Malibu 2001-2005

Transmission Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Install an Engine Support Fixture.
  4.  
  5. Drain the transmission.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Front transmission mount bolts
     
    Front wheels
     
    Left and right splash shields
     
    Shift linkage from the transaxle
     
    Wiring harness connection from the transaxle
     
    Ground cables from the engine block
     
    Park Neutral Position (PNP) switch electrical connector
     
    Lower radiator and condenser support
     
    Front transmission mount bracket
     
    Anti-lock Brake System (ABS) wheel speed sensors and electrical harnesses from the suspension supports
     
    Brake modulator assembly
     
    Vehicle Speed Sensor (VSS)
     
    Torque converter cover
     
    Torque converter-to-flywheel bolts
     
    Ball joints from the steering knuckles
     
    Halfshafts from the transaxle
     
    ABS module
     
    Outer tie rod ends from the steering knuckles
     
    Pressure line from the rack and pinion
     
    Transmission fluid cooler lines
     
    Brake hose bracket from the body
     
    Intermediate shaft
     
    Transmission-to-engine bolts
     
    Transaxle from the engine
     

  8.  

To install:

  1. Apply a thin film of grease on the torque converter pilot hub.
    WARNING
    Be sure to properly seat the torque converter in the pump.

  2.  
  3. Install or connect the following:

    Transaxle. Torque the transmission-to-engine bolts to 66 ft. lbs. (90 Nm).
     
    Intermediate shaft. Torque the pinch bolt to 15 ft. lbs. (20 Nm).
     
    Brake hose bracket to the body
     
    Transaxle fluid cooler lines
     
    Pressure line to the rack and pinion
     
    Outer tie rod ends. Torque the nuts to 14 ft. lbs. (20 Nm) plus an additional 180 degree turn.
     
    ABS module
     
    Halfshafts to the transaxle
     
    Ball joints. Torque the nuts to 48 ft. lbs. (65 Nm).
     
    Torque converter. Torque the bolts to 46 ft. lbs. (62 Nm).
     
    Torque converter cover
     
    VSS electrical connector
     
    Brake modulator assembly
     
    Front ABS wheel speed sensors and harnesses to the suspension support
     
    Front transmission mount bracket
     
    Lower radiator and condenser support
     
    PNP switch electrical connector
     
    Ground cables to the engine block
     
    Transmission electrical connections
     
    Shift cable bracket. Torque the bolt to 18 ft. lbs. (24 Nm) and the nut to 37 ft. lbs. (50 Nm).
     
    Air cleaner assembly
     
    Left and right splash shields
     
    Front wheels
     

  4.  
  5. Remove the engine support fixture.
  6.  
  7. Install or connect the following:

    Shift linkage
     
    Negative battery cable
     

  8.  
  9. Refill the transmission.
  10.  
  11. Apply the brakes and start the engine.
  12.  
  13. Shift the transaxle from R to D and back to P .
  14.  
  15. Recheck the fluid level.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Install an engine support fixture.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Matchmark the flywheel to the torque converter.



    Negative battery cable
     
    Air intake assembly
     
    Transaxle wiring harness from the transaxle and Park/Neutral Position (PNP) switch
     
    Shift linkage from the transaxle
     
    Transmission wiring harness from the retainer on the transmission
     
    Upper transmission-to-engine bolts
     
    Front wheels
     
    Splash shields
     
    Steering gear intermediate shaft
     
    Control arm from the frame. Support with mechanics wire or equivalent.
     
    Outer tie rod ends from the steering knuckles.
     
    Frame
     
    Transmission brace mounting bolts near the right axle shaft
     
    Oil pan to bell housing bolts
     
    Flywheel inspection cover
     
    Starter
     



    Torque converter-to-flywheel bolts
     
    Transmission cooler lines
     
    Vehicle speed sensor (VSS)
     
    Rear O 2 sensor
     
    Halfshalfts from the transaxle
     
    Front transmission bracket
     

  8.  
  9. Support the transmission using a transmission jack or suitable equivalent.
  10.  
  11. Remove the remaining bell housing bolts and separate the transmission from the engine.
  12.  
  13. Lower the transmission and remove.
  14.  

To install:

  1. Install or connect the following:

    Transaxle. Tighten the transmission-to-engine bolts to 66 ft. lbs. (90 Nm).
     
    Front transmission mount bracket
     
    Halfshafts
     
    Rear O 2 sensor
     
    VSS
     
    Torque converter to flywheel bolts. Tighten to 46 ft. lbs. (62 Nm).
     
    Starter
     
    Flywheel inspection cover
     
    Transmission cooler lines
     
    Oil pan-to-bell housing bolts
     
    Transmission brace mounting bolts near the right axle shaft. Tighten to 53 ft. lbs. (72 Nm).
     
    Frame
     
    Outer tie rod ends to steering knuckles
     
    Control arms to the frame
     
    Steering gear intermediate shaft
     
    Splash shields
     
    Front wheels
     
    Upper transmission-to-engine bolts. Tighten to 66 ft. lbs. (90 Nm).
     
    Shift linkage
     
    PNP switch and transaxle electrical connectors
     
    Air intake assembly
     
    Negative battery cable
     

  2.  
  3. Refill transmission with ATF to the proper level.
  4.  

 
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