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

Installation Procedure

  1. Place the transaxle on a hydraulic lift table and position the table under the vehicle.
  2. Slowly lower the vehicle and position the transaxle to the engine.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: The bottom 2 and top 3 engine-to-transaxle mounting bolts will be installed later in this procedure.
    IMPORTANT: Ensure that the wiring harness bracket is installed behind the engine-to-transaxle mounting bolt near the starter motor on the V6 engine.
  3. Install the engine-to-transaxle mounting bolts as shown. V6 shown, L4 similar.

    Tighten:  Tighten engine-to-transaxle bolts to 65 N.m (48 lb ft).

  4. Raise the vehicle and remove the hydraulic lift table.
  5. Lower the vehicle.
    6. Fig 1: 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.
  6. 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).

  7. Raise the vehicle.
  8. Install the 2 bottom engine-to-transaxle mounting bolts.
    9. Fig 2: Removing & Installing Transaxle Oil Cooler Line Assembly
    GM893244Courtesy of GENERAL MOTORS CORP.
    NOTE: Failure to lubricate the cooler line seals with automatic transaxle fluid DEXRON® III before installing into the case or before installing the cooler line pipes into the seals may cause damage to the seal.
  9. Install the transaxle oil cooler line assembly to the transaxle.

    Tighten:  Tighten the transaxle oil cooler line assembly nut to 8 N.m (71 lb in).

    10. Fig 3: Removing & Installing Flexplate-To-Torque Converter Bolts
    GM897507Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The J 44014  must be used to install the flex plate to torque converter bolts. See Special Tools . Care must be taken not to drop the bolts inside the torque converter housing of the transaxle. If a bolt is dropped inside the housing, the transaxle must be separated from the engine to retrieve it.
  10. Loosely install the flex plate to torque converter bolts using the J 44014  through the starter opening. See Special Tools . The J 42098  can be used to turn the V6 crankshaft. After all bolts are installed, torque to specification.

    Tighten:  Tighten the flex plate-to-torque converter bolts to 45 N.m (33 lb ft).

    11. Fig 4: Removing & Installing Starter Motor - L81
    GM895774Courtesy of GENERAL MOTORS CORP.
  11. Install the starter assembly. V6 shown, L4 similar.

    Tighten:  Tighten the starter assembly bolts to 40 N.m (30 lb ft).

  12. Connect the starter solenoid electrical connections.
  13. Install the wire harness mounting bracket to the rear of the engine block. V6 only.
    14. Fig 5: Removing & Installing Engine-To-Transaxle Bracket (L4 Shown; V6 Similar)
    GM893258Courtesy of GENERAL MOTORS CORP.
  14. Install the engine-to-transaxle bracket. L4 shown, V6 similar.

    Tighten:  Tighten the engine-to-transaxle bracket bolts to 35 N.m (26 lb ft).

    15. NOTE: In order to prevent damage to the axle shaft splines during vehicle operation, add grease P/N 7843867 to the splines prior to installing the axle shafts.
  15. Install the new axle shaft retaining rings on the end of the output shafts of the transaxle and install the axle shafts into the transaxle.
  16. Install the frame assembly. Refer to Frame Replacement Front in Frame and Underbody.
  17. Lower the vehicle and remove the engine support fixture.
    18. Fig 6: Removing & Installing Transaxle Output Speed Sensor
    GM893903Courtesy of GENERAL MOTORS CORP.
  18. Connect the output speed sensor electrical connector. Secure the harness to the mounting stud.
    19. Fig 7: Removing & Installing Generator Assembly
    GM895788Courtesy of GENERAL MOTORS CORP.
  19. Install the generator for V6 only.

    Tighten:  Tighten the generator bolts to 40 N.m (30 lb ft).

    20. Fig 8: Removing & Installing Drive Belt Tensioner
    GM896418Courtesy of GENERAL MOTORS CORP.
  20. Install the accessory drive belt tensioner assembly for V6 only.

    Tighten:  Tighten the accessory drive belt tension assembly bolts to 40 N.m (30 lb ft).

    21. Fig 9: Using 15 mm Wrench To Rotate Tensioner Pulley
    GM894336Courtesy of GENERAL MOTORS CORP.
  21. Install the accessory drive belt for V6 only.
  22. Install the remaining transaxle-to-engine mounting bolts.

    Tighten:  Tighten the engine-transaxle bolts to 65 N.m (48 lb ft).

    23. Fig 10: Removing & Installing Transaxle Electrical Connector & Ground Strap
    GM893248Courtesy of GENERAL MOTORS CORP.
  23. Install the transaxle electrical connector and ground wire to the transaxle.

    Tighten:  Tighten the ground wire bolt to 25 N.m (18 lb ft).

  24. Install the remaining wire harness attachments to the transaxle side cover.

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

    25. Fig 11: Removing & Installing Control Cable & Control Cable Bracket
    GM893893Courtesy of GENERAL MOTORS CORP.
  25. Install the control cable mounting bracket to the rear powertrain mount.

    Tighten:  Tighten the control cable mounting bracket bolts to 20 N.m (15 lb ft).

  26. Connect the control cable to the transaxle range switch lever.
    27. Fig 12: Removing & Installing Battery Tray
    GM886646Courtesy of GENERAL MOTORS CORP.
  27. Install the battery tray and battery tray fasteners.

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

    28. Fig 13: Removing & Installing Underhood Electrical Center Or Junction Block
    GM886877Courtesy of GENERAL MOTORS CORP.
  28. 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).

    29. Fig 14: Harness Routing At Underhood Electrical Center Or Junction Block
    GM886874Courtesy of GENERAL MOTORS CORP.
  29. Install the wire harnesses to the fuse block case. The wire harness grommets have retaining tabs that lock into the case when the harnesses are fully installed.
    • Engine (A)
    • Forward Lamp (B)
    • Instrument Panel (I/P) (C)
  30. Snap the fuse block onto the fuse block case hinges.
  31. Install the following connectors to the underhood fuse block:
    • Engine 68-way (1)
    • Forward Lamp 68-way (2)
    • I/P 68-way (3)
    32. Fig 15: Disconnecting & Connecting Underhood Electrical Center Or Junction Block Electrical Connectors
    GM886875Courtesy of GENERAL MOTORS CORP.
  32. 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)
    33. Fig 16: Disconnecting & Connecting Underhood Electrical Center Or Junction Block Electrical Connectors
    GM886875Courtesy of GENERAL MOTORS CORP.
  33. Secure the underhood fuse block to the fuse block case by rotating down and snapping into place.
  34. Install the underhood fuse block cover.
  35. Secure the coolant hose into place on the fuse block cover.
  36. Install the battery feed cable to underhood fuse block.

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

    37. Fig 17: View Of Battery, Fan Control Module & Battery Hold-Down Bracket
    GM886658Courtesy of GENERAL MOTORS CORP.
  37. 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 ft).

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

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

    38. IMPORTANT: If a new transaxle assembly was installed, the transaxle was filled with the proper amount of transaxle fluid at the factory. No additional fluid is required.
  38. Fill the transaxle assembly to the specified refill capacity using DEXRON®III automatic transaxle fluid P/N 21019223 or equivalent.

    Specification: 

    • The bottom pan removal capacity is approximately 6.5 L (6.9 qt).
    • The complete overhaul capacity is approximately 9 L (9.5 qt).
    • The dry capacity is approximately 12.2 L (12.9 qt).

  39. Start the engine, warm up the transaxle, and check for fluid leaks.
  40. Inspect for proper fluid level. Refer to Transmission Fluid Check Procedure.
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