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. Remove the control lever knob and boot assembly.

    Click image to see an enlarged view

    Fig. Control lever knob and boot assembly Saturn Sky shown Pontiac Solstice similar

  4.  
  5. Remove the turbocharger, if equipped. Refer to Turbocharger Replacement.
  6.  
  7. Remove the clutch hose/pipe assembly retainer clip from the clutch master cylinder.
  8.  
  9. Disconnect the clutch hose/pipe assembly from the clutch master cylinder.
  10.  
  11. Cap the clutch hose/pipe assembly in order to prevent fluid loss and contamination. It is not necessary to plug the lower hose end or slave cylinder fitting as they are equipped with check valves, only minimal fluid loss may be experienced.
  12.  
  13. Remove the transmission support.
  14.  
  15. Drain the transmission fluid if necessary.
  16.  
  17. Disconnect the electrical connector from the backup lamp switch.
  18.  
  19. Disconnect the electrical connector from the Vehicle Speed Sensor (VSS).
  20.  
  21. Disconnect the wiring harness from the clip bracket.
  22.  
  23. Disconnect the wiring harness clips from the clip brackets, and position the harness aside.
  24.  
  25. Support the transmission using a transmission jack.
  26.  
  27. Remove the propeller shaft and driveline support.
  28.  
  29. Remove the 5 transmission to engine mounting bolts.
  30.  
  31. Remove the 2 engine to transmission mounting bolts.

    Click image to see an enlarged view

    Fig. Manual transmission and mounting bolts

  32.  
  33. Remove the 2 remaining transmission mounting bolts.
    WARNING
    Do not allow the transmission to hang from the clutch assembly.

  34.  
  35. Pull the transmission straight back off the clutch hub splines.
  36.  
  37. Using the transmission jack, carefully lower the transmission from the vehicle.
  38.  

To install:

  1. Ensure clearance is maintained between the transmission and the following:

    The catalytic converter
     
    The clutch assembly
     
    The engine wiring harness
     

  2.  
  3. Using the transmission jack, carefully raise the transmission to the engine.
  4.  
  5. Align the transmission with the engine dowels 
  6.  
  7. Install the 2 transmission mounting bolts and tighten to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the 2 engine to transmission mounting bolts and tighten to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the 5 transmission to engine mounting bolts and tighten to 37 ft. lbs. (50 Nm).
  12.  
  13. Install the driveline support and propeller shaft.
  14.  
  15. Remove the transmission jack.
  16.  
  17. Lay the engine wiring harness over the transmission.
  18.  
  19. Connect the wiring harness clips to the clip brackets.
  20.  
  21. Connect the wiring harness to the clip bracket.
  22.  
  23. Connect the electrical connector to the VSS.
  24.  
  25. Connect the electrical connector to the backup lamp switch.
  26.  
  27. Fill the transmission fluid if removed.
  28.  
  29. Install the transmission support and closeout panels.
    WARNING
    Ensure the clutch hydraulic hose does not come in contact with any sharp or potentially hot surfaces.

  30.  
  31. Install the clutch hose/pipe assembly retainer clip to the clutch master cylinder.
  32.  
  33. Connect the clutch hose/pipe assembly to the clutch master cylinder.
  34.  
  35. Tug gently on the clutch hose/pipe assembly to ensure proper retention into the clutch master cylinder.
  36.  
  37. Install the turbocharger, if equipped. Refer to Turbocharger Replacement.
  38.  
  39. Install the control lever knob and boot assembly.
  40.  

 
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