Transaxle Installation

TRANSAXLE INSTALLATION

Good Advice: When reinstalling the transaxle, tap out the ignition module mounting holes prior to installing the transaxle.






1. Place transaxle securely on jack and position under vehicle. Install axle seal protector into seals on both sides; use protector SA91112T
2. Place transaxle in any gear.
3. Raise transaxle into vehicle to align input shaft to the center of the clutch. Guide trans axle into position, rotate back and forth to align input shaft splines to clutch disk.
4. Install two lower clutch housing to engine bolts.
Torque: 140 Nm (103 ft-lbs)

NOTICE: Make sure input shaft splines line up with the clutch disk splines before tightening clutch housing bolts. Do not use bolts to pull transaxle up to engine.

5. Remove transaxle jack.
6. Install left-hand side axle into transaxle.
7. After splines clear the seal protector but before snapping the axle into place, remove the seal protector tool.

NOTICE: Use caution not to damage axle seal when intermediate shaft is installed into transaxle.






8. Install axle seal protector tool SA91112T inside seal. (Left side shown, right side similar.)
9. Install intermediate shaft into transaxle.
10. After splines clear the seal protector but before snapping the axle into place, remove the seal protector tool.






11. Position intermediate shaft support and install three bolts.
Torque: 54 Nm (40 ft-lbs)
12. Install starter bracket to intermediate shaft bolt, if removed.
Torque: 30 Nm (22 ft-lbs)
13. On DOHC (LLO) vehicles, position intake manifold support bracket and install intake bracket to intake manifold bolt.
Torque: 30 Nm (22 ft-lbs)
14. Install intake bracket to intermediate shaft support nut.
Torque: 54 Nm (40 ft-lbs)
15. Install right axle to intermediate shaft.

NOTICE: Take care not to damage rubber boot when installing ball joint to knuckle.

16. Clean and lubricate ball joint threads.
17. Place cradle on lift and raise to vehicle and place lower ball joint into knuckles when raising cradle up.






IMPORTANT: Make sure that the following parts are correctly positioned when raising cradle into vehicle.

a. Lower control arm bar studs to knuckle.
b. Cooling module support bushings.
c. Engine strut cradle bracket.
d. Transaxle mount.






NOTICE: Cradle-to-body guide pins must be used to maintain proper alignment. Insert using 9/16 in. round steel rod for alignment pins. Alignment holes are at both front cradle mounting locations. Mount studs must be guided into holes in cradle as cradle is installed.

18. Install two rear cradle-to-body fasteners.

IMPORTANT: Do not tighten fasteners at this time.

19. Position cradle-to-body at the two front cradle to body fasteners.
20. Tighten four cradle-to-body fasteners.
Torque: 210 Nm (155 ft-lbs)
21. Remove powertrain support dolly.
22. Lower vehicle and remove engine support bar SA9105E.






23. On 1991 vehicles, install the front transaxle mount and loosely tighten the mount-to-transaxle bolts.






24. On 1992,1993, and 1994 vehicles, install the transaxle strut, transaxle bracket-to-transaxle bolts, if removed.
Torque: 54 Nm (40 ft-lbs)






25. On 1994 vehicles install transaxle strut-to-mid-rail bracket fastener.
Torque: 50 Nm (37 ft-lbs)
26. On 1992 and 1993 vehicles, install transaxle strut-to-cradle bracket fasteners. (Automatic shown, manual transaxle similar.)
Torque: 50 Nm (37 ft-lbs)
27. On 1992, 1993 and 1994 vehicles, tighten transaxle strut-to-trans axle bracket fastener, if removed.
Torque: 70 Nm (52 ft-lbs)
28. On 1992 and 1993 vehicles, tighten transaxle strut, cradle bracket-to-cradle fasteners, if removed.
Torque: 50 Nm (37 ft-lbs)
29. Remove cooling module support wire.






NOTICE: Run a tap through ignition module mounting holes in transaxle to remove any thread sealant residue. Tap size 6 x 1.0 mm.

30. Inspect new electronic ignition module bolts to make sure they are coated with yellow thread sealant and the mating surfaces are free from grit and dirt.

NOTICE: Always use new electronic ignition module bolts to insure proper thread sealant.

NOTICE: Use extreme care when installing the electronic ignition module bolts make sure the bolt head is seated on the electronic ignition module when the torque specification is reached. If the bolt head is not seated on the electronic ignition module, remove the bolt and tap the hole to clean any debris from the threads.

31. Install electronic ignition module and bolts. (Automatic shown, manual transaxle similar.)
Torque: 8 Nm (71 in-lbs)






32. Install the top two clutch housing to to engine studs. (Automatic shown, manual transaxle similar.)
Torque: 100 Nm (74 ft-lbs)






33. Connect electrical connectors to transaxle.
a. Vehicle speed sensor.
b. Back-up light switch.
c. Two ground terminals to top two clutch housing studs.
Torque: 25 Nm (18 ft-lbs)
d. Install vent hose clip to housing.
e. On 1991 vehicles, install oxygen sensor wire clip to clutch housing.






34. Connect shifter cables to shift arms and clutch housing. Install cable retainers.






35. Un-wire dampener and actuator from battery tray. Install two dampener to clutch housing nuts.
Torque: 25 Nm (18 ft-lbs)
36. Install actuator into clutch housing. Push in and rotate 1/4 turn clockwise. Install retaining clip.

