GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Opel 🢒 1999 🢒 Sintra 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - 4T65-E 🢒 Control Valve Body Cover Replacement

Removal Procedure
  1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the throttle body air inlet duct. Refer to Air Cleaner Element Replacement in Engine Controls - 3.4L.
  3. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.4L.
  4. Remove the engine mount struts. Refer to Engine Mount Strut Replacement in Engine Mechanical - 3.4L.
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  6. Remove the left front tire and wheel.
    7. • For vehicles with steel wheels, refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    • For Chevrolet and Oldsmobile vehicles with aluminum wheels, refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    • For Pontiac and Export vehicles with aluminum wheels, refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  7. Remove the left engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
  8. Remove the stabilizer shaft links from the lower control arms. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
  9. Remove the left tie rod end from the steering knuckle. Refer to Steering Knuckle Replacement in Front Suspension.

    10. Object Number: 188809 Size: SH
  10. Remove the wheel speed sensor harness connector (2).
  11. Remove the left lower ball joint from the left steering knuckle. Refer to Steering Knuckle Replacement in Front Suspension.
  12. Disconnect the left drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  13. Reposition and secure the drive axle.

    14. Object Number: 281705 Size: SH

    Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

  14. Remove the intermediate shaft from the steering gear. Refer to Lower/Upper Intermediate Steering Shaft Replacement Steering Wheel and Column - Tilt.
  15. Disconnect the catalytic converter pipe from the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
  16. Support the right side of the frame with a utility stand.
  17. Support the left side of the frame with a utility stand.
  18. Remove the transaxle mount bracket. Refer to Transmission Mount Bracket Replacement .
  19. Remove the transaxle mount. Refer to Transmission Mount Replacement .
  20. Loosen the engine mount lower nuts. Refer to Engine Mount Replacement in Engine Mechanical - 3.4L.
  21. Loosen the right side frame bolts. Refer to Frame Replacement in Frame and Underbody.
  22. Remove the left side frame bolts. Refer to Frame Replacement in Frame and Underbody.
  23. Use the utility stand in order to lower left side of the frame.
  24. Position the drain pan under the transaxle.

    25. Object Number: 161104 Size: SH
  25. Remove the wiring harness connectors.

    26. Object Number: 164786 Size: SH
  26. Remove the case side cover bolts (56-58).

    27. Object Number: 48208 Size: SH
  27. Remove the case side cover pan (53).
  28. Remove the case side cover gasket (54).
  29. Remove the case side cover inner gasket (59).

    30. Object Number: 49472 Size: SH
  30. Inspect the case side cover (53) for the following conditions:
    31. • Damaged or porous gasket sealing surfaces
    • Damaged or porous casting surfaces
    • Damaged or stripped bolt holes
  31. 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.
  32. Clean the case side cover.
  33. Clean the case side cover gasket surfaces.

Installation Procedure

    Object Number: 48208 Size: SH
  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).

    4. Object Number: 164786 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

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

    5. Tighten
    Tighten the case side cover bolts (56-58) to 25 N·m (18 lb ft).

  5. Remove the drain pan from under the transaxle.

    6. Object Number: 161104 Size: SH
  6. Install the wiring harness connectors.
  7. Use the utility stand in order to raise the left side of the frame.
  8. Install the NEW left side frame bolts. Refer to Frame Replacement in Frame and Underbody.
  9. Install the NEW right side frame bolts. Refer to Frame Replacement in Frame and Underbody.
  10. Install the engine mount lower nuts. Refer to Engine Mount Replacement in Engine Mechanical - 3.4L.
  11. Install the transaxle mount. Refer to Transmission Mount Replacement .
  12. Install the transaxle mount bracket. Refer to Transmission Mount Bracket Replacement .
  13. Remove the utility stand support from the right side of the frame.
  14. Remove the utility stand support from the left side of the frame.
  15. Connect the catalytic converter pipe to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.

    16. Object Number: 281705 Size: SH

    Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.

  16. Install the intermediate shaft to the steering gear. Refer to Lower/Upper Intermediate Steering Shaft Replacement Steering Wheel and Column - Tilt.
  17. Install the left drive axle to the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  18. Install the left lower ball joint to the left steering knuckle. Refer to Steering Knuckle Replacement in Front Suspension.

    19. Object Number: 188809 Size: SH
  19. Install the wheel speed sensor harness connector (2).
  20. Install the left tie rod end to the steering knuckle. Refer to Steering Knuckle Replacement in Front Suspension.
  21. Install the stabilizer shaft links to the lower control arms. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
  22. Install the left engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
  23. Install the left front tire and wheel.
    24. • For vehicles with steel wheels, refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    • For Chevrolet and Oldsmobile vehicles with aluminum wheels, refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    • For Pontiac and Export vehicles with aluminum wheels, refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  24. Lower the vehicle.
  25. Install the engine mount struts. Refer to Engine Mount Strut Replacement in Engine Mechanical - 3.4L.
  26. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.4L.
  27. Remove the throttle body air inlet duct. Refer to Air Cleaner Element Replacement in Engine Controls - 3.4L.
  28. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

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

  29. Adjust the fluid level. Refer to the following information.
    30. •  Transmission Fluid Check
    •  Fluid and Lubricant Recommendations in Maintenance and Lubrication
    •  Approximate Fluid Capacities in Maintenance and Lubrication
  30. Inspect for proper completion of the repairs.
  31. Inspect for fluid leaks.