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Home >> Saturn >> 2003 >> L200 Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transaxle >> Repair Instructions >> Axle Seals Replacement >> Installation Procedure

Installation Procedure

  1. Clean the seal bore in housing.
  2. Apply a light bead of LOCTITE 515® gasket eliminator sealant P/N 21005993 or equivalent on the diameter of the seal that presses into the case bore.
    3. NOTE: Prior to using Axle Seal Installer SA9113T inspect tool for any nicks or burrs that may damage seal lip.
    Fig 1: Installing Axle Seal
    GM895455Courtesy of GENERAL MOTORS CORP.
  3. Install the axle seal using the SA91113T . Place the seal on the tool and insert into the transaxle. Make sure to keep the seal lined up with the bore during installation. (Right side shown, left side similar.)
    4. Fig 2: Installing SA91112T On Wheel Drive Shaft Oil Seal
    GM895295Courtesy of GENERAL MOTORS CORP.
    NOTE: Use care when removing end cover as the tubes can bend easily.
  4. Install the SA91112T  inside the seal.
  5. Install the axle into the transaxle.
  6. After the shaft splines clear the seal but before snapping the axle into place, remove the seal protector tool.
  7. Push the axle all the way into the transaxle.
    8. Fig 3: Connecting Lower Control Arms
    GM891570Courtesy of GENERAL MOTORS CORP.
    NOTE: Take care not to damage rubber boot when installing ball joint to knuckle.
  8. Insert the lower control arm ball stud into the steering knuckle.
  9. Install the lower control arm ball stud retaining bolt and nut.

    Tighten:  Tighten the lower control arm ball stud bolt and nut-to-steering knuckle to 100 N.m (74 lb ft).

    10. Fig 4: View Of Tie Rod, Knuckle & Tapered Ball Stud
    GM891579Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The tie rod ends must be thoroughly cleaned before installing and tightening.
  10. Install the tie rod end into the steering knuckle.
  11. Using the J 44015  , seat the tie rod end into the steering knuckle.

    Tighten:  Tighten the linkage installer-to-seat tie rod ends to 45 N.m (33 lb ft).

    12. IMPORTANT: Use a new nut. Torque retention of the old nut may not be sufficient.
  12. Remove the linkage installer and install a new tie rod end nut.

    Tighten:  Tighten the tie rod end-to-steering knuckle to 60 N.m (44 lb ft).

    13. Fig 5: Locating Transaxle Fluid Level & Drain Plugs
    GM895261Courtesy of GENERAL MOTORS CORP.
  13. Clean and apply thread sealant P/N 21485278 to the transaxle drain plug (1) and install.

    Tighten:  Tighten the transaxle drain plug to 50 N.m (37 lb ft).

  14. Remove the transaxle level plug (2) and, using a funnel with a flexible spout or a quart bottle hand pump, add manual transaxle lubricant P/N 21018899 until the fluid begins to flow out of the level plug opening.
  15. Clean and apply thread sealant P/N 21485278 to the transaxle level plug (2) and install.

    Tighten:  Tighten the transaxle level plug to 50 N.m (37 lb ft).

    16. NOTE: Caution: Before installing wheels, remove any rust or corrosion from the wheel mounting surfaces and the brake rotors/drums. Failure to do so may cause the wheel nuts to loosen while driving, which may cause personal injury and/or vehicle damage.
  16. Position the wheel onto the hub.
  17. Install the wheel bolts and tighten in a star pattern.
    1. Hand tighten all 5 wheel bolts.
    2. Use a torque wrench to tighten the wheel bolts using a star pattern.

      Tighten:  Initial tighten the wheel bolts to 63 N.m (46 lb ft).

    3. Use a torque wrench to final tighten wheel bolts using a star pattern.

      Tighten:  Final tighten the wheel bolt to 125 N.m (92 lb ft).

  18. Lower the vehicle from the hoist.
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