37. Check master cylinder at front of dash connection to be sure it is locked in place.






38. Install battery tray.
39. Torque battery tray bolts.
Torque: 10 Nm (89 in-lbs)






40. Install battery.
41. Install battery shield.
42. Torque battery shield bolts.
Torque: 9 Nm (80 in-lbs)






43. Install air induction tube. Make sure the resonator support button is properly located in the engine support bracket.
a. Install air box with three fasteners.
Torque: 10 Nm (89 in-lbs)
b. Connect the flex tub to air box.
c. Align arrows and tighten clamps.
Torque: 2 Nm (18 in-lbs)






44. Install the cross-car duct with two fasteners.
45. Connect the inlet air temperature (IAT) sensor connector.






CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

46. Raise vehicle on hoist.
47. On 1991 vehicles, install transaxle lower mount-to-cradle fastener.
Torque: 48 Nm (35 ft-lbs)
48. On 1992, 1993 and 1994 vehicles, install transaxle lower mount-to-cradle fastener.
Torque: 50 Nm (37 ft-lbs)






49. On 1991 vehicles, swing trans axle rear mount bracket towards the front of the vehicle and secure transaxle rear mount bracket onto transaxle with four fasteners.
Torque: 54 Nm (40 ft-lbs)
50. On 1991 vehicles, tighten rear transaxle mount pivot bolt.
Torque: 70 Nm (52 ft-lbs)






51. Install engine mount-to-cradle fastener.
Torque: 90 Nm (66 ft-lbs)






52. On 1991 vehicles, install nuts to front transaxle-mount-to-cradle studs.
Torque: 48 Nm (35 ft-lbs)
53. On 1991 vehicles, tighten front transaxle mount, mount-to-transaxle bolts.
Torque: 48 Nm (35 ft-lbs)






IMPORTANT: To insure proper powertrain alignment, make sure that all other mounts have been torqued.

54. On 1992, 1993 and 1994 vehicles, install two engine strut cradle bracket-to-cradle fasteners.
Torque: 50 Nm (37 ft-lbs)






55. Install steering gear-to-cradle attachment fasteners. (Power steering gear shown, manual similar.)
Torque: 50 Nm (37 ft-lbs)
56. Remove steering gear support wire.






57. Connect brake line-to-cradle retainer.






58. Install dust cover and install dust cover to clutch housing bolts.
Torque: 11 Nm (97 in-lbs)






59. Install powertrain stiffening bracket and install bracket to engine and transaxle bolts.
Torque: 54 Nm (40 ft-lbs)






60. Position exhaust manifold pipe into vehicle.
61. Install exhaust manifold pipe-to-exhaust manifold fasteners and tighten. For 1991 and 1992 DOHC (LLO) engines, tighten in sequence shown.






For 1991 and 1992 SOHC and all 1993 and 1994 engines no tightening sequence is required.
Torque: 31 Nm (23 ft-lbs)






62. On 1993 and 1994 vehicles, install the intermediate exhaust pipe-to-three way catalytic converter flange fasteners.
Torque: 25 Nm (18 ft-lbs)






63. On 1993 and 1994 vehicles, install front exhaust pipe clamp support to engine stiffening bracket bolts and pipe clamp bolt, if removed.
Clamp Support to Engine Stiffening Bracket:
Torque: 30 Nm (22 ft-lbs)
Clamp Support to Front Exhaust Pipe:
Torque: 60 Nm (44 ft-lbs)






64. On 1991 and 1992 vehicles, install exhaust manifold pipe-to-catalytic converter fasteners.
Torque: 45 Nm (33 ft-lbs)

IMPORTANT: A converter fastener kit Saturn PIN 21010753 is used in place of the self tapping screws when the converter flange threads are damaged or stripped. The repair kit is designed to provided gasket clamp load and prevent exhaust leaks.

65. On 1991 and 1992 vehicles, install exhaust pipe- to-transaxle support bracket fasteners.
Torque: 31 Nm (23 ft-lbs)







66. Install nut to lower ball joint, and torque.
Torque: 75 Nm (55 ft-lbs)
a. After torquing, if necessary, tighten nut additionally to align slot in the nut with the cotter pin hole in the ball joint. Install the cotter pin.
67. On 1991 vehicles, align powertrain mounts.






68. Install right side, left side, and front splash shield to cradle fasteners.

NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel lug nuts to loosen in service.

69. On coupes, install right and left lower fascia brace to cradle 3-nuts.
Torque: 10 Nm (89 in-lbs)
70. Position wheels onto hubs.
71. Install wheel nuts and tighten in a crisscross pattern.
Torque: 140 Nm (103 ft-lbs)
a. Repeat tightening pattern to be sure torque is correct.
72. Install drain plug with a new drain plug washer (if equipped). On 1993 vehicles, a seal is used as part of the drain plug and does not have to be replaced each time the drain plug is removed.
Torque: 45 Nm (40 ft-lbs) (with aluminum washer)
Torque: 30 Nm (22 ft-lbs) (with rubber seal)

NOTICE: Clean and lubricate fastener with ATF (DEXRON-IIE or DEXRON-III). Wipe off excess fluid and install.

73. Fill trans axle to proper level using DEXRON-IIE or DEXRON-III 2.5L (2.6 US Qt)
74. Connect battery terminals.
Torque: 17 Nm (150 in-lbs)

CAUTION: THE POSITIVE TERMINAL MUST BE CONNECTED FIRST TO PREVENT ARCING.

75. Perform vehicle alignment.

NOTICE: On vehicles equipped with an SIR system, enable the SIR system. (Refer to "Enabling the SIR System.")