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

Installation Procedure

    Fig 1: Installing Engine-To-Transaxle Mounting Bolts
    GM895333Courtesy of GENERAL MOTORS CORP.
  1. Securely place the transaxle on the transmission jack. Place the transaxle in any gear.
  2. Raise the transaxle into the vehicle and align the transaxle input shaft to the center of the clutch disc. Guide the transaxle into position. Rotate back and forth to align the input shaft splines to the clutch disc.
    3. IMPORTANT: Make sure the input shaft splines line up with the clutch disc splines before tightening the transaxle-to-engine mounting bolts. Do not use the bolts to pull the transaxle up to the engine.
  3. Install the lower transaxle-to-engine mounting bolts.

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

  4. Remove the transmission jack.
  5. Install the control shaft lever assembly pivot pin bracket onto the transaxle case.

    Tighten:  Tighten the control shaft lever pivot pin bracket-to-transaxle bolts to 24 N.m (18 lb ft).

    6. Fig 2: Installing SA91112T On Wheel Drive Shaft Oil Seal
    GM895295Courtesy of GENERAL MOTORS CORP.
  6. Using the, insert the axle shafts into the transaxle. After the splines clear seal protector but before snapping the axle into place, remove the seal protector.
  7. Ensure the transaxle drain plug is installed in the transaxle case. If it is not installed, clean and apply sealant P/N 21485278 to the threads and install the plug.

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

  8. Lower the vehicle.
  9. Remove the transaxle fill plug from the top of the transaxle. Fill the transaxle with 2 quarts of manual transaxle lubricant P/N 21018899.
  10. Clean and apply sealant P/N 21485278 to the threads and install the transaxle fill plug.

    Tighten:  Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 50 N.m (37 lb ft).

    11. Fig 3: Installing Left Transaxle Mount Bracket
    GM891646Courtesy of GENERAL MOTORS CORP.
  11. Install the left transaxle mount bracket onto the transaxle. (Automatic shown, manual similar).

    Tighten:  Tighten the left transaxle mount bracket-to-transaxle bolts to 55 N.m (41 lb ft).

  12. Raise the left side of the powertrain to the correct height using the.
  13. Raise the vehicle.
    14. Fig 4: Installing A/C Line & Clips
    GM895486Courtesy of GENERAL MOTORS CORP.
  14. Reposition the A/C line against the body and install the A/C line retaining clips.
    15. Fig 5: Installing Rear Transaxle Mount-To-Transaxle Bolts
    GM891637Courtesy of GENERAL MOTORS CORP.
  15. Install the rear transaxle mount onto the transaxle.

    Tighten:  Tighten the rear transaxle mount-to-transaxle bolts to 55 N.m (41 lb ft).

    16. Fig 6: Installing Front Transaxle Mount-To-Transaxle Bolts
    GM891626Courtesy of GENERAL MOTORS CORP.
  16. Install the front transaxle mount onto the transaxle.

    Tighten:  Tighten the front transaxle mount-to-transaxle bolts to 55 N.m (41 lb ft).

    17. Fig 7: Installing Frame Alignment Fixture (J 43628)
    GM891923Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Be sure the frame alignment tool fully engages in all gage holes.
  17. Install the new cage nuts into the body as the torque retention of the old nuts may not be sufficient.
  18. Raise the frame assembly to the body.
    19. Fig 8: Identifying Remaining Frame Attachment Fasteners
    GM891622Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not tighten the fasteners at this time.
  19. Install 4 new frame-to-body bolts.
    20. Fig 9: Removing & Installing Front Suspension Support Assembly
    GM891611Courtesy of GENERAL MOTORS CORP.
  20. Install the new cage nuts into the body for suspension supports. Torque retention of the old nuts may not be sufficient.
  21. Install the suspension supports using new bolts and tighten all frame bolts.

    Tighten:  Tighten the frame-to-body bolts to 90 N.m (60 lb ft) + 45° to 60°.

    22. Fig 10: Connecting Lower Control Arms
    GM891570Courtesy of GENERAL MOTORS CORP.
  22. Install the ball stud into the steering knuckle.

    Tighten:  Tighten the ball stud into the steering knuckle to 100 N.m (74 lb ft).

    23. Fig 11: Disconnecting Frame-To-Shift Pin Clip - Manual Transmission
    GM893335Courtesy of GENERAL MOTORS CORP.
  23. Install the frame-to-shifter link pivot pin clip.
    24. Fig 12: Installing Steering Gear-To-Frame Bolts & Nuts
    GM891603Courtesy of GENERAL MOTORS CORP.
  24. Install the steering gear-to-frame using new bolts and nuts. (Automatic shown, manual similar).

