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Home >> Saturn >> 2003 >> Ion 1 Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle - AF23-5 >> Repair Instructions >> Transmission Replacement >> Installation Procedure
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Installation Procedure

  1. Install the rear transmission mount to the transmission. Refer to Transmission Mount Replacement - Rear .
  2. Install the front transmission mount to the transmission. Refer to Transmission Mount Replacement - Front .
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the shift cable bracket.

    Tighten 

    Tighten the bolts to 23 N.m (17 lb ft).

  4. Install the PNP switch. Refer to Park/Neutral Position Switch Replacement .
  5. Use a transmission jack to position the transmission to the vehicle.

    Important:  The number three position does not require a bolt.

  6. Secure the transmission to the engine.

    Tighten 

    Tighten the bolts to 75 N.m (55 lb ft).

    Fig 1: Tightening Transmission To Engine Bolts
    G02125422Courtesy of GENERAL MOTORS CORP.
  7. Connect the shift cable to the transmission. Refer to Shift Cable Replacement .
    Fig 2: Connecting Shift Cable To Transmission
    G02125423Courtesy of GENERAL MOTORS CORP.
  8. Install the torque converter to flywheel bolts.

    Tighten 

    Tighten the bolts to 65 N.m (48 lb ft).

  9. Install the starter. Refer to STARTER in Starters.
    Fig 3: Installing Torque Converter To Flywheel Bolts
    G02125424Courtesy of GENERAL MOTORS CORP.
  10. Connect the drive axles to the transmission. Refer to WHEEL DRIVE SHAFT REPLACEMENT in Wheel Drive Shafts.

    Important:  Lubricate the transmission cooler pipes in order to prevent damage to the seals.

  11. Connect the transmission cooler lines to the transmission.
  12. Lower the vehicle.
  13. Use the engine support fixture in order to raise the powertrain assembly.
  14. Install the transmission side mount. Refer to Transmission Mount Replacement - Side .
  15. Install the frame. Refer to FRAME REPLACEMENT in Frame and Underbody.
  16. Remove the engine support fixture.
    Fig 4: Connecting Transmission Cooler Lines To Transmission
    G02125425Courtesy of GENERAL MOTORS CORP.
  17. Install the top engine to transmission bolt

    Tighten 

    Tighten the bolt to 75 N.m (55 lb ft).

  18. Connect the main transmission harness connector.
  19. Connect the park/neutral position switch harness connector.
  20. Position the underhood junction block to the original position.
  21. Install the surge tank inlet hose to the surge tank.
    Fig 5: Positioning Underhood Junction Block
    G02125426Courtesy of GENERAL MOTORS CORP.
  22. Install the front wiring harness to the junction block bracket.
  23. Connect the positive battery cables to the junction block bracket (1).
  24. Install the positive battery post to the junction block bracket (2).

    Tighten 

    Tighten the bolt to 17 N.m (13 lb ft).

    Fig 6: Installing Positive Battery Cables & Positive Battery Post To Junction Block Bracket
    G02125427Courtesy of GENERAL MOTORS CORP.
  25. Install the junction block bracket, bolt (3) and nuts (1,2).

    Tighten 

    • Tighten the nuts to 10 N.m (89 lb in).
    • Tighten the bolt to 25 N.m (18 lb ft).
  26. Install the transmission control module (TCM). Refer to Transmission Control Module Replacement .
  27. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  28. Fill the transmission to the proper level. Refer to Transmission Fluid Checking Procedure .
    Fig 7: Installing Junction Block Bracket, Bolt & Nuts
    G02125428Courtesy of GENERAL MOTORS CORP.
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