GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 ION 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - AF23-5 🢒 Control Valve Body Replacement

Removal Procedure
  1. Place the vehicle in neutral.
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General information.

    3. Object Number: 868017 Size: SH
  3. Remove the transaxle cooler lines from the transaxle. Refer to Oil Cooler Hose/Pipe Replacement .

    4. Object Number: 886301 Size: SH
  4. Remove the control valve body cover bolts.
  5. Remove the control valve body cover from the transaxle.

    6. Object Number: 749337 Size: SH
  6. Disconnect the solenoid wire connectors.
    7. 6.1. Blue (1)
    6.2. Black (2)
    6.3. Green (3)
    6.4. Black  (4)
    6.5. Blue (5)
    6.6. Gray (6)
    6.7. Brown (7)
    6.8. Black (8)

    Object Number: 749339 Size: SH
  7. Remove the fluid temperature sensor bolt (31).
  8. Remove the fluid temperature sensor clamp (49).
  9. Remove the fluid temperature sensor (36) and O-ring (32).

    10. Object Number: 749343 Size: SH
  10. Remove control valve body passage cover bolts (31), cover (37) and gasket (38).

    11. Object Number: 773157 Size: SH
  11. Remove the valve body assembly to transaxle case bolts (1, 2, 3, 4,5, 6).

    12. Object Number: 749347 Size: SH
  12. While holding the valve body assembly (39), disconnect the manual shift detent lever assembly (710) from the manual valve link (336).
  13. Move the detent lever assembly (710) clockwise for ease of removing the manual valve.
  14. Remove the valve body assembly (39) from the vehicle.

    15. Object Number: 749350 Size: SH
  15. Remove the case fluid passage seals (86) and discard.

Installation Procedure

    Object Number: 749350 Size: SH
  1. Install new case fluid passage seals (86).

    2. Object Number: 749347 Size: SH
  2. While holding the valve body assembly (39), connect the manual shift detent lever assembly (710) to the manual valve link (710).

    3. Object Number: 749344 Size: SH
  3. Install the valve body assembly to transaxle case bolts (34, 35, 47) hand tight.

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


    Object Number: 749345 Size: SH
  4. Tighten the valve body assembly-to-transaxle case bolts in the sequence shown.

    5. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 749343 Size: SH
  5. Install a new valve body fluid passage cover gasket (38).
  6. Install a new control valve body fluid passage cover (37).
  7. Install the control valve body fluid passage cover bolts (31).

    8. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

    Important: Apply transaxle fluid to the new fluid temperature sensor O-ring.

  8. Install a new O-ring (32) into the groove of the transaxle fluid temperature sensor (36).
  9. Install the temperature fluid sensor (36) into the valve body.
  10. Install the fluid temperature sensor clamp (49).

    11. Object Number: 749339 Size: SH
  11. Install the fluid temperature sensor bolt (31).

    12. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 749337 Size: SH
  12. Connect the solenoid harness connectors in the following order:
    13. 12.1. Blue (1)
    12.2. Black (2)
    12.3. Green (3)
    12.4. Black (4)
    12.5. Blue (5)
    12.6. Gray (6)
    12.7. Brown (7)
    12.8. Black (8)

    Object Number: 749819 Size: SH

    Important: The cover and transaxle must be free of dirt, gasket material and debris in order to seal properly.

  13. Clean and inspect the valve body cover and transaxle gasket surfaces for gasket material and debris.

    14. Object Number: 886301 Size: SH
  14. Install RTV sealer Saturn P/N 89020326 onto the control valve body cover and install the control valve body cover.
  15. Apply threadlocker Saturn P/N 21485277 to the bolts. Hand tighten the bolts.

    16. Object Number: 749335 Size: SH
  16. Tighten the valve body cover bolts using the sequence shown.

    17. Tighten
    Tighten the bolts to 13 N·m (115 lb in).


    Object Number: 868017 Size: SH
  17. Install the transaxle cooler lines to the transaxle. Refer to Oil Cooler Hose/Pipe Replacement .
  18. Lower the vehicle.

    19. Important: Do not use AF P/N 21005966 or P/N 21019223, these fluids are not compatible with this transaxle. Use Saturn T-IV P/N 22689186.

  19. Add fluid to the transaxle as necessary. Refer to Transmission Fluid Check .
  20. Start the engine and check for leaks.

    21. Important: It is recommended that the transmission adaptive pressure (TAP) information be reset.

    Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the ECM, PCM or TCM will need to relearn the TAP values. Transmission performance may be affected as new TAP values are learned.

  21. Reset the TAP values. Refer to Transmission Adaptive Learn .