Solstice 2006-2008, Sky 2007-2008

Transmission 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. Remove the starter motor to gain access to the torque converter bolts.
  6.  
  7. Remove the left side transmission to engine mounting bolt.
  8.  
  9. Remove the two upper transmission mounting bolts.
  10.  
  11. Remove the turbocharger, If equipped. Refer to Turbocharger Replacement.
  12.  
  13. Remove the right side transmission to engine mounting bolts.
  14.  
  15. Raise and support the vehicle.
  16.  
  17. Remove the exhaust system pipe.
  18.  
  19. Remove the front closeout panel.
  20.  
  21. Drain the transmission fluid if disassembly of the transmission is necessary.
  22.  
  23. Remove the transmission manual shift shaft nut.
  24.  
  25. Disconnect the shift linkage from the transmission.
  26.  
  27. Place the transmission in Neutral by rotating the transmission shift shaft clockwise 2 clicks.
  28.  
  29. Remove the propeller shaft.
  30.  
  31. Disconnect the transmission wiring harness connector from the transmission by rotating the locking latch counterclockwise.
  32.  
  33. Disconnect the wiring harness clips from the transmission, and position the wiring harness aside.
  34.  
  35. Remove the flywheel inspection cover bolt and cover.
  36.  
  37. Mark the torque converter to flexplate/flywheel orientation to ensure proper realignment.
  38.  
  39. Repeat the following steps for all 3 torque converter bolts:
    1. Rotate the harmonic balancer center bolt clockwise only, in order to align the torque converter bolt with the starter motor opening in the engine block.
    2.  
    3. Remove and discard the torque converter bolt. The bolt is self locking and is not reusable.
    4.  

  40.  
  41. Place an oil drain pan under the transmission fluid cooler pipes.
  42.  
  43. Remove the bolt securing the transmission fluid cooler pipes retainer to the transmission.
  44.  
  45. Remove the transmission fluid cooler pipes from the transmission, and position aside.
  46.  
  47. Remove the O-rings. Do not reuse the O-rings.
  48.  
  49. Plug the open outlet ports to prevent fluid loss and contamination.
  50.  
  51. Position a suitable transmission jack under the transmission.
  52.  
  53. Remove the transmission mount.
  54.  
  55. Remove the left side transmission to engine mounting bolts.
  56.  
  57. Remove the right side transmission to engine mounting bolts.
  58.  
  59. Pull the transmission free from the engine dowels.
  60.  
  61. Carefully lower the transmission from the vehicle.
  62.  
  63. Flush the transmission oil cooler.
  64.  
  65. If the transmission is being replaced, remove the drive flange and install it on the replacement unit.
  66.  

To install:

  1. Using the transmission jack, carefully raise the transmission to the vehicle.
  2.  
  3. Align the transmission with the engine dowels.
  4.  
  5. Install the right transmission mounting bolts and tighten to 37 ft. lbs. (50 Nm).
  6.  
  7. Install the left transmission mounting bolts and tighten to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the transmission mount and tighten mounting bolts to 41 ft. lbs. (55 Nm).
  10.  
  11. Remove transmission jack from under the transmission.
  12.  
  13. Place new seals over the transmission fluid cooler pipes.
  14.  
  15. Insert the transmission fluid cooler pipes into the transmission.
  16.  
  17. Install the bolt securing the transmission fluid cooler pipe retainer to the transmission. Tighten the bolt to 18 ft. lbs. (25 Nm).
  18.  
  19. Align the torque converter to flexplate/flywheel orientation marks made during the removal procedure.
    WARNING
    Torque converter bolts are self locking and must be replaced with new torque converter bolts every time the bolts are removed.

  20.  
  21. Repeat the following steps for all 3 torque converter bolts:
    1. Rotate the harmonic balancer center bolt clockwise ONLY, in order to align the torque converter bolt holes in the flexplate/flywheel with the starter motor opening in the engine block.
    2.  
    3. To aid in alignment of the torque converter to the flexplate/flywheel. Install all 3 NEW torque converter bolts before fully tightening.
    4.  

  22.  
  23. Tighten torque converter bolts to 46 ft. lbs. (63 Nm).
  24.  
  25. Install the flywheel inspection cover and bolt.
  26.  
  27. Connect the wiring harness clips to the transmission.
  28.  
  29. Connect the transmission wiring harness connector to the transmission by rotating the locking latch clockwise.
  30.  
  31. Install the propeller shaft.
  32.  
  33. Place the transmission in the park position by rotating the shift shaft fully counterclockwise.
  34.  
  35. Connect the shift linkage to the transmission.
  36.  
  37. Install the transmission manual shift shaft nut and tighten to 80 inch. lbs. (9 Nm).
  38.  
  39. Check the transmission fluid level (fill as needed).
  40.  
  41. Adjust the shift control linkage.
  42.  
  43. Install the exhaust system pipe and tighten the nuts to 13 ft. lbs. (17 Nm).
  44.  
  45. Install the front closeout panel, tighten mounting bolts to 80 inch. lbs. (9 Nm).
  46.  
  47. Lower the vehicle.
  48.  
  49. Install the right transmission mounting bolts and tighten to 37 ft. lbs. (50 Nm).
  50.  
  51. Install the turbocharger, If equipped. Refer to Turbocharger Replacement.
  52.  
  53. Install the two upper transmission mounting bolts and tighten to 37 ft. lbs. (50 Nm).
  54.  
  55. Install the left transmission mounting bolt and tighten to 37 ft. lbs. (50 Nm).
  56.  
  57. Install the starter motor and tighten mounting bolts to 30 ft. lbs. (40 Nm).
  58.  
  59. Tighten starter solenoid terminal no. nut to 89 inch. lbs. (10 Nm).
  60.  
  61. Tighten starter solenoid "S" terminal no. nut to 27 inch. lbs. (3 Nm).
  62.  
  63. Connect the negative battery cable.
  64.  
  65. The transmission control module must be programmed with the proper software/calibrations.
  66.  
  67. Complete the following procedure after the transmission is installed in the vehicle:

    With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
     
    Start the engine and listen for abnormal conditions.
     
    While the engine continues to idle raise and support the vehicle.
     
    Inspect for fluid leaks while the engine is idling.
     
    Lower the vehicle.
     
    Perform a final inspection for the proper fluid level.
     
    Reset the Transmission Adaptive Functions (TAP) values.
     
    Road test the vehicle.
     

  68.  

 
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