtesy of GENERAL MOTORS CORP.
  27. Install the underhood fuse block case to the battery tray and install the bolt.

    Tighten:  Tighten the underhood fuse block case bolt to 9 N.m (80 lb in).

    28. Fig 13: Harness Routing At Underhood Electrical Center Or Junction Block
    GM886874Courtesy of GENERAL MOTORS CORP.
  28. Install the wire harnesses to the fuse block case. The wire harness grommets have retaining tabs that lock into the case (3) when the harnesses are fully installed.
    • Engine (A)
    • Forward Lamp (B)
    • Instrument Panel (I/P) (C)
  29. Snap the fuse block onto the fuse block case hinges.
  30. Install the following connectors to the underhood fuse block:
    • Engine 68-way (1)
    • Forward Lamp 68-way (2)
    • I/P 68-way (3)
    31. Fig 14: Disconnecting & Connecting Underhood Electrical Center Or Junction Block Electrical Connectors
    GM886875Courtesy of GENERAL MOTORS CORP.
  31. Install the following connectors to the underhood fuse block:
    • Forward Lamp 2-way (White) (4)
    • I/P 2-way (Black) (5)
    • I/P 2-way (Green) (6)
    • I/P 2-way (Brown) (7)
  32. Secure the underhood fuse block to the fuse block case by rotating down and snapping into place.
  33. Install the underhood fuse block cover.
  34. Secure the coolant hose into place on the fuse block cover.
  35. Install the battery feed cable to the underhood fuse block.

    Tighten:  Tighten the battery feed cable-to-underhood fuse block bolt to 16 N.m (12 lb ft).

    36. Fig 15: View Of Battery, Fan Control Module & Battery Hold-Down Bracket
    GM886658Courtesy of GENERAL MOTORS CORP.
  36. Install the battery.
    1. Install the battery into the battery tray.
    2. Install the battery hold-down bracket.

      Tighten:  Tighten the battery hold down bracket bolt to 20 N.m (15 lb in).

      3. IMPORTANT: The positive battery terminal must be connected first to prevent arcing.
    3. Install the fan control module by sliding down onto the battery hold-down bracket.
    4. Install the positive battery cables first and then the negative battery cable.

      Tighten:  Tighten the battery cables-to-battery to 17 N.m (13 lb ft).

  37. Start the engine, warm up the transaxle, and check for fluid leaks.
  38. Check for proper fluid level. Refer to Transmission Fluid Checking Procedure .
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