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A/T - Case Side Cover Replacement Revision

Revised Case Side Cover Replacement Procedure # 04-07-30-038B - (Feb 16, 2005)

Models:
2005 Buick Terraza
2002-2005 Chevrolet Venture
2005 Chevrolet Uplander
2002-2004 Oldsmobile Silhouette
2002-2005 Pontiac Montana
2005 Pontiac Montana SV6
2005 Saturn Relay

without All-Wheel Drive (AWD)

This bulletin is being revised to add a step for installing the engine support fixture. Please discard Corporate Bulletin Number 04-07-30-038A (Section 07 - Transmission/Transaxle).

This bulletin is being issued to revise the Case Side Cover Replacement procedure in the Automatic Transmission sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information.

The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page.

Case Side Cover Replacement

Removal Procedure

1. Remove the throttle body air inlet duct. Refer to Air Cleaner Element in Engine Controls.

2. Remove the engine mount struts.

3. Remove the wiper cover.

4. Disconnect the 20-way electrical connector at the transmission.

5. Remove the shift cable bracket from the transmission.

6. Install the engine support fixture and support the engine/transaxle assembly. Refer to Engine Support Fixture in Engine Mechanical.

7. Raise and support the vehicle.

8. Remove the left front tire and wheel.

9. Remove the left wheel speed sensor harness connector (1).

10. Remove the left engine splash shield.

11. Remove both stabilizer shaft links from the lower control arms.





12. Remove the wheel speed sensor harness connector (2).

13. Remove the left lower ball joint from the left steering knuckle.

14. Disconnect the left drive axle from the transaxle.

15. Reposition and secure the drive axle.





16. Remove the heat shield bolts from the frame (2).

17. Remove the steering gear-to-frame bolts (2).

18. Support the left side of the frame with a utility stand.

19. Remove the transaxle mount lower nuts only.

20. Loosen the engine mount lower nuts.

21. Remove the air deflector.

22. Remove the left side frame bolts.

23. Use the utility stand in order to lower left side of the frame.

24. Position the drain pan under the transaxle.

25. Remove the left axle.

26. Remove the utility stand and lower the vehicle.

27. Loosen the motor support bolts.

28. Raise the vehicle.

29. Remove the motor mount bracket.





30. Remove the wiring harness connectors.





31. Remove the case side cover bolts (56-58).





32. Remove the case side cover pan (53).

33. Remove the case side cover gasket (54).

34. Remove the case side cover inner gasket (59).

35. Inspect the case side cover (53) for the following conditions:

- Damaged or porous gasket sealing surfaces

- Damaged or porous casting surfaces

- Damaged or stripped bolt holes

38. Inspect the case side cover gasket (54) and case side cover inner gasket (59) for damage. The gaskets are reusable if they are NOT damaged.

39. Clean the case side cover.

40. Clean the case side cover gasket surfaces.

Installation Procedure





1. Install the case side cover inner gasket (59).

2. Install the case side cover gasket (54).

3. Install the case side cover pan (53).

Notice:
Refer to Fastener Notice in Cautions and Notices.





4. Install the case side cover bolts (56-58).





Tighten

Tighten the bolts (56-58) to 25 Nm (18 lb-ft).

5. Install the motor mount bracket.

Tighten

Tighten to 95 Nm (70 lb-ft).

6. Remove the drain pan from under the transaxle.

7. Install the wiring harness connectors.

8. Use the utility stand in order to raise the left side of the frame.

9. Install the left side frame bolts.

Tighten

Tighten the bolts to 165 Nm (122 lb-ft).

10. Install the transaxle mount.

11. Remove the utility stand support from the left side of the frame.

12. Install the air deflector (4 bolts).

13. Install the left drive axle to the transaxle.

14. Install the left lower ball joint to the left steering knuckle.

15. Install two steering gear bolts.

Tighten

Tighten the bolts to 80 Nm (59 lb-ft).

16. Install the heat shield.

17. Install the lower ball joint nut and tighten





18. Install the wheel speed sensor harness connector (1).

19. Install the transmission mount lower nuts.

20. Install the stabilizer shaft links to the lower control arms.

Tighten

Tighten to 23 Nm (17 lb-ft).

21. Install the left engine splash shield.

22. Install the left front tire and wheel.

23. Lower the vehicle.

24. Remove the engine support fixture from the engine/transaxle assembly.

25. Install the shift cable bracket.

26. Connect the 20-way transmission electrical connector.

27. Install the engine mount struts.

28. Install the throttle body air inlet duct.

29. Install the engine mount struts.

30. Install the wiper cover.

Notice:
Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle.

31. Adjust the fluid level. Refer to the following information.

- Line Pressure Check Procedure

- Fluid and Lubricant Recommendations in Maintenance and Lubrication

- Capacities - Approximate Fluid in Maintenance and Lubrication

34. Inspect for proper completion of the repairs.

35. Inspect for fluid leaks.





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