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

Removal Procedure

    Fig 1: View Of Battery, Fan Control Module & Battery Hold-Down Bracket
    GM886658Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to LIFTING AND JACKING THE VEHICLE in Cautions and Notices.
  1. Position the vehicle on a hoist.
  2. Remove the battery.
    1. Disconnect the negative battery cable.
    2. Disconnect the positive battery cable.
    3. Move the fan control module. Leave the wiring connected, lift the module up and away from the bracket, and position out of the way.
    4. Remove the battery hold down bracket.
    5. Remove the battery.
    3. Fig 2: Removing & Installing Underhood Electrical Center Or Junction Block
    GM886877Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the battery feed to the underhood fuse block (UHFB).
  4. Disconnect the coolant hose from the UHFB.
  5. Release the retaining tabs on the UHFB cover and remove.
  6. Release the retaining tabs (2) on the UHFB and roll the fuse block back (1) to access the electrical connectors.
    7. Fig 3: Harness Routing At Underhood Electrical Center Or Junction Block
    GM886874Courtesy of GENERAL MOTORS CORP.
  7. Remove the following connectors from the UHFB:
    1. Engine 68-way (1)
    2. Forward lamp 68-way (2)
    3. I/P 68-way (3)
    4. Forward lamp 2-way (White) (4)
    5. I/P 2-way (Black) (5)
    6. I/P 2-way (Green) (6)
    7. I/P 2-way (Brown) (7)
  8. Lift the fuse block off the case.
    9. Fig 4: Disconnecting & Connecting Underhood Electrical Center Or Junction Block Electrical Connectors
    GM886875Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: There are 2 tabs that hold the hard shell grommets in place at the bottom of the grommet. Disengage the tabs to remove the grommet from the case.
  9. Remove the harnesses from the UHFB case.
    • Engine (A)
    • Forward Lamp (B)
    • Instrument Panel (I/P) (C)
  10. Remove the UHFB case fastener, and remove the case from the battery tray.
    11. Fig 5: Installing Battery Tray & Fasteners
    GM886646Courtesy of GENERAL MOTORS CORP.
  11. Remove the battery tray fasteners and the battery tray.
    12. Fig 6: Separating Air Hose From Air Tube
    GM893363Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Note the original position of the AIR components.
  12. Remove clamp from AIR hose behind the cooling fan.
  13. Separate the AIR tube from the hose and push the tube back towards the transaxle.
    14. Fig 7: Removing Power Steering Lines Clip
    GM893364Courtesy of GENERAL MOTORS CORP.
  14. Remove the hose clip holding the 2 power steering lines together.
    15. Fig 8: Removing Control Assembly Rod To Control Shaft Lever Pinch Bolt
    GM895332Courtesy of GENERAL MOTORS CORP.
  15. Loosen the pinch bolt securing the control assembly rod to control shaft lever assembly.
    16. NOTE: The control shaft lever retaining pin has a spring loaded locking feature securing the pin in place. If this spring is not depressed before attempting to remove the pin, damage to the pin will result.
    Fig 9: Removing Control Shaft Lever Retaining Pin
    GM895346Courtesy of GENERAL MOTORS CORP.
  16. Remove the pin retaining control shaft lever to shift control shaft of the transaxle.
  17. Remove the retaining clips holding the control shaft lever assembly to transaxle and frame assembly brackets.
  18. Remove the control shaft lever assembly by pulling straight up off the pivot pins.
    19. Fig 10: View Of Backup Lamp Switch Harness Connector
    GM895439Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the back-up lamp switch electrical connector.
  20. Remove the wire harness from the transaxle.
    21. Fig 11: View Of Spring Loaded Locking Pin/Hole Plug
    GM895462Courtesy of GENERAL MOTORS CORP.
  21. There is a hole on top of the transaxle that will have either a spring loaded locking pin or a hole plug.
    • If the hole has a spring loaded locking pin, remove it and discard. A new hole plug will be installed.
    • If the hole has a hole plug, remove it and retain for reuse.
    22. Fig 12: Removing clutch hydraulic fitting & Clip
    GM895341Courtesy of GENERAL MOTORS CORP.
  22. Remove the clutch hydraulic fitting from the transaxle. Elevate and secure the fitting to prevent excessive loss of brake fluid.
  23. Remove the upper transaxle-to-engine mounting bolts.
    24. Fig 13: Identifying Properly Installed Engine Support Fixture
    GM893249Courtesy of GENERAL MOTORS CORP.
  24. Install the SA9105E  with the adapter kit J43405  as shown.
    25. Fig 14: Locating Transmission Mount-To-Transmission Bolts
    GM891639Courtesy of GENERAL MOTORS CORP.
  25. Mark the position of and remove the left transaxle mount bolts.
    26. Fig 15: Removing Rear Transaxle Mount Through Bolt
    GM891631Courtesy of GENERAL MOTORS CORP.
  26. Remove the rear transaxle mount through bolt, and transaxle mount-to-frame bolt.
    27. Fig 16: Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  27. Fasten the radiator to upper radiator support.
    28. CAUTION: Refer to LIFTING AND JACKING THE VEHICLE in Cautions and Notices.
  28. Raise the vehicle on a hoist.
  29. Remove the front wheel and tire assemblies.
    30. Fig 17: Removing/Installing Right Front Lower Splash Shield
    GM894225Courtesy of GENERAL MOTORS CORP.
  30. Remove the right front lower splash shield.
  31. Remove the left front wheel liner push pin from the frame.
    32. Fig 18: Attaching Rear O2 Sensor Harness To Frame
    GM892567Courtesy of GENERAL MOTORS CORP.
