GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 Transmission/Transaxle 🢒 Clutch 🢒 Transmission Replacement

Removal Procedure

    Object Number: 873343 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the positive battery post from the underhood junction block (2).
  3. Disconnect the positive cables from the underhood junction block (1).
  4. Disconnect the surge tank inlet hose from the surge tank.

    5. Object Number: 889782 Size: SH
  5. Remove the underhood junction block bracket nuts (1,2).
  6. Loosen the underhood junction block bracket bolt (3).
  7. Disconnect the front wiring harness from the underhood junction block bracket.

    8. Object Number: 888342 Size: SH
  8. Reposition the underhood junction block bracket aside.

    9. Object Number: 851233 Size: SH
  9. Disconnect the hydraulic clutch hose from the clutch actuator cylinder.
  10. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical 2.2L-(L61).

    11. Object Number: 857193 Size: SH
  11. Secure the cooling module to the upper body structure.

    12. Object Number: 851558 Size: SH
  12. Remove the upper transmission to mount bolts.
  13. Remove the upper transmission to engine bolt.
  14. Remove the frame. Refer to Frame Replacement in Frame and Underbody.
  15. Drain the transaxle. Refer to Transmission Fluid Replacement .
  16. Disconnect the drive axles from the transmission and secure out of the way. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  17. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.

    18. Object Number: 880090 Size: SH
  18. Disconnect the shift cables from the transmission. Refer to Shift Control Cable Replacement .

    19. Object Number: 857190 Size: SH
  19. Disconnect the backup lamp switch harness connector (1).
  20. Disconnect the vehicle speed sensor (2).
  21. Lower the vehicle.
  22. Use the engine support fixture rear hook to lower the powertrain enough to allow clearance between the side rail and powertrain.
  23. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  24. Use a transmission jack to secure the transmission, and remove the transmission to engine bolts.
  25. Remove the transmission from the vehicle.
  26. Remove the front transmission mount from the transmission. Refer to Transmission Front Mount Replacement .
  27. Remove the rear transmission mount and bracket from the transmission. Refer to Transmission Rear Mount Replacement .

Installation Procedure
  1. Install the rear transmission mount to the transmission. Refer to Transmission Rear Mount Replacement .
  2. Install the front transmission mount to the transmission. Refer to Transmission Front Mount Replacement .
  3. Use a transmission jack to position the transmission to the vehicle.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 851293 Size: SH

    Important: The number 3 position does not require a bolt.

  4. Secure the transmission to the engine.

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


    Object Number: 857190 Size: SH
  5. Connect the vehicle speed sensor (2).
  6. Connect the backup lamp switch harness connector (1).
  7. Connect the shift cable to the transmission. Refer to Shift Control Cable Replacement .
  8. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
  9. Connect the drive axles to the transmission. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  10. Lower the vehicle.
  11. Use the engine support fixture in order to raise the powertrain assembly.
  12. Install the transmission side mount. Refer to Transmission Mount Replacement - Side .

    13. Object Number: 888342 Size: SH
  13. Position the underhood junction block to the original position.
  14. Install the surge tank inlet hose to the surge tank.

    15. Object Number: 873343 Size: SH
  15. Install the front wiring harness to the junction block bracket.
  16. Connect the positive battery cables to the junction block bracket (1).
  17. Install the positive battery post to the junction block bracket (2).

    18. Object Number: 889782 Size: SH
  18. Install the junction block bracket, bolt (3) and nuts (1,2).

    19. Tighten

        • Tighten the nuts to 10 N·m (89 lb in).
        • Tighten the bolt to 25 N·m (18 lb ft).
  19. Install the frame. Refer to Frame Replacement in Frame and Underbody.
  20. Remove the engine support fixture.
  21. Install the top engine to transmission bolt.

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


    Object Number: 851233 Size: SH
  22. Connect the hydraulic clutch hose to the clutch actuator cylinder.
  23. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding in Clutch.

    24. Object Number: 857193 Size: SH
  24. Release the cooling module from the upper body structure.
  25. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  26. Fill the transmission to the proper level. Refer to Transmission Fluid Replacement