    Tighten:  Tighten the steering gear-to-frame bolts 45 N.m (33 lb ft) + 90°.

  25. Install the stabilizer bar links-to-strut assemblies using new nuts.

    Tighten:  Tighten the stabilizer bar links-to-strut assemblies to 65 N.m (48 lb ft).

  26. Inspect the rubber boots for damage and replace the part if damaged.
    27. Fig 13: Installing Rear Transaxle Mount-To-Frame Bolts
    GM891633Courtesy of GENERAL MOTORS CORP.
  27. Install the rear transaxle mount.
  28. Install the rear transaxle mount-to-frame bolts.

    Tighten:  Tighten the rear transaxle mount-to-frame bolts to 60 N.m (44 lb ft).

  29. Install the front transaxle mount through bolt.

    Tighten:  Tighten the front transaxle mount through the bolt to 55 N.m (41 lb ft).

    30. Fig 14: Installing New Exhaust Manifold Flange Gasket Onto Exhaust Manifold Flange Studs
    GM892169Courtesy of GENERAL MOTORS CORP.
  30. Position the gasket on the manifold pipe.
  31. Position the manifold pipe into the vehicle.
    32. IMPORTANT: Do not tighten the fastener at this time.
  32. Install the exhaust manifold pipe to exhaust manifold nuts.
    33. Fig 15: Removing & Installing Exhaust Manifold Pipe-To-Exhaust/Resonator Fasteners
    GM892067Courtesy of GENERAL MOTORS CORP.
  33. Install the exhaust manifold pipe to exhaust manifold nuts. (Automatic shown, manual similar).
  34. Position the gasket between the manifold pipe and resonator.
  35. Install the exhaust manifold pipe to resonator bolts and tighten.

    Tighten:  Tighten the exhaust manifold-to-resonator bolts to 20 N.m (15 lb ft).

  36. Tighten the exhaust manifold pipe to exhaust manifold nuts.

    Tighten:  Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 N.m (22 lb ft).

    37. Fig 16: Connecting A/C Pipe-To-Frame Clip
    GM892718Courtesy of GENERAL MOTORS CORP.
  37. Attach the A/C line clip to the front of the frame assembly.
    38. Fig 17: Removing/Installing Right Front Lower Splash Shield
    GM894225Courtesy of GENERAL MOTORS CORP.
  38. Install the right front lower splash shield.

    Tighten:  Tighten the right front lower splash shield-to-frame assembly to 5 N.m (44 lb in).

  39. Install the left front wheel liner push pin to the frame.
    40. Fig 18: Installing O2 Sensor Harness-To-Underbody Clamp Attachment Nut - L61 Engine
    GM892079Courtesy of GENERAL MOTORS CORP.
  40. Install the O2 sensor clamp to the underbody attachment nut.

    Tighten:  Tighten the O2 sensor clamp-to-heat shield to 4 N.m (35 lb in).

    41. Fig 19: Attaching Rear O2 Sensor Harness To Frame
    GM892567Courtesy of GENERAL MOTORS CORP.
  41. Connect the O2 sensor electrical connector and attach the harness to the frame.
  42. Install the wheel and tire assemblies onto the hub.
  43. Install the wheel bolts and tighten is 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 the wheel bolts using s star pattern.

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

  44. Install the remaining rear transaxle mount-to-frame bolts.

    Tighten:  Tighten the rear transaxle mount-to-frame bolts to 60 N.m (44 lb ft).

  45. Install the rear transaxle mount through bolt.

    Tighten:  Tighten the rear transaxle mount through the bolt to 90 N.m (66 lb ft).

  46. Perform the vehicle alignment. Refer to MEASURING WHEEL ALIGNMENT in Wheel Alignment.
  47. Lower the vehicle.
  48. Install the upper transaxle-to-engine mounting bolts.

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

    49. Fig 20: Locating Transmission Mount-To-Transmission Bolts
    GM891639Courtesy of GENERAL MOTORS CORP.
  49. Reference the alignment marks made during disassembly and install the left transaxle mount bolts.

    Tighten:  Tighten the left transaxle mount bolts to 55 N.m (41 lb ft).

