Cobalt 2006-2008, G5 2007

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. Disconnect the air inlet duct hose from the intake plenum.
  6.  
  7. Disconnect the transaxle wiring harness from the transaxle and the PNP switch.
  8.  
  9. Remove the upper transaxle to engine bolts and stud.

    Click image to see an enlarged view

    Fig. Engine support fixture installed-2.2L engine

  10.  
  11. Install the engine support fixture.
    1. Place the engine support fixture long bar (2), from kit SA9105E across the engine compartment.
    2.  
    3. Install the engine support fixture legs (3) from the kit on the engine support fixture long bar and center above the engine.
    4.  
    5. Install the engine support fixture hooks (4) and engine support fixture handle to the engine support cross bar.
    6.  
    7. Place the engine support cross bar over the engine support long bar and connect the hooks to the engine lift brackets.
    8.  

  12.  
  13. Raise and support the vehicle.

    Click image to see an enlarged view

    Fig. Frame assembly removal

  14.  
  15. Remove the front wheel and tire assemblies.
  16.  
  17. Remove the both front fender liners.
  18.  
  19. Remove the steering gear mounting bolts and secure the steering gear with mechanic-s wire.
  20.  
  21. Disconnect the wheel speed sensor wires from the both front wheels and unclip from the frame.
  22.  
  23. Separate the ball joints from the steering knuckles.
  24.  
  25. With the wheels in the straight ahead position, remove the key from the ignition switch.
  26.  
  27. Secure the cooling module to the upper body structure.
  28.  
  29. Remove the left and right splash shields.
  30.  
  31. Remove the front transaxle mount to cradle through bolt.
  32.  
  33. Remove the rear transaxle mount to frame bolts.
  34.  
  35. Remove both stabilizer link to Stabilizer bar nuts.
  36.  
  37. Remove both tie rod to steering knuckle nuts.
  38.  
  39. Separate the outer tie rods from the steering knuckles.
  40.  
  41. Remove the intermediate steering shaft to steering gear pinch bolt and discard.
    WARNING
    DO NOT rotate the intermediate shaft once separated from the gear. Possible damage or a malfunction could occur.

  42.  
  43. Disconnect the intermediate steering shaft from the steering gear.
  44.  
  45. Remove both lower control arm ball stud to steering knuckle pinch bolts.
    WARNING
    Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result.

  46.  
  47. Lower the lower control arms in order to disengage the steering knuckle.
  48.  
  49. Mark the frame to body position with a paint pen or permanent marker.
  50.  
  51. Lower the vehicle to about 3 feet off the ground in order to place a hydraulic lift table under the frame.
  52.  
  53. Use two 2 x 4's between the lift table and the frame and lift the table to the frame.
  54.  
  55. Slowly remove the frame bolts using the following sequence:
    1. Remove the front frame bolts.
    2.  
    3. Partially unscrew the rear frame bolts exposing 1 1 / 2 inches (25mm) of bolt shank.
    4.  

  56.  
  57. Slowly lower the lift table to the floor.
  58.  
  59. Remove the 2 bolts from the transaxle brace.
  60.  
  61. Disconnect the shift cable from the shift linkage.
  62.  
  63. Disconnect the cable from the bracket.
  64.  
  65. Remove the flywheel inspection cover.
  66.  
  67. Remove the starter.
  68.  
  69. Mark the relationship of the flywheel to the torque converter for reassembly.
  70.  
  71. Prevent the crankshaft from rotating.
  72.  
  73. Remove the torque converter to flywheel bolts.
  74.  
  75. Remove the transaxle cooler lines by removing the nut holding the bracket to the transaxle case.
  76.  
  77. Disconnect the VSS wiring harness from the sensor.
  78.  
  79. Disconnect the halfshafts from the transaxle.
  80.  
  81. Lower the vehicle.
  82.  
  83. Remove the body to transaxle mount bolts.
  84.  
  85. Lower the transaxle with the engine support fixture enough to remove the transaxle.
  86.  
  87. Raise the vehicle.
  88.  
  89. Loosen the oil pan bolts.
  90.  
  91. Drain the oil. Use a suitable container to catch the transaxle fluid.
  92.  
  93. Remove the oil pan attaching bolts.
  94.  
  95. Remove the oil pan to drain the transaxle.
  96.  
  97. Install the oil pan gasket. Use a new gasket if the sealing ribs are damaged.
  98.  
  99. Install the oil pan.
  100.  
  101. Install the oil pan attaching bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  102.  
  103. Support the transaxle with a suitable jack.
  104.  
  105. Remove the transaxle to engine nut.
  106.  
  107. Separate the engine and the transaxle.
  108.  
  109. Remove the transaxle from the vehicle.
  110.  
  111. Remove the PNP switch.
  112.  
  113. Remove the shifter cable bracket.
  114.  
  115. Remove the lower transaxle to engine stud.
  116.  
  117. Remove the transaxle mount.
  118.  
  119. Flush the transaxle cooler and lines.
  120.  

