Automatic Transaxle Removal & Installation: Overview Chevrolet Malibu V facelift

IDENTIFICATION

BODY CODE IDENTIFICATION

1. Disconnect battery cables. Remove air cleaner housing, duct assembly, air intake temperature sensor, and resonator. Remove air box. Remove transaxle strut from midrail bracket and transaxle bracket, and position aside. Remove battery.
2. Disconnect PCM J2 (Black 28-way) harness connector. Remove PCM attaching bolts, and position out of way. Remove battery tray. Disconnect the following: transaxle solenoid harness connector, input and output speed sensor harness connectors, transaxle fluid temperature sensor harness connector, transaxle range switch harness connector, 2 ground terminals at top 2 converter housing bolts, and ground wire from transaxle range switch.
3. Remove top 2 converter housing-to-engine bolts. Note spark plug wire-to-coil tower relationship, and remove spark plugs wires from coil towers. Disconnect ignition control module harness connector, and remove module. Wire radiator onto upper radiator support (to hold in place as frame is removed).
4. Install Engine Support Bar Assembly (SA9105E). Raise and support vehicle, and drain transaxle fluid. Remove front wheels. Remove right and left splash shields. Remove front engine splash shield. On coupe models, remove left and right lower fascia braces. On all models, remove engine strut bracket-to-frame fasteners. Remove transaxle mount-to-frame fastener.
5. Remove front exhaust pipe. Remove steering gear-to-frame fasteners, and support gear with safety wire. Remove brake pipe bracket push pin at rear of frame. Remove engine-to-transaxle stiffening brace. Remove dust cover from converter housing. Mark torque converter-to-flywheel relationship for reassembly reference, and remove bolts.
6. Remove cotter pin from lower ball joints, and discard. DO NOT use wedge-type tool to separate ball joint. Using Lower Control Arm Ball Separator (SA9132S), remove nut. Separate left side axle from transaxle using appropriate pry bar. Remove axle partially, and install Axle Seal Protector (SA9112T). Repeat for other side.
7. On DOHC engines, remove intake bracket-to-intake manifold bolt. Remove intake manifold support bracket-to-intermediate shaft support bolt. Remove 2 intermediate shaft support-to-engine block bolts, and carefully slide shaft out of transaxle.
8. On all models, use powertrain support dolly and 2 blocks of wood to support frame on dolly. Disconnect transaxle cooler lines from transaxle, and plug to prevent leakage/contamination).
9. Remove 4 frame-to-body bolts, and carefully lower frame from vehicle. Support transaxle securely with jack. Remove 2 bottom torque converter housing-to-engine bolts. Separate transaxle from engine, and lower transaxle. Lower transaxle enough to reach transaxle shifter cable, and release cable from converter housing. Lower transaxle from vehicle.

1. Flush transaxle oil cooler using Oil Cooler Line Flusher (SA9165T). Tap out ignition control module holes with M6 x 1.0 mm tap. To install, reverse removal procedure. Before installing cooler lines onto transaxle, lines must be flushed using oil cooler line flusher. Before installing air cleaner and duct assembly, adjust shift control cable. See ADJUSTMENTS in appropriate SERVICING article.
2. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-94685-S18377767122001033100000) . Fill transaxle with appropriate fluid. See appropriate SERVICING article. Using scan tool, reset adaptives following scan tool manufacturer's instructions. Check wheel alignment.

