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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1748 (Manual Transmission - GETRAG 5 Speed) >> Repair Instructions >> Transmission Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Installing Wheel Drive Shaft Into Transaxle Through J 44394
    GM857191Courtesy of GENERAL MOTORS CORP.
  1. Place the transaxle securely on a jack and position under the vehicle.
  2. Install the SA91112T  into both axle seals.
  3. Place the transaxle into any gear.
  4. Raise the transaxle into the vehicle in order to align the input shaft to the center of the clutch. Guide the transaxle into position and rotate back and forth to align the input shaft splines to the clutch disc.
    5. Fig 2: Transaxle Housing & Bolts
    GM1159656Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
    IMPORTANT:
    • Ensure the input shaft splines line up with the clutch disc splines before tightening the clutch housing bolts. Do not use the bolts to pull the transaxle up to the engine.
    • Ensure that proper fastening locations are used.
  5. Install the transaxle to engine bolt from the transaxle side.

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

  6. Install the engine to transaxle bolts from the engine side.

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

  7. Raise the transaxle jack until the transaxle lines up with the top of the transaxle mount.
  8. Hand start the top transaxle mount bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

  9. Remove the transaxle jack.
    10. Fig 3: Installing Wheel Drive Shaft Into Transaxle Through J 44394
    GM857191Courtesy of GENERAL MOTORS CORP.
  10. Install the drive axles into the transaxle. Refer to Wheel Drive Shaft Replacement - Front in Driveline/Axle.
    11. Fig 4: Front Transaxle Mount & Bolts
    GM1159501Courtesy of GENERAL MOTORS CORP.
  11. Install the front transaxle mount to the transaxle.
  12. Install the front transaxle mount bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

  13. Install the rear transaxle mount and bracket to the transaxle.
  14. Install the rear transaxle mount-to-transaxle bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

  15. Raise the cradle and place the lower ball joints into the knuckles while installing.
    16. IMPORTANT: Ensure the following components are correctly positioned when raising the frame into the vehicle.
    • The lower control arm studs to the knuckle
    • The cooling module support bushings
    • The front pitch restrictor
  16. Tighten the cradle-to-body bolts.

    Tighten:  Tighten the bolts to 155 N.m (114 lb ft).

  17. Install the front air dam to body push pins.
  18. Install the front transaxle mount through bolt.

    Tighten:  Tighten the bolt to 110 N.m (81 lb ft).

  19. Install the rear transaxle mount through bolt.

    Tighten:  Tighten the bolt to 110 N.m (81 lb ft).

  20. Connect the steering gear to the steering column assembly.
  21. Install the steering gear-to-steering column bolt.

    Tighten:  Tighten the bolts to 34 N.m (25 lb ft).

    22. Fig 5: Lower Control Arm Ball Stud, Cotter Pin & Nut
    GM1159273Courtesy of GENERAL MOTORS CORP.
  22. Install the lower control arm ball stud to the knuckle.
  23. Install the lower control arm nut and a new cotter pin.

    Tighten:  Tighten the nut to 10 N.m +150° (89 lb in +150°).

    24. IMPORTANT: Do not allow the stud to rotate.
  24. Tighten the nut one additional flat in order to align the cotter pin hole, if necessary. Secure the cotter pin.
    25. Fig 6: Lower Stabilizer Bar Links & Bolts
    GM1159655Courtesy of GENERAL MOTORS CORP.
  25. Install new stabilizer bar link nuts to the lower stabilizer bar links.

    Tighten:  Tighten the nuts to 65 N.m (48 lb ft).

    26. Fig 7: Tie Rod-To-Knuckle & J 44015
    GM1159441Courtesy of GENERAL MOTORS CORP.
  26. Insert the tie rod-to-knuckle.
  27. Install the J 44015  and tighten.

    Tighten:  Tighten the tie rod end installation to 40 N.m (30 lb ft).

  28. Install the outer tie rod ends and tighten.

    Tighten:  Tighten the tie rod-to-steering knuckle nut to 50 N.m (37 lb ft).

  29. Install the backup lamp switch.
  30. Install the front wheel speed sensor.
    31. Fig 8: Clutch Line & Clutch Master Cylinder
    GM1145224Courtesy of GENERAL MOTORS CORP.
  31. Connect the clutch hydraulic line to the actuator cylinder by inserting and pushing in the C-clip until it stops.
  32. Connect the shift cables into the shift cable bracket.
  33. Connect the shift cable ends to the transaxle.
  34. Install the left inner splash shield.
    35. Fig 9: Left Inner Splash Shield & Ball Joints
    GM1159151Courtesy of GENERAL MOTORS CORP.
  35. Install the wheels.
  36. Install the wheel nuts.

    Tighten:  Tighten the nuts in a crisscross pattern to 125 N.m (92 lb ft).

  37. Bleed the clutch system. Refer to Hydraulic Clutch Bleeding in Clutch.
  38. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnect/Connect Procedure in Battery.

    Tighten:  Tighten the battery terminal bolts to 17 N.m (13 lb ft).

  39. Install the battery cover and screws.

    Tighten:  Tighten the battery cover screws to 2 N.m (18 lb in).

  40. Program the radio stations.
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