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Home >> Saturn >> 2003 >> L200 Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transaxle >> Repair Instructions >> Transaxle Disassemble >> Removal Procedure

Removal Procedure

    Fig 1: Identifying Backup Lamp Switch
    GM1227213Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: In all work involving disassembly of the transaxle, a new output shaft nut and crush sleeve must be installed during reassembly.
  1. Remove the back-up lamp switch to prevent the switch from being damaged during disassembly.
  2. Cover the holes for clutch hydraulics, axles, and the reverse lamp switch, and clean the transaxle if necessary.
    3. Fig 2: Mounting Transaxle On J 43707
    GM895488Courtesy of GENERAL MOTORS CORP.
  3. Mount the transaxle on holding J 43707  . See Special Tools and Equipment . Mount the transaxle and fixture in the J 43964  . See Special Tools and Equipment .
    4. Fig 3: Removing Pipe From Slave Cylinder
    GM895568Courtesy of GENERAL MOTORS CORP.
  4. Remove the pipe from the slave cylinder.
    5. Fig 4: Removing Pipe From Slave Cylinder
    GM895568Courtesy of GENERAL MOTORS CORP.
  5. Using pliers, pinch together the bottom halves of the pipe sleeve and move the pipe and sleeve upward.
    6. Fig 5: Prying Up Locking Tabs
    GM895576Courtesy of GENERAL MOTORS CORP.
  6. Pry up the locking tabs on the sleeve and remove the pipe.
    7. Fig 6: View Of Slave Cylinder
    GM895580Courtesy of GENERAL MOTORS CORP.
  7. Remove the slave cylinder bolts and slave cylinder.
  8. Remove the reverse idler gear shaft bolt with an O-ring.
    9. Fig 7: View Of Transaxle Rear Cover
    GM895031Courtesy of GENERAL MOTORS CORP.
  9. Remove the transaxle rear cover and discard the gasket.
    10. Fig 8: View Of Synchronizer Springs
    GM895592Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not shift gears using the 1st/2nd, 3rd/4th, or 5th shift shafts. All shifting should be done using the shift control shaft.
  10. Put the transaxle into 3rd gear by pulling the shift control shaft out. Other gears can be selected as follows:
    • Even gears = push shaft in
    • Odd gears = pull shaft out
    • 1st/2nd shift gate = turn shaft counter-clockwise
    • 5th and reverse gears = turn shaft clockwise.
    11. Fig 9: Locating 5th Gear Fork Retaining Pin
    GM895034Courtesy of GENERAL MOTORS CORP.
  11. Using a punch and hammer, tap out the 5th gear fork retaining pin.
    12. Fig 10: View Of Output Shaft Nut
    GM1227214Courtesy of GENERAL MOTORS CORP.
  12. Engage the 5th gear by pressing the synchronizer sleeve and fork down onto the 5th gear. Two gears must be engaged at the same time to allow removal of output shaft nut.
  13. Pry up the locking tab on the output shaft nut and remove the nut.
    14. Fig 11: View Of 5th Gear Shift Fork & Synchronizer Sleeve
    GM1227215Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Before removing the 5th gear synchronizer sleeve, mark its position relative to the 5th gear synchronizer hub to assist in assembly.
    IMPORTANT: Make sure the 5th gear shift shaft does not come out of the transaxle when the 5th gear shift fork is removed.
  14. Remove the 5th gear shift fork and synchronizer sleeve together.
    15. Fig 12: Removing 5th Gear Synchronizer Hub & Snap Ring
    GM895037Courtesy of GENERAL MOTORS CORP.
  15. Remove the 5th gear synchronizer hub snap ring. This will be easier if the hub is tapped down first.
  16. Use the J 25031-A  to remove the 5th gear synchronizer hub.
  17. Remove the blocking ring, blocking ring spring, 5th gear, and 5th gear bearing assembly.
    18. Fig 13: Identifying 1st Design & 2nd Design Of 5th Gear Synchronizer Components
    GM895596Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When a manual transaxle with a serial number before T02075 is repaired for a 5th gear synchronizer failure, it must be determined whether the synchronizer components are of the 1st design or the 2nd design.
    The illustrations show the 1st design, the left half of the illustration, and the 2nd design, the right half of the illustration, of the 5th gear synchronizer components.
    IMPORTANT: All transaxles built prior to the T02075 serial number will be of the 1st design unless they have been previously repaired for this condition. All service parts are of the 2nd design.
  18. If the 5th synchronizer sleeve removed from the transaxle looks like the sleeve on the left, then it is a 1st design. The identification mark for the 2nd design is the extra groove on the top of the 5th gear sleeve.
    19. Fig 14: View Of 1st Design & 2nd Design Of 5th Gear Synchronizer Sleeve Or Blocking Ring
    GM895599Courtesy of GENERAL MOTORS CORP.
  19. If the 5th gear blocking ring removed from the transaxle does not have a part number embossed on the bottom of the blocking ring, then it is a 1st design.

    If either the 5th synchronizer sleeve or blocking ring is a 1st design and needs to be replaced, then both the sleeve and the blocking ring must be replaced with the 2nd design parts as a unit. If the blocking rings and sleeve have already been replaced with the 2nd design components, then only replace parts as needed.

