GM Malibu/Cutlass 1997-2000

Automatic Transaxle Assembly

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REMOVAL & INSTALLATION





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Fig. Typical engine support fixture needed to hold the engine in place as the transaxle is being removed from the bottom of the vehicle


NOTE
Special lifting and support equipment is required for this procedure. The engine must be supported from above to hold the weight of the engine. The subframe and transaxle are lowered out from the bottom of the vehicle. This is not a job for the inexperienced or ill-equipped.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Disconnect the shift linkage from the transaxle.
  6.  
  7. Detach the wiring connections from the transaxle.
  8.  
  9. Install an engine support fixture.
  10.  
  11. Unfasten the upper engine-to-transaxle bolts.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Remove both front tire and wheel assemblies. Remove the left and right splash shields.
  16.  
  17. Remove both front ABS wheel speed sensors and the harness from the left suspension support.
  18.  
  19. Remove both outer tie rods from the steering knuckle, as outlined in .
  20.  
  21. Separate both ball joints from the steering knuckle, as outlined in .
  22.  
  23. Remove the front suspension support brace, then remove the engine mount strut from the strut mount bracket.
  24.  
  25. Support the suspension support assembly, then remove the bolts. Loosen the suspension support assembly enough to disconnect the steering coupling and both power steering fluid lines.
  26.  
  27. Remove both drive axles (halfshafts) from the transaxle, then support them.
  28.  
  29. Unfasten the engine-to-transaxle brace.
  30.  
  31. Remove the shift cable bracket.
  32.  
  33. As outlined in of this guide, remove the starter.
  34.  
  35. Unfasten the retaining bolts, then remove the transaxle converter cover/shield.
  36.  
  37. Matchmark the flexplate-to-torque converter for reassembly, then unfasten the torque converter-to-flexplate bolts.
  38.  
  39. Disconnect and plug the transaxle cooler pipes. Remove the brake hose bracket-to-body bolts.
  40.  
  41. Unfasten the transaxle mount pipe expansion bolt.
  42.  
  43. Unfasten the transaxle mount-to-body bolts.
  44.  
  45. Carefully lower the vehicle.
  46.  
  47. Lower the transaxle with the engine support fixture enough to remove the transaxle.
  48.  
  49. Raise and safely support the vehicle.
  50.  
  51. Support the transaxle with a suitable jack.
  52.  
  53. Unfasten the remaining transaxle-to-engine bolts, then remove the transaxle from the vehicle.
  54.  

To install:


NOTE
Whenever the transaxle has been removed, the transaxle cooler lines should be flushed.

  1. Place a thin film of GM part no. 1051344 or equivalent grease on the torque converter pilot knob. Make sure to properly seat the torque converter in the oil pump.
  2.  
  3. Position the transaxle in the vehicle, then secure with the lower transaxle-to-engine bolts.
  4.  
  5. Carefully lower the vehicle. Raise the transaxle with the engine support fixture.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Fasten the transaxle mount-to-body bolts.
  10.  
  11. Attach the brake hose bracket to body.
  12.  
  13. Unplug and connect the transaxle cooler pipes.
  14.  
  15. Fasten the torque converter-to-flexplate bolts. Hand start the bolts, then tighten them to 46 ft. lbs. (62 Nm). Install the converter cover/shield.
  16.  
  17. Install the starter, as outlined in .
  18.  
  19. Connect the shift cable bracket. Tighten the bolt to 18 ft. lbs. (24 Nm) and the nut to 37 ft. lbs. (50 Nm).
  20.  
  21. Install the engine-to-transaxle brace.
  22.  
  23. Install both drive axles (halfshafts).
  24.  
  25. Raise the suspension support assembly enough to connect the steering coupling and both power steering fluid lines.
  26.  
  27. Support the suspension support assembly, then install the retaining bolts.
  28.  
  29. Fasten the engine mount strut to the suspension support. Install the front suspension support brace. Tighten the retaining bolt to 49 ft. lbs. (66 Nm).
  30.  
  31. Attach both ball joints to the steering knuckle assembly, then connect both outer tie rods to the steering knuckle. For more information, please refer to of this guide.
  32.  
  33. Attach both front ABS wheel speed sensors and fasten the harness to the left suspension support.
  34.  
  35. Install the right and left splash shields and the front tire and wheel assemblies.
  36.  
  37. Carefully lower the vehicle.
  38.  
  39. Install the upper transaxle-to-engine bolts, the remove the engine support fixture.
  40.  
  41. Attach the wiring connections to the transaxle, then connect the shift linkage to the transaxle.
  42.  
  43. Install the air cleaner assembly, then connect the negative battery cable.
  44.  
  45. Check the transaxle fluid lever, and fill with the proper type of oil, if necessary.
  46.  
  47. Apply the brakes, start the engine, then shift the transaxle from "Reverse" to "Drive". Fasten the transaxle mount pipe expansion bolt.
  48.  

ADJUSTMENTS



Throttle Valve (TV) Cable

Setting of the TV cable must be done by rotating the throttle lever at the throttle body. Do not use the accelerator pedal to rotate the throttle lever.

  1. With the engine OFF , depress and hold the reset tab at the engine end of the TV cable.
  2.  
  3. Move the slider until it stops against the fitting.
  4.  
  5. Release the rest tab.
  6.  
  7. Rotate the throttle lever to its full travel.
  8.  
  9. The slider must move (ratchet) toward the lever when the lever is rotated to its full travel position.
  10.  
  11. Recheck after the engine is hot and road test the vehicle.
  12.  

 
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