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Case Side Cover (4T65-E): Removal

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.
CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.
  1. Lock the steering column by installing Steering Column Anti-Rotation Pin (J-42640) into the underside of the steering column. See Fig 1 . Disconnect the negative battery cable. Remove the air cleaner assembly.
    2. NOTE: Remove both the throttle and the cruise control cables in order to prevent kinking of the cables during lowering of the transaxle.
  2. Remove both the throttle and the cruise control cables (1) from the throttle body and the accelerator control bracket (2). See Fig 2 . Use a large flat-blade tool in order to remove the shift cable from the manual selector lever. See Fig 3 . Remove the shift cable bracket from the transaxle case and set aside.
  3. Remove nut (5) and bolt (2) from A.I.R. pipe. See Fig 4 . Remove bolt (3) from A.I.R. pipe (2). Remove the ground cable bolt (1) from the transaxle. See Fig 6 . Disconnect the transaxle harness connector C100 (2). See Fig 5 . Disconnect the wiring harness (3) from the wiring harness retainer (1) on the transaxle.
  4. Install the engine support fixture. See appropriate REMOVAL & INSTALLATION article. Raise and support the vehicle. Remove the left front tire and wheel assembly. Remove the left fascia extension (2). See Fig 7 .
  5. Remove the front air deflector. Remove the left tie rod end from the steering knuckle. See appropriate POWER RACK & PINION article in STEERING. Remove the left ball joint from the steering knuckle. See appropriate FRONT article in SUSPENSION. Remove the left drive axle from the transaxle. See appropriate article in DRIVE AXLES.
    6. WARNING: Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear or to the intermediate shaft. This damage may cause loss of steering control, which could result in an accident and possible personal injury.
  6. Remove the intermediate shaft lower pinch bolt. See Fig 8 . Disconnect the intermediate shaft from the power steering gear. Remove the power steering gear heat shield. See appropriate POWER RACK & PINION article in STEERING. Remove the power steering gear mounting bolts. See Fig 9 .
  7. Remove the power steering line retainers from the frame. Secure the power steering gear to the exhaust manifold. Remove the 4 nuts securing the catalytic converter to the exhaust manifold pipe.
  8. Separate the catalytic converter from the exhaust manifold pipe. Suitably secure the exhaust system to the underside of the vehicle. Remove the catalytic converter gasket. Do not reuse the gasket.
  9. Loosen the 2 mounting nuts (2) in order to allow removal of the brake pressure modulator valve (1) from the bracket (3). See Fig 10 . Remove the brake line retainers from the frame. Remove the left transaxle mount.
  10. Remove the 2 lower bolts and lower nut from the rear transaxle mount. See Fig 11 . Remove the lower nut from the front transaxle mount. Support the left side of the frame with an appropriate jack.
  11. Remove the 3 frame-to-body bolts on the left side. See appropriate REMOVAL & INSTALLATION article. Loosen, but do not remove, the 3 frame-to-body bolts on the right side.
    12. NOTE: Insure that all pipes, hoses and wires are clear and not being bound or stressed when lowering the frame.
  12. Carefully lower the left side of the frame and let hang. Lower the vehicle enough to gain access to the engine support fixture. Using the engine support fixture, carefully lower the transaxle in order to allow access to the case side cover.
  13. Raise the vehicle enough to gain access to the transaxle case side cover. Remove the left transaxle bracket from the case side cover. See LEFT TRANSAXLE MOUNT & BRACKET  . Remove the case side cover bolts. See Fig 12 . Remove the case side cover (53). See Fig 13 . Clean the case and side cover gasket surfaces.
Fig 1: Removing & Installing Steering Column Anti-Rotation Pin
G00087771Courtesy of GENERAL MOTORS CORP.
Fig 2: Identifying Throttle & Cruise Control Cables
G00087772Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing & Installing Shift Cable (4T65-E)
G00087773Courtesy of GENERAL MOTORS CORP.
Fig 4: Removing & Installing A.I.R. Pipe
G00094530Courtesy of GENERAL MOTORS CORP.
Fig 5: Removing & Installing Harness Connector C100
G00087774Courtesy of GENERAL MOTORS CORP.
Fig 6: Removing & Installing Ground Bolt
G00087775Courtesy of GENERAL MOTORS CORP.
Fig 7: Removing & Installing Left Fascia Extension
G00094519Courtesy of GENERAL MOTORS CORP.
Fig 8: Removing & Installing Intermediate Shaft Pinch Bolt
G00087779Courtesy of GENERAL MOTORS CORP.
Fig 9: Removing & Installing Power Rack & Pinion Mounting Bolts
G00087776Courtesy of GENERAL MOTORS CORP.
Fig 10: Identifying Brake Pressure Modulator Valve
G00087778Courtesy of GENERAL MOTORS CORP.
Fig 11: Identifying Rear Transaxle Nuts & Bolts
G00087789Courtesy of GENERAL MOTORS CORP.
Fig 12: Identifying Case Side Cover Bolt Locations
G00057584Courtesy of GENERAL MOTORS CORP.
Fig 13: Identifying Case Side Cover
G00087729Courtesy of GENERAL MOTORS CORP.
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