GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 RELAY 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - 4T65-E 🢒 Control Valve Body Cover Replacement

Removal Procedure
  1. Remove the throttle body air inlet duct. Refer to Air Cleaner Element Replacement .
  2. Remove the engine mount struts. Refer to Engine Mount Strut Replacement - Left Side and Engine Mount Strut Replacement - Right Side .
  3. Remove the wiper module cover.

    4. Object Number: 161104 Size: SH
  4. Disconnect the 20-way electrical connector at the transaxle.
  5. Remove the shift cable bracket from the transaxle. Refer to Range Selector Lever Cable Bracket Replacement .
  6. Install the engine support fixture and support the engine/transaxle assembly. Refer to Engine Support Fixture .
  7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  8. Remove the left front tire and wheel. Refer to Tire and Wheel Removal and Installation .

    9. Object Number: 188809 Size: SH
  9. Disconnect the left wheel speed sensor harness connector (1).
  10. Remove the left engine splash shield. Refer to Engine Splash Shield Replacement .
  11. Remove both stabilizer shaft links from the lower control arms. Refer to Stabilizer Shaft Link Replacement .
  12. Remove the wheel speed sensor harness from the control arm (1).
  13. Remove the left lower ball joint from the left steering knuckle. Refer to Steering Knuckle Replacement .
  14. Remove the left drive axle from the transaxle. Refer to Front Wheel Drive Shaft Replacement .
  15. Reposition and secure the drive axle.
  16. Remove the heat shield bolts from the frame. Refer to Steering Gear Heat Shield Replacement .
  17. Remove the steering gear-to-frame bolts and secure the steering gear.
  18. Support the left side of the frame with a utility stand.
  19. Remove the transaxle mount lower nuts only. Refer to Transmission Mount Replacement .
  20. Loosen the engine mount lower nuts. Refer to Engine Mount Replacement .
  21. Remove the air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors .
  22. Remove only the left side frame bolts. DO NOT LOOSEN the right side frame-to-body bolts. Refer to Front Frame Replacement .
  23. Use the utility stand in order to lower the left side of the frame.
  24. Position a drain pan under the transaxle.
  25. Remove the utility stand and lower the vehicle.
  26. Loosen the right engine support bolts. Refer to Engine Mount Strut Replacement - Right Side .
  27. Raise the vehicle.
  28. Remove the transaxle mount bracket. Refer to Transmission Mount Bracket Replacement .
  29. Remove the transaxle wiring harness connectors.

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

    31. Object Number: 48208 Size: SH
  31. Remove the case side cover pan (53).
  32. Remove the case side cover gasket (54).
  33. Remove the case side cover inner gasket (59).

    34. Object Number: 49472 Size: SH
  34. Inspect the case side cover (53) for the following conditions:
    35. • Damaged or porous gasket sealing surfaces
    • Damaged or porous casting surfaces
    • Damaged or stripped bolt holes
  35. 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.
  36. Clean the case side cover.
  37. 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. Notice: Refer to Fastener Notice in the Preface section.


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

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

  5. Install the transaxle mount bracket.

    6. Torque
    Torque to 95 N·m (70 lb ft).

  6. Remove the drain pan from under the transaxle.

    7. Object Number: 161104 Size: SH
  7. Install the wiring harness connectors.
  8. Use the utility stand in order to raise the left side of the frame.
  9. Install the left side frame bolts. Refer to Front Frame Replacement .

    10. Tighten
    Tighten the bolts to 165 N·m (122 lb ft).

  10. Install the transaxle mount. Refer to Transmission Mount Replacement .
  11. Remove the utility stand support from the left side of the frame.
  12. Install the air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors .
  13. Install the left drive axle to the transaxle. Refer to Front Wheel Drive Shaft Replacement .
  14. Install the left lower ball joint to the left steering knuckle. Refer to Steering Knuckle Replacement .

    15. Important: This is a prevailing torque type fastener. This fastener may be reused ONLY if:

       • The fastener and its counterpart are clean and free from rust.
       • The fastener develops 2 N·m (18 lb in) of torque/drag against its counterpart prior to the fastener seating.
            If the fastener does not meet these criteria, REPLACE the fastener.

  15. Install two steering gear bolts.

    16. Tighten
    Tighten the bolts to 80 N·m (59 lb ft).

  16. Install the heat shield. Refer to Steering Gear Heat Shield Replacement .
  17. Install the lower ball joint nut and tighten.

    18. Object Number: 188809 Size: SH
  18. Install and connect the wheel speed sensor harness (1).
  19. Tighten the engine mount lower nuts. Refer to Engine Mount Replacement .
  20. Install the stabilizer shaft links to the lower control arms. Refer to Stabilizer Shaft Link Replacement .

    21. Tighten
    Tighten to 23 N·m (17 lb ft).

  21. Install the left engine splash shield. Refer to Engine Splash Shield Replacement .
  22. Install the left front tire and wheel. Refer to Tire and Wheel Removal and Installation .
  23. Lower the vehicle.
  24. Remove the engine support fixture from the engine/transaxle assembly. Refer to Engine Support Fixture .
  25. Install the shift cable bracket. Refer to Range Selector Lever Cable Bracket Replacement .
  26. Connect the 20-way transmission electrical connector.
  27. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Left Side and Engine Mount Strut Replacement - Right Side .
  28. Install the throttle body air inlet duct. Refer to Air Cleaner Element Replacement .
  29. Install the wiper module cover.

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

  30. Adjust the fluid level. Refer to the following information:
    31. •  Line Pressure Check
    •  Fluid and Lubricant Recommendations
    •  Approximate Fluid Capacities
  31. Inspect for proper completion of the repairs.
  32. Inspect for fluid leaks.