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Removal & Installation: Transaxle: Installation

NOTE: The bottom 2 and top 3 engine-to-transaxle mounting bolts will be installed later in this 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. CAUTION: 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. See Figure . Tighten engine-to-transaxle bolts to specification. See TORQUE SPECIFICATIONS  .
  4. Raise the vehicle and remove the hydraulic lift table.
  5. Lower the vehicle.
    6. NOTE: If the powertrain mount is not reinstalled in its original position, it could lead to premature mount wear. See Figure .
  6. Reference the alignment marks made during disassembly and install the left transaxle mount bolts. Tighten the left transaxle mount-to-transaxle mount bracket bolts to specification. See TORQUE SPECIFICATIONS  .
  7. Raise the vehicle.
  8. Install the 2 bottom engine-to-transaxle mounting bolts.
    9. NOTE: Failure to lubricate the cooler line seals with automatic transaxle fluid 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. See Figure . Tighten the transaxle oil cooler line assembly nut to specification. See TORQUE SPECIFICATIONS  .
    10. CAUTION: The torque converter bolt magnetic socket must be used to install the flex plate to torque converter bolts. 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 torque converter bolt magnetic socket through the starter opening. The V6 crankshaft bolt socket can be used to turn the V6 crankshaft. After all bolts are installed, torque to specification. Tighten the flexplate-to-torque converter bolts to specification. See TORQUE SPECIFICATIONS  .
  11. Install the starter assembly. See Figure . Tighten the starter assembly bolts to specification. See TORQUE SPECIFICATIONS  .
  12. Connect the starter solenoid electrical connections.
  13. Install the wire harness mounting bracket to the rear of the engine block (V6 only).
  14. Install the engine-to-transaxle bracket. See Figure . Tighten the engine-to-transaxle bracket bolts to specification. See TORQUE SPECIFICATIONS  .
    15. NOTE: In order to prevent damage to the axle shaft splines during vehicle operation, add grease 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.
  17. Lower the vehicle and remove the engine support fixture.
  18. Connect the output speed sensor electrical connector. Secure the harness to the mounting stud. See Figure .
  19. Install the generator (V6 only). See Figure . Tighten the generator bolts to specification. See TORQUE SPECIFICATIONS  .
  20. Install the accessory drive belt tensioner assembly (V6 only). See Figure . Tighten the accessory drive belt tension assembly bolts to specification. See TORQUE SPECIFICATIONS  .
  21. Install the accessory drive belt (V6 only). See Figure .
  22. Install the remaining transaxle-to-engine mounting bolts. Tighten the engine-transaxle bolts to specification. See TORQUE SPECIFICATIONS  .
  23. Install the transaxle electrical connector and ground wire to the transaxle. See Figure . Tighten the ground wire bolt to specification. See TORQUE SPECIFICATIONS  .
  24. Install the remaining wire harness attachments to the transaxle side cover. Tighten the wiring harness attachment fasteners to specification. See TORQUE SPECIFICATIONS  .
  25. Install the control cable mounting bracket to the rear powertrain mount. See Figure . Tighten the control cable mounting bracket bolts to specification. See TORQUE SPECIFICATIONS  .
  26. Connect the control cable to the transaxle range switch lever.
    NOTE: Perform steps  27 - 31 if equipped with AIR.
  27. Install the air pump onto the air pump bracket.
  28. Install and tighten the bolt. See Figure . Tighten the air pump-to-bracket bolts to specification. See TORQUE SPECIFICATIONS  .
  29. Install the inlet and outlet hoses to the air pump assembly.
  30. Install the air pump assembly to the oil pan. Tighten the air pump-to-oil pan bolts to specification. See TORQUE SPECIFICATIONS  .
  31. Connect the air pump harness connector. Push in the connector until a click is heard and pull back to confirm a positive engagement.
  32. Install the battery tray and battery tray fasteners. See Figure . Tighten the battery tray bolts to specification. See TORQUE SPECIFICATIONS  .
  33. Install the underhood fuse block case to the battery tray and install the bolt. See Figure . Tighten the underhood fuse block case bolt to specification. See TORQUE SPECIFICATIONS  .
  34. Install the wire harnesses to the fuse block case. See Fig 1 . The following 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)
    Fig 1: Installing Wire Harnesses To Fuse Block Case
    G00078024Courtesy of GENERAL MOTORS CORP.
  35. Snap the fuse block onto the fuse block case hinges.
  36. Install the following connectors to the underhood fuse block:
    • Engine 68-way (1)
    • Forward Lamp 68-way (2)
    • I/P 68-way (3)

    See Fig 2 .

    Fig 2: Installing Connectors To Underhood Fuse Block
    G00078025Courtesy of GENERAL MOTORS CORP.
  37. 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)
  38. Secure the underhood fuse block to the fuse block case by rotating down and snapping into place. See Fig 2 .
  39. Install the underhood fuse block cover.
  40. Secure the coolant hose into place on the fuse block cover.
  41. Install the battery feed cable to underhood fuse block. See Figure . Tighten the battery feed cable-to-underhood fuse block bolt to specification. See TORQUE SPECIFICATIONS  .
    42. CAUTION: The positive battery terminal must be connected first to prevent arcing.
  42. Install the battery as follows:
    1. Install the battery into the battery tray.
    2. Install the battery hold-down bracket. Tighten the battery hold down bracket bolt to specification. See TORQUE SPECIFICATIONS  .
    3. Install the fan control module by sliding down onto the battery hold-down bracket.
    4. Install the positive battery cable and then the negative battery cable. Tighten the battery cables to specification. See TORQUE SPECIFICATIONS  .
  43. Fill the transaxle with appropriate fluid to proper level. See LUBRICATION in appropriate SERVICING article.
  44. Start the engine and warm up the transaxle. Check for fluid leaks.
  45. Recheck fluid level.
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