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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 › Removal Procedure

Removal Procedure

    CAUTION: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.
    Fig 1: View Of Battery, Fan Control Module & Battery Hold-Down Bracket
    GM886658Courtesy of GENERAL MOTORS CORP.
  1. Position the vehicle on a hoist.
  2. Remove the battery.
    1. Disconnect the negative battery cable.
    2. Disconnect the positive battery cable.
    3. Move the fan control module. Leave the wiring connected, lift the module up and away from the bracket, and position out of the way.
    4. Remove the battery hold-down bracket.
    5. Remove the battery.
    3. Fig 2: Rolling Back Underhood Fuse Block To Access Electrical Connectors
    GM886881Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the battery feed to the underhood fuse block.
  4. Disconnect the coolant hose from the underhood fuse block.
  5. Release the retaining tabs on the underhood fuse block cover and remove.
  6. Release the retaining tabs (2) on the underhood fuse block and roll the fuse block (1) back to access the electrical connectors.
    7. Fig 3: Harness Routing At Underhood Electrical Center Or Junction Block
    GM886874Courtesy of GENERAL MOTORS CORP.
  7. Remove the following connectors from the underhood fuse block:
    • Engine 68-way (1)
    • Forward Lamp 68-way (2)
    • I/P 68 way (3)
    8. Fig 4: Disconnecting & Connecting Underhood Electrical Center Or Junction Block Electrical Connectors
    GM886875Courtesy of GENERAL MOTORS CORP.
  8. Remove the following connectors from 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)
  9. Lift the fuse block off the case.
    10. Fig 5: Harness Routing At Underhood Electrical Center Or Junction Block
    GM886874Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: There are 2 tabs that hold the hard shell grommets in place at the bottom of the grommet. Disengage the tabs to remove the grommet from the case.
  10. Remove the harnesses from the underhood fuse block case by releasing the retaining tabs on the bottom of the hard shell grommets.
    • Engine (A)
    • Forward Lamp (B)
    • Instrument Panel (I/P) (C)
  11. Remove the underhood fuse block case fastener and the case from the battery tray.
    12. Fig 6: Removing & Installing Battery Tray
    GM886646Courtesy of GENERAL MOTORS CORP.
  12. Remove the battery tray fasteners and the battery tray.
  13. Remove the wire harness from the transaxle case side cover.
    14. Fig 7: Removing Power Steering Line Hose Clip
    GM893366Courtesy of GENERAL MOTORS CORP.
  14. Remove the hose clip, holding the 2 power steering lines together.
    15. Fig 8: Identifying Automatic Transmission Cable & Selector Lever
    GM893831Courtesy of GENERAL MOTORS CORP.
  15. Apply the parking brake and place the control assembly in NEUTRAL. The transaxle manual shaft must be in NEUTRAL position prior to installing the range switch.
  16. Remove the shift control cable from the transaxle range switch lever.
  17. Disconnect the electrical connectors from the transaxle range switch.
    18. Fig 9: Removing/Installing Transaxle Range Switch Lever & Nut
    GM893829Courtesy of GENERAL MOTORS CORP.
  18. Remove the transaxle range switch lever nut and lever.
    19. Fig 10: Locating Transaxle Range Switch Bolts
    GM893832Courtesy of GENERAL MOTORS CORP.
  19. Remove the transaxle range switch bolts and remove the switch.
    20. Fig 11: Removing Upper Transaxle Case Side Cover Bolts
    GM893277Courtesy of GENERAL MOTORS CORP.
  20. Remove the upper transaxle case side cover fasteners.
    21. Fig 12: Identifying Properly Installed Engine Support Fixture
    GM893249Courtesy of GENERAL MOTORS CORP.
  21. Install the SA9105E  with the J 43405  as shown. L61 (L4) is shown.
    22. Fig 13: Supporting Engine With Engine Support Fixture
    GM893254Courtesy of GENERAL MOTORS CORP.
  22. Install the SA9105E  with the J 43405  as shown. L81 (V6) is shown.
    23. Fig 14: Removing & Installing Rear Transaxle Mount
    GM891641Courtesy of GENERAL MOTORS CORP.
  23. Mark the position of and remove the left transaxle mount bolts.
  24. Remove the left transaxle mount from the engine compartment rail.
  25. Remove the frame assembly. Refer to Frame Replacement in Frame and Underbody.
    26. Fig 15: Removing Drive Axle From Transaxle
    GM891575Courtesy of GENERAL MOTORS CORP.
    NOTE: To prevent damage to CV Joint boots, be careful not to allow them to contact other parts during the removal/installation process. Also, never pull on the shaft assembly.
  26. Remove the left drive axle from the transaxle using a pry bar. Remove the axle retaining ring from the output shaft of the transaxle and discard. The axle can be left in the steering knuckle. Tie the axle up and out of the way.
    27. Fig 16: Removing & Installing Left Transaxle Mount Bracket At Transaxle
    GM891647Courtesy of GENERAL MOTORS CORP.
  27. Remove the power steering lines from left transaxle mount bracket. Remove the transaxle mount bracket fasteners and remove the bracket.
    28. Fig 17: Removing & Installing Lower Transaxle Case Side Cover Bolts
    GM893279Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Pry on the side cover near locating dowel pins to prevent damage to the sealing surfaces.
  28. Remove the remaining transaxle case side cover bolts and remove the case side cover.
    29. Fig 18: Removing Transaxle Case Side Cover
    GM894906Courtesy of GENERAL MOTORS CORP.
  29. Remove the 2 case side cover gaskets and side cover to driven support thrust washer, if they did not remain with the side cover assembly when it was removed.
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