Alero, Grand Am 1999-2005

Transaxle Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the transaxle.
  6.  
  7. Install an engine support fixture.
  8.  
  9. Remove or disconnect the following:

    Front transaxle mount bolts
     
    Splash shield
     
    Air cleaner and duct assembly
     
    Upper transaxle mount
     
    Shifter cable
     

  10.  
  11. Secure the radiator and condenser to the upper radiator support.
  12.  
  13. Remove or disconnect the following:

    Ground cables from the engine
     
    Park/Neutral Position (PNP) switch electrical connectors
     
    Front suspension crossmember
     
    Front wheels and splash shields
     
    Lower radiator and condenser support
     
    Front transaxle mount and bracket
     
    Both front Antilock Brake System (ABS) Wheel Speed sensor (WSS) electrical connectors
     
    Brake modulator assembly
     
    Vehicle Speed Sensor (VSS)
     
    Torque converter bolts
     
    Ball joints from the control arms
     
    Halfshafts
     
    Front transaxle mount
     
    ABS brake control module
     
    Tie rod ends from the steering knuckles
     
    Power steering pressure line from the steering rack
     
    Brake lines from the retainer under the steering rack
     
    Steering column intermediate shaft from the steering gear
     

  14.  
  15. Place a jack under the transaxle.
    CAUTION
    The torque converter may fall out of the transaxle if it is tilted downward.

  16.  
  17. Remove or disconnect the following:

    Transaxle-to-engine bolts
     
    Transaxle
     

  18.  

To install:

  1. Install the transaxle onto the engine and torque the bolts to 66 ft. lbs. (90 Nm).
  2.  
  3. Remove the jack from the transaxle.
  4.  
  5. Install or connect the following:

    Intermediate shaft to the steering gear. Torque the pinch bolt to 30 ft. lbs. (41 Nm).
     
    Brake lines in the retainer under the steering gear
     
    Power steering pressure line to the steering gear
     
    Tie rod ends to the steering knuckles. Torque the nuts to 15 ft. lbs. (20 Nm) plus an additional 180 degree turn.
     
    ABS control module
     
    Front transaxle mount bracket. Torque the bolts to 96 ft. lbs. (130 Nm).
     
    Front transaxle mount. Torque the bolt to 55 ft. lbs. (75 Nm).
     
    Halfshafts
     
    Ball joints to the control arms. Torque the nuts to 41 ft. lbs. (55 Nm).
     
    Torque converter bolts. Torque them to 46 ft. lbs. (62 Nm).
     
    VSS
     
    Brake modulator assembly. Torque the nut to 22 ft. lbs. (30 Nm) and the fluid lines to 18 ft. lbs. (24 Nm).
     
    WSS electrical connectors
     
    Lower radiator and condenser support
     
    Splash shields and the front wheels
     
    Front suspension crossmember. Torque the bolts to 81 ft. lbs. (110 Nm).
     
    PNP switch electrical connector
     
    Ground wiring to the engine
     
    Shifter cable and the upper transaxle mount
     
    Upper transaxle mount. Torque the bolts to 89 ft. lbs. (120 Nm).
     
    Air cleaner and duct assembly
     
    Splash shield
     
    Front transaxle mount. Torque the bolts to 89 ft. lbs. (120 Nm).
     

  6.  
  7. Remove the engine support fixture.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Refill the transaxle with fluid.
  12.  
  13. Refill and bleed the power steering system.
  14.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the transaxle.
  6.  
  7. Remove or disconnect the following:

    Air inlet duct hose from the intake plenum
     
    Wiring harness from the transaxle and the Park Neutral Position (PNP) switch
     
    Upper transaxle-to-engine bolts and stud
     

  8.  
  9. Install an engine support fixture.

    Front wheels
     
    Both front fender liners
     
    Steering gear mounting bolts and secure the steering gear with mechanics wire
     
    Wheel Speed Sensor (WSS) wires from the front wheels and unclip them from the frame
     
    Ball joints from the steering knuckles
     
    Antilock Brake System (ABS) sensor from the WSS and frame
     
    Brake modulator assembly from the support
     
    Tie rod ends from the steering knuckles
     
    Front and rear transaxle mount bracket bolts
     
    Brake lines from the retainers on the crossmember
     

  10.  
  11. Lower the vehicle until the suspension crossmember rests on the jack stands.
  12.  
  13. Remove or disconnect the following:

    Front suspension crossmember support bolts
     
    Rear suspension crossmember support bolts
     
    Suspension crossmember-to-body bolts
     

  14.  
  15. Raise the vehicle off of the suspension

    Frame
     
    Bolts from the transaxle brace
     
    Shift cable from the shift linkage
     
    Cable from the bracket
     
    Flywheel inspection cover
     
    Starter
     
    Torque converter-to-flywheel bolts
     
    Transaxle cooler lines by removing the nut holding the bracket to the transaxle case
     
    Vehicle Speed Sensor (VSS) wiring harness from the sensor
     
    Drive shafts from the transaxle
     
    Body-to-transaxle mount bolts
     

  16.  
  17. Lower the transaxle with the engine support fixture enough to remove the transaxle.
  18.  
  19. Support the transaxle with a suitable jack.
  20.  
  21. Remove or disconnect the following:

    Transaxle-to-engine nut
     
    Engine from the transaxle
     
    Transaxle
     

  22.  

To install:

  1. Install or connect the following:

    Transaxle
     
    Lower transaxle-to-engine bolts and nuts and tighten to 66 ft. lbs. (90 Nm)
     
    Transaxle cooler pipes to the transaxle and tighten to 71 inch lbs. (8 Nm)
     
    Torque converter-to-flywheel bolts tighten to 46 ft. lbs. (62 Nm)
     
    Drive shafts
     
    VSS wiring
     
    Starter
     
    Flywheel inspection cover bolts tighten to 97 inch lbs. (11 Nm)
     

  2.  
  3. Use the engine support fixture to raise the engine and transaxle assembly.
  4.  
  5. Remove or disconnect the following:

    Transaxle mount-to-body bolts tighten to 66 ft. lbs. (90 Nm)
     
    Frame and hand-tighten the bolts
     

  6.  
  7. Once all the bolts have been installed tighten them as follows:

    Crossmember rear bolts to 180 ft. lbs. (245 Nm) plus an additional 180 degrees
     
    Front crossmember bolts to 84 ft. lbs. (115 Nm) plus an additional 120 degrees
     
    Front crossmember-to-body bolts to 81 ft. lbs. (110 Nm)
     

  8.  
  9. Raise the vehicle and support with jack stands

    Brake lines to the retainers on the crossmember
     
    Front and rear transaxle mount bracket bolts
     
    Power steering gear mounting bolts to 81 ft. lbs. (110 Nm)
     
    Tie rod ends to the steering knuckles
     
    Brake modulator assembly to the support bracket
     
    Lower ball joints to the steering knuckles
     
    ABS sensor to the WSS and frame
     
    Transaxle-to-engine brace bolts and tighten to 53 ft. lbs. (72 Nm)
     
    Both front fender liners
     
    Front wheels
     
    Upper transaxle-to-engine bolts and stud and tighten to 66 ft. lbs. (90 Nm)
     

  10.  
  11. Remove the engine support fixture.

    Shift linkage
     
    PNP switch and transaxle connections
     
    Air duct hose to the intake plenum
     
    Negative battery cable
     

  12.  
  13. Refill the transaxle with fluid.
  14.  
  15. Refill and bleed the power steering system.
  16.  

 
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