  50. Remove the and the J-43405  .
    51. Fig 21: View Of Backup Lamp Switch Harness Connector
    GM895439Courtesy of GENERAL MOTORS CORP.
  51. Install the back-up lamp switch electrical connector.
  52. Install the wire harness onto the transaxle.
    53. Fig 22: Installing Control Shaft Lever Assembly Into Pivot Pin Brackets
    GM895346Courtesy of GENERAL MOTORS CORP.
  53. Install the control shaft lever assembly onto the pivot pin brackets.
  54. Install the retaining clips to hold the control shaft lever assembly to the transaxle and frame assembly brackets.
  55. Install the pin to retain the control shaft lever to shift control shaft of the transaxle.
    56. Fig 23: View Of Control Shaft Lever Retaining Pin
    GM895537Courtesy of GENERAL MOTORS CORP.
  56. Rotate the transaxle shift control shaft clockwise, toward the passenger side of the vehicle, and install the into the hole in the top of the transaxle.
    57. Fig 24: Removing & Installing Shifter Boot - 5-Speed Transaxles
    GM895322Courtesy of GENERAL MOTORS CORP.
  57. Pull up the control lever assembly boot to disengage from the console.
    58. Fig 25: Securing Shift Lever With Punch
    GM895436Courtesy of GENERAL MOTORS CORP.
  58. Move the shift lever to the 5th/Reverse Gate and use a 3/8 in. punch to hold in place.
  59. Tighten the pinch bolt securing control assembly rod to control shaft lever assembly.

    Tighten:  Tighten the control assembly rod-to-control lever assembly pinch bolt to 12 N.m (9 lb ft).

    60. Fig 26: Removing Spring Loaded Locking Pin
    GM895537Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The spring loaded locking pin can not be reused. Install a shift lever hole plug.
  60. Remove the from the transaxle and install the shift lever hole plug.
    61. Fig 27: Locating Clutch Hydraulic Fitting & Clip
    GM895341Courtesy of GENERAL MOTORS CORP.
  61. Install the clutch hydraulic fitting onto the transaxle.
  62. Bleed the clutch hydraulic system. Refer to HYDRAULIC CLUTCH BLEEDING (MANUAL BLEEDING) or HYDRAULIC CLUTCH BLEEDING (PRESSURE BLEEDING) in Clutch.
    63. Fig 28: Removing Power Steering Line Hose Clip
    GM893366Courtesy of GENERAL MOTORS CORP.
  63. Install the hose clip to the tow power steering lines.
  64. Pull the AIR tube back to the original position.
    65. Fig 29: Installing AIR Tube Into AIR Hose
    GM893363Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The clamp must be installed with the locking portion facing down.
  65. Insert the tube into the hose and install the clamp.
    66. Fig 30: Installing AIR Tube Stand-Off Clip
    GM893364Courtesy of GENERAL MOTORS CORP.
  66. Ensure the stand-off clip between the AIR tube and the wiring harness is installed correctly.
    67. Fig 31: Installing Battery Tray & Fasteners
    GM886646Courtesy of GENERAL MOTORS CORP.
  67. Install the battery tray fasteners and the battery tray.

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

    68. Fig 32: Removing & Installing Underhood Electrical Center Or Junction Block
    GM886877Courtesy of GENERAL MOTORS CORP.
  68. Install the underhood fuse block (UHFB) case to battery tray and install the bolt.

    Tighten:  Tighten the underhood fuse block case bolt to 9 N.m (80 lb in).

  69. Install the air harness to UHFB case. The wire harness grommets have retaining tabs that lock into the case (3) when the harnesses are fully installed.
  70. Snap the fuse block onto the fuse block case hinges (1).
    71. Fig 33: Harness Routing At Underhood Electrical Center Or Junction Block
    GM886874Courtesy of GENERAL MOTORS CORP.
  71. Install the following connectors to the UHFB:
    1. Engine 68 way (1)
    2. Forward Lamp 68 way (2)
    3. I/P 68 way (3)
    4. Forward Lamp 2 way (4)
    5. I/P 2 way (Black) (5)
    6. I/P 2 way (Green) (6)
    7. I/P 2 way (Brown) (7)
    72. Fig 34: Disconnecting & Connecting Underhood Electrical Center Or Junction Block Electrical Connectors
    GM886875Courtesy of GENERAL MOTORS CORP.
  72. Secure the UHFB to the fuse block case by rotating down and snapping into place.
  73. Install the UHFB cover.
  74. Install the coolant hose into place on the fuse block.
  75. Install the battery feed to the underhood fuse block.

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

    76. Fig 35: View Of Battery, Fan Control Module & Battery Hold-Down Bracket
    GM886658Courtesy of GENERAL MOTORS CORP.
  76. Install the battery.
    1. Install the battery onto the battery tray.
    2. Install the battery hold down bracket.

      Tighten:  Tighten the battery hold down bracket fasteners to 20 N.m (15 lb ft).

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

      Tighten:  Tighten the battery cable terminals to 17 N.m (13 lb ft).

    5. Install the negative battery cable.

      Tighten:  Tighten the battery cable terminals to 17 N.m (13 lb ft).

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