GM Grand Am/Achieva/Calais/Skylark/Somerset 1985-98

Transaxle

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REMOVAL & INSTALLATION



1985-93 Vehicles

See Figures 1 through 6

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Fig. Fig. 1: An engine support fixture must be used to remove the transaxle



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Fig. Fig. 2: The wiring harness around the transaxle should be carefully tagged, disconnected, and set aside

  1. Disconnect the negative battery cable.
  2.  
  3. If necessary, drain the coolant and disconnect the heater core hoses.
  4.  
  5. Remove the air cleaner assembly. If equipped with a 3.0L or 3.3L engine, also remove the mass air flow sensor and air intake duct.
  6.  
  7. Disconnect the Throttle Valve (TV) cable from the throttle lever and the transaxle.
  8.  
  9. If equipped with a 2.3L engine, remove the power steering pump and bracket and position it aside.
  10.  
  11. Remove the transaxle dipstick and tube.
  12.  
  13. Install J 28468 or equivalent suitable engine support fixture. Insert a 1 /4 x 2 in. long bolt in the hole at the front right motor mount to maintain driveline alignment.
  14.  
  15. Remove the wiring harness-to-transaxle nut. Detach the wiring connectors from the speed sensor, TCC connector, neutral safety switch and reverse light switch.
  16.  



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Fig. Fig. 3: View of the transaxle mount

  1. Disconnect the shift linkage from the transaxle.
  2.  
  3. Remove the upper two transaxle-to-engine bolts and the upper left transaxle mount along with the bracket assembly.
  4.  
  5. Remove the rubber hose from the transaxle vent pipe. Remove the remaining upper engine-to-transaxle bolts.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove both front wheel and tire assemblies.
  10.  
  11. If equipped with a 2.3L engine, remove both lower ball joints and stabilizer shafts links.
  12.  
  13. Drain the transaxle fluid.
  14.  
  15. Remove the shift linkage bracket from the transaxle.
  16.  


CAUTION
On some vehicles, the subframe must be lowered for clearance. This means the intermediate shaft must be disconnected from the rack and pinion stub shaft. Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub can result in damage to the steering gear and/or intermediate shaft. This damage can cause loss of steering control, which could result in an accident and possibly personal injury.

  1. Install a halfshaft boot seal protector on the inner seals.
  2.  

Some vehicles may use a gray silicone boot on the inboard axle joint. Use boot protector tool on these boots. All other boots are made from a black thermo-plastic material and do not require the use of a boot seal protector.



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Fig. Fig. 4: Flex plate-to-torque converter mounting detail (flex plate removed from engine for clarity)



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Fig. Fig. 5: Engine-to-transaxle brace mounting detail



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Fig. Fig. 6: Transaxle-to-engine mounting detail (flex plate omitted for clarity)

  1. Remove both ball joint-to-control arm nuts, then separate the ball joints from the control arms.
  2.  
  3. Remove both halfshafts and support them with a cord or wire.
  4.  
  5. Unfasten and remove the transaxle mounting strut.
  6.  
  7. Remove the left stabilizer bar link pin bolt, left frame bushing clamp nuts and left frame support assembly.
  8.  
  9. Remove the torque converter cover. Matchmark the flexplate and torque converter for installation purposes.
  10.  
  11. Remove the torque converter-to-flexplate bolts.
  12.  
  13. Disconnect and plug the transaxle oil cooler lines.
  14.  
  15. Remove the transaxle-to-engine support bracket, then install a suitable transaxle removal jack.
  16.  
  17. Unfasten the remaining transaxle-to-engine attaching bolts, then carefully remove the transaxle from the vehicle.
  18.  

To install:
  1. Securely mount the transaxle on the jack.
  2.  
  3. Apply a small amount of grease on the torque converter hub and seat in the oil pump.
  4.  
  5. Position the transaxle in the vehicle, then install the lower engine to transaxle bolts.
  6.  
  7. Install the transaxle to engine support bracket. Once the transaxle is securely held in place, remove the jack.
  8.  
  9. Connect the cooler lines.
  10.  
  11. Install the torque converter bolts and tighten to specification.
  12.  
  13. Fasten the torque converter cover.
  14.  
  15. Install the left frame support assembly.
  16.  
  17. Fasten the left stabilizer shaft frame busing nuts and link pin bolt.
  18.  
  19. Install the transaxle mounting strut.
  20.  
  21. Install the halfshafts and the ball joints.
  22.  
  23. Position and secure the shift linkage bracket to the transaxle.
  24.  
  25. If equipped attach the ABS connectors. Install the inner splash shields.
  26.  
  27. Install the wheel and tire assemblies, then carefully lower the vehicle.
  28.  
  29. Fasten the upper transaxle to engine bolts.
  30.  
  31. Install the left side transaxle mount.
  32.  
  33. Connect the shift linkage to the transaxle.
  34.  
  35. Attach the wiring connectors to their switches on the transaxle.
  36.  
  37. Remove the engine support tool.
  38.  
  39. Install the dipstick tube and dipstick.
  40.  
  41. Install the TV cable and rubber vent tube.
  42.  
  43. Install the air cleaner assembly and air tubes.
  44.  
  45. If detached, connect the heater hoses.
  46.  
  47. Fill all fluids to their proper levels. Adjust cables as required.
  48.  
  49. Connect the negative battery cable, then check the transaxle for proper operation and leaks.
  50.  