  32. Disconnect the rear O2 sensor connection, and remove the harness from the frame at 2 attachment points.
    33. Fig 19: Installing O2 Sensor Harness-To-Underbody Clamp Attachment Nut - L61 Engine
    GM892079Courtesy of GENERAL MOTORS CORP.
  33. Remove the O2 sensor clamp to underbody attachment nut.
    34. Fig 20: Removing Exhaust Manifold Pipe
    GM892082Courtesy of GENERAL MOTORS CORP.
  34. Remove the exhaust manifold pipe to exhaust manifold nuts. (Automatic shown, manual similar.)
    35. Fig 21: Removing & Installing Exhaust Manifold Pipe-To-Exhaust/Resonator Fasteners
    GM892067Courtesy of GENERAL MOTORS CORP.
  35. Remove the exhaust manifold pipe to exhaust resonator pipe bolts.
  36. Remove the exhaust manifold pipe.
    37. Fig 22: Locating Front Transmission Mount Through-Bolt - Manual Transaxle
    GM891625Courtesy of GENERAL MOTORS CORP.
  37. Remove the front transaxle mount through bolt.
    38. Fig 23: Removing Rear Transaxle Mount-To-Frame Bolts
    GM891635Courtesy of GENERAL MOTORS CORP.
  38. Remove the remaining rear transaxle mount-to-frame bolts.
  39. Remove the rear transaxle mount.
    40. Fig 24: Connecting A/C Pipe-To-Frame Clip
    GM892718Courtesy of GENERAL MOTORS CORP.
  40. Remove the A/C line to frame attachment clip at the front of the vehicle.
    41. Fig 25: Disconnecting Frame-To-Shift Pin Clip - Manual Transmission
    GM893335Courtesy of GENERAL MOTORS CORP.
  41. Remove the frame-to-shifter link pivot pin clip.
    42. Fig 26: Installing Steering Gear-To-Frame Bolts & Nuts
    GM891603Courtesy of GENERAL MOTORS CORP.
  42. Remove the steering gear-to-frame assembly bolts. (Automatic shown, manual similar.)
  43. Using mechanics wire, secure the steering gear assembly to the body of the vehicle.
    44. Fig 27: Connecting Stabilizer Bar Link
    GM891609Courtesy of GENERAL MOTORS CORP.
    NOTE: Hold the ball stud from turning when removing/installing the nut. The boot can become torn and damaged if the ball stud turns.
  44. Remove the stabilizer bar links from the strut assemblies and discard the nuts.
    45. Fig 28: Connecting Lower Control Arms
    GM891570Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not attempt to separate ball studs with a wedge type separator tool because seal may be damaged.
  45. Remove the lower ball stud bolt and separate the ball stud from the steering knuckle assembly.
    46. Fig 29: Removing & Installing Front Suspension Support Assembly
    GM891611Courtesy of GENERAL MOTORS CORP.
  46. Remove the suspension support assemblies.
  47. Remove the suspension support cage nuts from the body. Discard the cage nuts and support bolts. New nuts and bolts must be used for assembly.
    48. Fig 30: Installing Frame Alignment Fixture (J 43628)
    GM891923Courtesy of GENERAL MOTORS CORP.
  48. Using the powertrain lifting table and J 43628  , support the frame assembly.
  49. Remove the remaining 4 frame-to-body attachment fasteners.
  50. Carefully lower the frame assembly from the vehicle.
    51. IMPORTANT: Discard the cage nuts and frame bolts. New nuts and bolts must be used during assembly.
  51. Remove the frame assembly cage nuts from the body.
  52. Remove the front transaxle mount from the transaxle.
    53. Fig 31: Removing Rear Transaxle Mount From Transaxle
    GM891637Courtesy of GENERAL MOTORS CORP.
  53. Remove the rear transaxle mount from the transaxle.
    54. Fig 32: Locating Transaxle Fluid Level & Drain Plugs
    GM895261Courtesy of GENERAL MOTORS CORP.
  54. Drain the transaxle fluid by removing the transaxle drain plug (1).
    55. Fig 33: Removing Drive Axle From Transaxle
    GM891575Courtesy of GENERAL MOTORS CORP.
    NOTE: To prevent damage to CV Joint boots, be careful not to allow them to contact other parts during the removal/installation process. Also, never pull on the shaft assembly.
  55. Use a pry bar to remove the axle shafts from the transaxle. Leave the axle shafts in the steering knuckles and secure the axle shafts up and out of way of the transaxle removal path.
    56. Fig 34: Removing A/C Line & Clips
    GM895486Courtesy of GENERAL MOTORS CORP.
    NOTE: If the A/C line is not removed and lowered from the body prior to lowering the powertrain, the engine crankshaft pulley will damage the A/C line possibly causing a Freon leak to occur.
  56. Remove the A/C line retaining clips and drop the A/C line down from the body as shown.
  57. Lower vehicle.
  58. Lower the driver side of the powertrain with the SA9105E  to allow the transaxle to clear the engine compartment rail.
    59. Fig 35: Removing Left Transaxle Mount Bracket
    GM891646Courtesy of GENERAL MOTORS CORP.
  59. Remove the left transaxle mount bracket from the transaxle.
  60. Raise the vehicle.
  61. Remove the control shaft lever assembly pivot pin bracket from the transaxle case.
    62. Fig 36: Removing Engine-To-Transaxle Mounting Bolts
    GM895333Courtesy of GENERAL MOTORS CORP.
  62. Support the transaxle securely with the transmission jack.
  63. Remove the remaining engine-to-transaxle mounting bolts.
  64. Separate the transaxle from the engine and lower the transaxle from the vehicle.
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