    20. Fig 15: View Of Differential Bearing Retainer
    GM1227193Courtesy of GENERAL MOTORS CORP.
  20. Remove the differential bearing retainer fasteners. The retainer will be removed after case removal.
    21. Fig 16: View Of Case-To-Clutch Housing Bolts
    GM895040Courtesy of GENERAL MOTORS CORP.
  21. Remove the case-to-reverse idler gear shaft bracket bolt.
  22. Remove the case-to-clutch housing bolts and tap down 2 case-to-clutch housing alignment sleeves.
    23. Fig 17: Removing Case From Output Shaft
    GM895043Courtesy of GENERAL MOTORS CORP.
  23. Remove the case from the output shaft.
    1. Check that 3rd gear is engaged.
    2. Install the 87-92-129  to the case. See Special Tools and Equipment .
    3. Install the 87-91-410  to the output shaft. See Special Tools and Equipment .
    4. Install the 87-91-287  with the 87-91-303  into the pulling eyes.
    5. Carefully tighten the puller until the output shaft bearing and 5th driven gear releases from the output shaft.
    24. Fig 18: Locating Differential Bearing Retainer
    GM895546Courtesy of GENERAL MOTORS CORP.
  24. Remove tools. Lift off transaxle case.
  25. Remove differential bearing retainer from transaxle case.
  26. Inspect the O-ring seal and axle seal for damage. Replace if damaged.
    27. Fig 19: View Of 87-92-202 & 87-91-204
    GM895047Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not re-install the bearing race until after the shimming procedure.
  27. Tap out differential bearing race using 87-92-202  and 87-91-204  . See Special Tools and Equipment .
    28. Fig 20: View Of Case-To-Clutch Housing Bolts
    GM895040Courtesy of GENERAL MOTORS CORP.
  28. Remove the reverse gear fork and shaft.
    29. Fig 21: View Of Reverse Shift Lever Assembly
    GM895053Courtesy of GENERAL MOTORS CORP.
  29. Put the transaxle in 4th gear by pushing the shift control shaft in.
  30. Remove the reverse shift lever assembly and bolts.
    31. Fig 22: Removing Shift Shaft Bolt, Shift Shaft, & Shaft Block
    GM895057Courtesy of GENERAL MOTORS CORP.
  31. Engage towards the reverse gear on the shift linkage assembly to access the shift control shaft bolt.
    32. IMPORTANT: Make sure the TORX® socket fully engages the bolt prior to attempting removal.
    IMPORTANT: Note the orientation of the shift shaft block.
  32. Remove the shift shaft bolt, the shift shaft, and the shaft block.
    33. Fig 23: Removing Shift Linkage Bolt
    GM895061Courtesy of GENERAL MOTORS CORP.
  33. Disengage the reverse on the shift linkage assembly. Remove the remaining shift linkage bolt and lift the mechanism slightly. Remove the locating sleeves.
  34. Put the transaxle in 2nd gear and remove the shift linkage assembly by moving it rearward, towards the differential, and angling it out while lifting.
    35. Fig 24: View Of Reverse Idler Gear Shaft Assembly
    GM895064Courtesy of GENERAL MOTORS CORP.
  35. Lift the input shaft far enough to allow removal of the reverse idler gear shaft assembly. Remove the reverse idler gear shaft.
    36. Fig 25: View Of 4th Driven Gear, Crush Sleeve & Spacer Sleeve
    GM895065Courtesy of GENERAL MOTORS CORP.
  36. Remove the 4th driven gear, crush sleeve, and spacer sleeve from the output shaft.
    37. Fig 26: Installing 87-92-103
    GM1227188Courtesy of GENERAL MOTORS CORP.
  37. Install the 87-92-103  around the 1st gear and 1st/2nd gear synchronizer sleeve as shown. See Special Tools and Equipment . This tool holds the 1st and 2nd synchronizer assemblies together. Secure the tool with a plastic tie.
    38. Fig 27: Removing Input Shaft
    GM895069Courtesy of GENERAL MOTORS CORP.
  38. Install the 87-91-410  on the output shaft. See Special Tools and Equipment .
  39. Install the 87-91-287  with the 87-91-295  under the 1st driven gear of the output shaft. See Special Tools and Equipment .
  40. Carefully tighten the puller until the remaining output shaft gears are up far enough to allow the removal of the input shaft, approximately 15 mm (0.6 in).
  41. Remove the input shaft.
    42. Fig 28: Removing Puller & Gears From Output Shaft
    GM895072Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Note the up/down orientation of the 3rd driven gear. If the old gear is installed, it must be installed in the same orientation to avoid noise concerns.
  42. Continue pulling the driven gears on the output shaft until all gears are loose.
  43. Remove the puller and gears from the output shaft.
    44. Fig 29: Removing Output Shaft Bearing Retainer Bolts
    GM895074Courtesy of GENERAL MOTORS CORP.
    NOTE: The output shaft bearing retainer bolts were installed using a threadlocker at the factory. A J43483 impact driver or equivalent must be used to remove these bolts or the bolt heads may strip out requiring additional repair time.
  44. Remove the output shaft bearing retainer bolts using the J 43483  or equivalent and remove the retainer. See Special Tools and Equipment .
    45. Fig 30: Removing Output Shaft
    GM895077Courtesy of GENERAL MOTORS CORP.
  45. Remove the output shaft using the 87-91-188  , the 87-91-972  , and the 87-91-261  . See Special Tools and Equipment .
    46. Fig 31: View Of Differential Assembly
    GM1227206Courtesy of GENERAL MOTORS CORP.
  46. Remove the differential assembly.
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