1. Ensure ignition key is in OFF or LOCK position. Disconnect and remove battery. Disconnect intake air temperature sensor, and remove air duct hose from intake plenum. Remove air cleaner outlet duct. Remove push pin from relay center. Disconnect relay battery feed cable from upper air cleaner cover. Remove relay center. Release air cleaner push-in retainer, and remove air cleaner assembly. Remove upper radiator filler panel.
2. Support engine using Engine Support Fixture (J-28467-360). Disconnect transaxle wiring harness from transaxle and park/neutral position switch. Remove screw from front coolant pipe bracket to allow freedom of movement. Remove 3 upper transaxle-to-engine bolts and one stud. Remove 2 top bolts from transaxle mount.
3. Raise and support vehicle. Remove wheels. Remove front fender liner. Disconnect engine strut from lower engine mount. Remove right engine splash shield. Remove engine mount strut. Disconnect front and rear oxygen sensors and wiring harness from shift cable bracket. Remove wiring harness from retaining clips.
4. Remove front exhaust pipe. Disconnect wheel speed sensor wires from both front wheels, and unclip clips from frame. Remove lower steering intermediate shaft pinch bolt. Remove outer tie rod ball stud nut. Loosen jam (adjuster) nut, and pull tie rod ball stud using Universal Steering Linkage Puller (J-24319-B).
5. Remove stabilizer shaft link, if equipped. Remove lower control arm wiring harness. Remove cotter pin and nut from ball joint. Separate ball joint from knuckle using Ball Joint Separator (J-43828). Remove lower control arm, and place into vice. Drill out ball joint rivets, and remove ball joint.
6. Remove drive shaft nut. Disconnect electrical connector from wheel speed sensor, and position aside. Install Front Hub Spindle Remover (J-28733-B) onto hub, and secure with lug nuts. Support drive shaft, and disengage drive shaft splines using spindle remover. Assemble Wheel Drive Shaft Remover (J-33008-A), Axle Shaft Remover Extension (J-29794) and Slide Hammer (J-2619-01), and disengage drive shaft from transaxle. Remove drive shaft.
7. Unclip brake line from retainers on crossmember. Remove power steering lines from steering gear, and plug openings. Remove power steering line bolt from right side of crossmember. Remove front suspension support brace. With aid of assistant, remove crossmember.
8. Remove 2 transaxle/support brace-to-transaxle bolts (at right side of transaxle output shaft). Disconnect shift cable from shift linkage and bracket. Remove flywheel inspection cover. Remove wiring harness from starter, and remove starter.
9. Mark flywheel-to-torque converter relationship for reassembly reference, and remove bolts. Remove transaxle cooler lines from transaxle case. Disconnect VSS harness connector. Disconnect transaxle output shafts from transaxle, and wire aside. Remove transaxle bracket-to-body bolts. Remove transaxle bracket-to-transaxle bolts. Remove wiring harness from body. Lower vehicle.
10. Remove transaxle-to-body bracket bolts. Lower transaxle with engine support fixture enough to remove transaxle. Raise vehicle. Remove bracket. Remove transaxle-to-engine bolts. Support transaxle with suitable jack. Separate engine and transaxle.

Flush transaxle cooler and lines. Apply a thin film of chassis grease onto torque converter pilot hub. To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS . Fill transaxle with appropriate. See appropriate SERVICING article. Road test vehicle.

1. Disconnect negative battery cable. Raise and support vehicle. Remove shift lever rod. Remove drive shaft coupling bolts. Using screwdriver, pry drive shaft coupling from drive flange.
2. Remove access plugs from bellhousing and oil pan area. Make reference marks on flex plate and torque converter for reassembly reference. Remove flex plate-to-torque converter bolts. Disconnect oil cooler lines from center pipes. Remove oxygen sensor harness connector.
3. Remove catalytic converters. Using Oxygen Sensor Wrench (J-39194-B), remove heated oxygen sensors. Remove transmission crossmember. Support transmission with appropriate jack. Support engine. Remove bellhousing-to-engine bolts. Lower engine/transmission assembly to access upper bellhousing-to-engine bolts, and remove.
4. Remove ventilation hose from transmission. Disconnect harness connectors to transmission control selector switch, adapter case, main, case and speed sensor. Lower transmission, and remove from vehicle.

Flush transmission oil cooler. Apply thread locking compound (P/N 12345382) onto bellhousing-to-engine bolt threads. To install, reverse removal procedure. Apply thread locking compound onto transmission housing-to-oil pan bolts when installing. Use NEW flywheel-to-torque converter bolts. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS . Adjust shift cable. See ADJUSTMENTS in appropriate SERVICING article.