To install:

  1. Install the PNP switch.
  2.  
  3. Install the shifter cable bracket.
  4.  
  5. Install the lower transaxle to engine stud.
  6.  
  7. Install the transaxle mount.
  8.  
  9. Position the transaxle in the vehicle.
  10.  
  11. Install the lower transaxle to engine bolts and nuts. Tighten the bolts and nuts to 66 ft. lbs. (90 Nm).
  12.  
  13. Connect the transaxle cooler pipes to the transaxle. Tighten the cooler pipes to 71 inch lbs. (8 Nm).
  14.  
  15. Prevent the crankshaft from rotating.
  16.  
  17. Install the torque converter to flywheel bolts. Tighten the torque converter bolts to 46 ft. lbs. (62 Nm).
  18.  
  19. Install the halfshafts to the transaxle.
  20.  
  21. Connect the wiring harness to the VSS.
  22.  
  23. Install the starter.
  24.  
  25. Install the flywheel inspection cover bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  26.  
  27. Lower the vehicle.
  28.  
  29. Use the engine support fixture to raise the engine and transaxle assembly.
  30.  
  31. Install the transaxle mount to body bolts. Tighten the bolts to 66 ft. lbs. (90 Nm).
  32.  
  33. Raise the vehicle.
  34.  
  35. With the frame on the lift table, raise the frame to the vehicle.
  36.  
  37. Hand-start all the frame bolts while aligning the frame to the paint marks.
  38.  
  39. Tighten the frame bolts. Tighten the bolts to 74 ft. lbs. (100 Nm) plus 180°.
  40.  
  41. Lower and remove the hydraulic table.
  42.  
  43. Connect the lower control arm to the steering knuckle.
    NOTE
    The torque sequence must be followed in the order that is listed.

  44.  
  45. Install the ball joint pinch bolt and nut.
    NOTE
    The front and rear transaxle mounts must be allowed to settle with the through bolts loosened.



    First Pass: Tighten the nut to 37 ft. lbs. (50 Nm). Reverse nut 3 / 4  turn
     
    Second Pass: Tighten the nut to 37 ft. lbs. (50 Nm) plus 30°.
     

  46.  
  47. Hand-start the front transaxle mount through bolt.
  48.  
  49. Loosen the rear transaxle mount through bolt.
  50.  
  51. Tighten the rear transaxle mount to frame bolts. Tighten the rear bolts to 37 ft. lbs. (50 Nm).
  52.  
  53. Tighten the front and rear transaxle mount through bolts in the following order. Tighten the rear bolt to 74 ft. lbs. (100 Nm). Tighten the front bolt to 74 ft. lbs. (100 Nm).
  54.  
  55. Install the outer tie rods to the steering knuckles.
  56.  
  57. Install the new outer tie rod to the knuckle nuts. Tighten the nuts to 15 ft. lbs. (20 Nm) plus 180°.
  58.  
  59. Connect the control links to the Stabilizer bar.
  60.  
  61. Connect the intermediate shaft to the steering gear.
  62.  
  63. Install a new intermediate shaft pinch bolt. Tighten the bolt to 25 ft. lbs. (34 Nm).
  64.  
  65. Install the left and right splash shields.
  66.  
  67. Install the front wheels.
  68.  
  69. Lower the vehicle.
  70.  
  71. Connect the ball joints to the steering knuckles.
  72.  
  73. Route and clip the wheel speed sensor wiring into the proper position on both sides.
  74.  
  75. Install the steering gear to the front suspension crossmember.
  76.  
  77. Install the steering gear bolts to the front suspension crossmember. Tighten the bolts to 81 ft. lbs. (110 Nm).
  78.  
  79. Install the transaxle to engine brace bolts. Tighten the bolts to 53 ft. lbs. (72 Nm).
  80.  
  81. Install the both front fender liners.
  82.  
  83. Install the front wheel and tire assemblies.
  84.  
  85. Lower the vehicle.
  86.  
  87. Install the upper transaxle to engine bolts and stud. Tighten all of the bolts to 66 ft. lbs. (90 Nm).
  88.  
  89. Install the engine wiring harness grounds to the transaxle to engine mount stud and nut. Tighten the nut to 71 inch lbs. (8 Nm).
  90.  
  91. Remove the engine support fixture.
  92.  
  93. Install the shift linkage to the transaxle.
  94.  
  95. Connect the electrical connectors to the PNP switch and transaxle.
  96.  
  97. Connect the air duct hose to the intake plenum.
  98.  
  99. Connect the negative battery cable.
  100.  
  101. Inspect the transaxle fluid level.
  102.  

 
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