GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 ION 🢒 Transmission/Transaxle 🢒 Manual Transmission - Getrag 5 Speed 🢒 Transmission Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the transmission control module (TCM). Refer to Transmission Control Module Replacement

    3. Object Number: 873343 Size: SH
  3. Remove the positive battery post from the underhood junction block (2).
  4. Disconnect the positive battery cables from the underhood junction block (1).
  5. Disconnect the surge tank inlet hose from the surge tank.

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

    9. Object Number: 888342 Size: SH
  9. Reposition the underhood junction block bracket aside.
  10. Disconnect the park/neutral position switch harness connector.
  11. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical 2.2L (L61).

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

    13. Object Number: 851558 Size: SH
  13. Remove the upper transmission to mount bolts.
  14. Remove the upper transmission to engine bolt.
  15. Remove the frame. Refer to Frame Replacement in Frame and Underbody.
  16. Drain the transmission. Refer to Transmission Fluid Replacement .

    17. Object Number: 866183 Size: SH
  17. Disconnect the transmission cooler lines from the transmission.
  18. Disconnect the drive axles from the transmission and secure out of the way. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  19. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.

    20. Object Number: 475919 Size: SH
  20. Remove the torque converter to flywheel bolts.
  21. Disconnect the shift cable from the transmission. Refer to Shift Cable Replacement .
  22. Lower the vehicle.
  23. Use the engine support fixture rear hook to lower the powertrain approximately 2-3 inches. This will allow clearance between the side rail and powertrain.
  24. Raise the vehicle.
  25. Use a transmission jack to secure the transmission, and remove the transmission to engine bolts.
  26. Remove the transmission from the vehicle.
  27. Remove the PNP switch. Refer to Park/Neutral Position Switch Replacement .
  28. Remove the shift cable bracket.
  29. Remove the front transmission mount from the transmission. Refer to Transmission Front Mount Replacement .
  30. Remove the rear transmission mount and bracket from the transmission. Refer to Transmission Rear Mount Replacement .
  31. Flush the transmission cooler lines. Refer to Transmission Fluid Cooler Flushing .

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

  3. Install the shift cable bracket.

    4. 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.

    6. Object Number: 851293 Size: SH

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

  6. Secure the transmission to the engine.

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

  7. Connect the shift cable to the transmission. Refer to Shift Cable Replacement .

    8. Object Number: 475919 Size: SH
  8. Install the torque converter to flywheel bolts.

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

  9. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
  10. Connect the drive axles to the transmission. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.

    11. Object Number: 866183 Size: SH

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

  11. Connect the transmission cooler lines to the transmission.

    12. Tighten
    Tighten the nut to 7 N·m (62 lb in).

  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.
  17. Install the top engine to transmission bolt

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


    Object Number: 857193 Size: SH
  18. Connect the park/neutral position switch harness connector.
  19. Release the cooling module from the upper body structure.

    20. Object Number: 888342 Size: SH
  20. Position the under hood junction block to the original mounting.
  21. Install the surge tank inlet hose to the surge tank.

    22. Object Number: 873343 Size: SH
  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 positive battery post to the junction block bracket (2).

    25. Object Number: 889782 Size: SH
  25. Install the junction block bracket , bolt and nuts.

    26. 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. Refer to Transmission Control Module Replacement .
  27. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  28. Fill the transmission to the proper level. Refer to Transmission Fluid Replacement .