Extension Housing: Service and Repair
- TOOLS REQUIRED- SA9132S Lower Control Arm Ball Stud Separator
REMOVAL
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE ADDITIONAL SUPPORT TO THE OPPOSITE END OF THE VEHICLE THAT COMPONENTS WILL BE REMOVED.
1. Raise vehicle on hoist.
2. Remove left front road wheel.
3. Remove left wheelhouse splash shield.
4. Drain transaxle fluid.
5. Remove cotter pin from lower ball joint and discard. Loosen nut and back off until top of nut is even with top of threads.
NOTICE: On ABS equipped vehicles, the outer CV joint has a speed sensor ring. Using the incorrect tool or procedure to separate the control arm from the knuckle can damage the ring, resulting in loss of ABS operation.
NOTICE: Do not attempt to separate joint using a wedge type tool because the boot may be damaged.
6. Separate ball joint from steering knuckle using SA9132S and remove nut.
7. Remove bolt retaining brake line bracket to inner fender and position brake line to avoid interference.
8. Remove transaxle mount-to-cradle fastener.
9. Place a screw type jack stand under the transaxle casing (use a block of wood between stand and casing) to unload transaxle lower mount.
10. Remove two mount-to-transaxle fasteners.
11. Loosen and back off on two cradle-to-body bolts. Do not remove bolts.
12. Raise powertrain enough to remove mount and remove mount from vehicle.
13. Lower jack.
14. Remove end cover bolts.
NOTICE: Use care when removing end cover as the tubes can bend easily.
15. Remove end cover.
Refer to the "End Cover Disassembly/Assembly" procedures if replacing or reconditioning end cover, tubes, or seals. Refer to the "1st Clutch, 1st Drive Gear and 1st Driven Gear Removal" procedures if replacing 1st gear assembly.
INSTALLATION
1. Clean gasket surfaces and install gasket on to end cover dowel pins.
2. Install the end cover to the transaxle case. Insert the input and output shaft tubes into the ends of the shafts and install cover. If the cover does not seat, rotate the axle to help align the tubes with the bushings in the shafts.
IMPORTANT: Clean and lubricate fasteners with Saturn Transaxle Fluid. Wipe off excess fluid.
3. Install the end cover to case bolts and torque using torque sequence.
- Torque: 28 Nm (21 ft. lbs.)
4. Install bolt into brake line bracket and torque.
- Torque: 5 Nm (44 inch lbs.)
5. Raise powertrain up and install transaxle mount.
6. Install two lower mount-to-transaxle fasteners.
- Torque: 32 Nm (24 ft. lbs.)
7. Tighten two cradle-to-body bolts.
- Torque: 210 Nm (155 ft. lbs.)
8. Lower powertrain completely.
IMPORTANT: Make sure that the lower mount stud inserts in cradle accurately, without damaging stud threads.
9. Install transaxle lower mount-to-cradle fastener.
- Torque: 48 Nm (35 ft. lbs.)
10. Install splash shield.
11. Clean and lubricate ball joint threads.
NOTICE: Take care not to tear rubber boot when installing ball joint to knuckle.
12. Position ball joint into steering knuckle.
13. Install nut to lower ball joint and torque.
- Torque: 75 Nm (55 ft. lbs.)
If necessary, after torquing, tighten nut additionally to align slot in nut with cotterpin hole in ball joint, and install cotterpin and bend ends.
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.
14. Position wheel onto hub.
15. Install wheel nuts and tighten in a crisscross pattern.
- Torque: 140 Nm (103 ft. lbs.)
Repeat tightening pattern to be sure torque is correct.
16. Lower vehicle from hoist.
17. Fill transaxle with fluid.
18. Install transaxle strut-to-midrail bracket fastener.
- Torque: 70 Nm (52 ft. lbs.)
19. Install air cleaner and duct assembly.
20. Verify fluid level.