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Case Side Cover (4T65-E): Installation

WARNING: This page is about a different car, the 2002 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect the case side cover (53) for the following conditions:
    • Damaged or porous gasket sealing surfaces.
    • Damaged or porous casting surfaces.
    • Damaged or stripped bolt holes.
  2. Inspect the case side cover gaskets (54, 59) for damage. See Figure . The gaskets are reusable if they are NOT damaged. Assemble the case side cover inner gasket (59) to the case side cover (53).
  3. Use Transmission Assembly Lubricant (J-36850) on the seal surfaces. Install the case side cover gasket (54) and case side cover (53) onto the case. Make sure the gaskets and electrical connector are positioned correctly.
  4. Install case side cover bolt and one side cover to case stud bolt in the locations shown. See Figure . These bolts will properly locate the case side cover and gasket to the case.
  5. Install the remaining bolts as indicated:
    • 9 case side cover flange bolts.
    • 4 side cover TORX(R) head bolts.
    • 4 side cover-to-case stud bolts.

    Tighten all bolts to specification. See TORQUE SPECIFICATIONS  .

  6. Install the left transaxle bracket (1) to the case side cover. See LEFT TRANSAXLE MOUNT & BRACKET  . Install the left transaxle bracket bolts. Tighten the left transaxle bracket bolts to specification. Lower the vehicle enough to gain access to the engine support fixture.
    7. NOTE: Insure that all pipes, hoses and wires are clear and not being bound or stressed when raising the transaxle.
  7. Using the engine support fixture, carefully raise the transaxle to it's original position. Raise vehicle. Using an appropriate jack, carefully raise the left side of the frame so that the frame-to-body bolts can be installed.
  8. Using 0.630" in. (16 mm) dowel pins in the alignment holes (1), align the engine frame (2) with the body. See Fig 1 . Install the frame-to-body bolts (3). Tighten the bolts to specification. See TORQUE SPECIFICATIONS  .
  9. Install the left transaxle mount. Install the lower nut (1) onto the front transaxle mount. See Fig 2 . Tighten the nut to specification. Install the 2 lower bolts and lower nut onto the rear transaxle mount. See Figure . Tighten the 2 lower bolts and lower nut to specification. See TORQUE SPECIFICATIONS  .
  10. Position the brake pressure modulator valve (1) into the bracket (3). See Figure . Tighten the 2 brake pressure modulator valve nuts (2) to specification. See TORQUE SPECIFICATIONS  . Install the brake line retainers onto the frame. Place a NEW catalytic converter gasket over the catalytic converter studs.
    11. NOTE: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of 6 degrees which is equivalent to the pipes connected at the joint which move one inch for each foot length of pipe. A 3-foot pipe would move a maximum of 3 inches.
  11. Position the catalytic converter onto the exhaust manifold pipe. Install the 4 catalytic converter nuts. Tighten the catalytic converter nuts to specification. See TORQUE SPECIFICATIONS  . Install the power steering gear. See appropriate POWER RACK & PINION article in STEERING. Install the power steering line retainers onto the frame. Install the power steering gear heat shield.
    12. WARNING: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the 2 mating shafts may disengage. Disengagement of the 2 mating shafts will cause loss of steering control which could result in personal injury.
  12. Connect the intermediate shaft to the power steering gear. Install the intermediate shaft lower pinch bolt. Tighten the bolt to 33 ft. lbs. (45 N.m). Install the drive axle into the transaxle. Install the ball joint into the steering knuckle. Install the tie rod end into the steering knuckle.
  13. Install the front air deflector. Install the left fascia extension (3). Install the left front tire and wheel assembly. Lower the vehicle. Remove the engine support fixture. Install the ground cable bolt (1) onto the transaxle. See Figure . Tighten the ground cable bolt to specification. See TORQUE SPECIFICATIONS  .
  14. Install bolt (3) to A.I.R. pipe (2). See Figure . Tighten bolt (3) to 17 ft. lbs. (23 N.m). Install the shift cable bracket and cable onto the transaxle case. Install the shift cable bracket nuts. Tighten the shift cable bracket nuts to specification. See TORQUE SPECIFICATIONS  .
  15. Install the shift cable onto the manual selector lever. Check adjustment of the shift cable. Re-adjust as needed. See SHIFT CABLE  under ADJUSTMENTS. Install nut (5) and bolt (2) to A.I.R. pipe. See Figure . Tighten bolt (2) and nut (5) to 17 ft. lbs. (23 N.m).
  16. Connect the transaxle electrical connector C100 (2). See Figure . Install the wiring harness (3) into the wiring harness retainer (1) on the transaxle. Install the throttle and cruise control cables (1) into the throttle body and the accelerator control bracket (2). See Figure .
  17. Install the air cleaner assembly. Connect the negative battery cable. Remove the steering column anti-rotation pin from the steering column.
    18. NOTE: Do not overfill the transaxle. Overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle.
  18. Fill transaxle with appropriate fluid to proper level. See LUBRICATION  . Inspect for fluid leaks. Check the front end alignment.
Fig 1: Locating Alignment Holes
G00087777Courtesy of GENERAL MOTORS CORP.
Fig 2: Identifying Front Transaxle Mount Nut
G00087780Courtesy of GENERAL MOTORS CORP.
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