Installation

1. Clean seal bore in housing.
2. Apply a light bead of Loctite 515 Gasket Eliminator sealant (P/N 21005993) or equivalent on the diameter of the seal that presses into the converter housing bore.

NOTICE: Prior to using seal installer SA9113T inspect the tool for any nicks or burrs that may damage the seal lip.

3. Use tool SA9113T to install seal. Place seal on tool and be sure to keep seal lined up with bore during installation.
4. Install flywheel dust cover if removed.

Torque: 11 Nm (97 inch lbs.)





5. Install engine to transaxle stiffening brace and install bracket to engine, and brace to transaxle bolts.

Torque: 54 Nm (40 ft. lbs.)

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

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





9. Position intermediate shaft support and install two bolts.

Torque: 54 Nm (40 ft. lbs.)

10. Position intake manifold support bracket and install intake bracket to intake manifold bolt.

Torque: 30 Nm (22 ft. lbs.)

11. Install intake bracket to intermediate shaft support nut.

Torque: 54 Nm (40 ft. lbs.)

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





12. Install right axle to intermediate shaft.
13. Clean and lubricate ball joint threads.
14. Position ball joint into steering knuckle.
15. Install nut to lower ball joint and torque.

Torque: 75 Nm (55 ft. lbs.)

IMPORTANT: If necessary, after torquing tighten nut additionally to align slot in nut with cotter pin hole in ball joint and install a new cotter pin and bend.

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





16. Position wheel onto hub.
17. Install wheel nuts and torque in a crisscross pattern. Repeat torquing procedure to make sure torque is correct.

Torque: 140 Nm (103 ft. lbs.)

IMPORTANT: Clean and lubricate fastener with Saturn Transaxle Fluid. Wipe off excess fluid.





18. Install drain plug.

Torque: 30 Nm (22 ft. lbs.)

19. Fill transaxle to proper level using Saturn Transaxle Fluid.
3.8L (4.0 Qt) - Fluid change only
4.0L (4.2 Qt) - Fluid change with a new pressure filter
Verify fluid level using the "Transaxle Fluid Level Checking Procedure" found.