1994-98 Vehicles
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air intake duct.
  4.  
  5. If equipped, disconnect the Throttle Valve (TV) cable.
  6.  
  7. Remove the shift cable and bracket.
  8.  
  9. Tag and disconnect the vacuum lines.
  10.  
  11. Detach the transaxle electrical connectors.
  12.  
  13. Remove the power steering pump from its bracket and set it aside.
  14.  
  15. Remove the transaxle filler tube.
  16.  
  17. Install an engine support fixture (J 28467-A or equivalent) to hold the engine in position while the transaxle is removed.
  18.  
  19. Unfasten the top engine-to-transaxle bolts.
  20.  
  21. Raise and safely support the vehicle.
  22.  
  23. Drain the fluid from the transaxle.
  24.  

It is advisable (but not necessary) to drain the fluid from the transaxle for removal. Once the inner CV joints are removed from the transaxle, fluid may escape when the transaxle is tilted during removal.

  1. Remove both wheel and tire assemblies, then remove the left splash shield.
  2.  
  3. Remove both ABS wheel speed sensors and harness from the left suspension support.
  4.  
  5. Remove both lower ball joints and the stabilizer shaft links.
  6.  
  7. Detach the front air deflector.
  8.  
  9. Remove the left suspension supports.
  10.  
  11. Remove both halfshafts (drive axles).
  12.  
  13. Unfasten and remove the transaxle-to-engine brace.
  14.  
  15. Remove the starter.
  16.  
  17. Unfasten the flywheel-to-torque converter bolts.
  18.  
  19. Remove the transaxle fluid cooler pipes.
  20.  
  21. Disconnect the ground wire(s) from the engine to the transaxle bolt.
  22.  
  23. Remove the fluid cooler pipe brace and the exhaust brace.
  24.  
  25. Support the transaxle with a suitable jack.
  26.  
  27. Remove the transaxle mount-to-body bolts.
  28.  
  29. Unfasten the heater core hose pipe brace-to-transaxle nut and bolt.
  30.  
  31. Unfasten the remaining engine-to-transaxle bolts, then carefully remove the transaxle assembly from the vehicle.
  32.  

To install:
  1. Place a thin film of grease on the torque converter pilot knob. Make sure to properly seat the torque converter in the oil pump.
  2.  
  3. Move the transaxle assembly into position with the jack, while installing the right drive axle (halfshaft). Be careful not to damage the axle seal during installation.
  4.  
  5. Fasten the lower engine-to-transaxle bolts into their proper locations.
  6.  
  7. Install the transaxle mount-to-body bolts.
  8.  
  9. Fasten the engine and transaxle attaching bolts.
  10.  
  11. Install the exhaust brace and the fluid cooler pipe brace.
  12.  
  13. Connect the ground wire at the engine to the transaxle bolt.
  14.  
  15. Attach the transaxle fluid cooler pipes.
  16.  
  17. Apply a suitable sealant compound on the flywheel-to-torque converter bolts, then install the bolts.
  18.  
  19. Fasten the transaxle converter cover.
  20.  
  21. Install the starter.
  22.  
  23. Connect the engine-to-transaxle brace.
  24.  
  25. Install the halfshafts (drive axles).
  26.  
  27. Install the left suspension support.
  28.  
  29. Fasten the air deflector.
  30.  
  31. Install the stabilizer shaft links and the lower ball joints.
  32.  
  33. Connect both ABS wheel speed sensors.
  34.  
  35. Install the left splash shield.
  36.  
  37. Fasten the heater core pipe brace nut and bolt.
  38.  
  39. Install both wheel and tire assemblies, then carefully lower the vehicle.
  40.  
  41. Fasten the top engine-to-transaxle bolts.
  42.  
  43. Remove the engine support fixture.
  44.  
  45. Install the transaxle filler tube.
  46.  
  47. Install the power steering pump assembly, then adjust the belt.
  48.  
  49. Attach the electrical connections and vacuum lines as tagged during removal.
  50.  
  51. Install the shift cable and bracket.
  52.  
  53. Install the TV cable, (if equipped) then connect the air intake duct.
  54.  
  55. Properly fill the transaxle, then connect the negative battery cable.
  56.  

 
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