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Automatic Transmission Removal & Installation: Application Pontiac Aztek I

Automatic Trans 19 illustrations ~1545 words

APPLICATION

ApplicationTransaxle Model (RPO Code)
AWD4T65-E (M76)
FWD4T65-E (M15)

TRANSAXLE APPLICATION

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTIONWhen battery is disconnected, vehicle computer may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

Note. Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

CAUTIONTransmission oil circulates between the transmission assembly and the transfer case. In situations where transmission related failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage. See appropriate OVERHAUL article in TRANSFER CASES.

Scheme 256

Scheme 256
Scheme 256

Scheme 257

Scheme 257
Scheme 257

Scheme 258

Scheme 258
Scheme 258

Scheme 259

Scheme 259
Scheme 259

Scheme 260

Scheme 260
Scheme 260

Scheme 261

Scheme 261
Scheme 261

Scheme 262

Scheme 262
Scheme 262
  1. Remove the push pins from the coolant recovery bottle. (Scheme 256)
  2. Position aside the coolant recovery bottle.
  3. Remove the air cleaner.
  4. Remove the automatic transmission range selector cable from the automatic transmission range selector cable lever.
  5. Remove the automatic transmission range selector cable bracket.
  6. Disconnect the wiring harness connectors from the transaxle. (Scheme 257)
  7. Remove the wiring harness from the transaxle.
  8. Remove the right side engine strut. See «ENGINE MOUNT STRUT»(ref-154467-S27775689902003051900000).
  9. Install the engine support fixture. See «ENGINE SUPPORT FIXTURE»(ref-154467-S32997825102003051500000).
  10. Raise the vehicle.
  11. Remove the top 4 bell housing bolts (2, 3, 4 and 5). (Scheme 258)
  12. If the vehicle is equipped with All-Wheel-Drive (AWD), perform the following steps: Remove the drive shaft. (Scheme 259) For additional information, see appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Remove the transfer case brace.
  13. Remove the frame. See «FRAME REPLACEMENT»(ref-154467-S17144872012003051600000).
  14. Remove the filler tube.
  15. Remove the torque converter cover. (Scheme 260)
  16. Remove the torque converter bolts. (Scheme 261)
  17. Disconnect the Vehicle Speed Sensor (VSS) electrical connector.
  18. Remove the right and left drive axles from the transaxle.
  19. Disconnect the transmission cooler hoses from the transaxle.
  20. Position the transmission jack under the transaxle.
  21. Remove the transaxle/transfer case brace. (Scheme 262)
  22. Remove the lower transaxle bolts (6) and stud (1). (Scheme 258)
  23. Remove the transaxle from the vehicle.
  24. Use appropriate transaxle oil cooler flushing equipment to flush the transaxle oil cooler and the transaxle oil cooler hoses. See LUBRICATION in appropriate SERVICING article.
  25. If the vehicle is equipped with AWD, remove the transfer case. See appropriate REMOVAL & INSTALLATION article in TRANSFER CASES.
CAUTIONIf you are replacing the transaxle, transfer case or any internal components, you must inspect the end play and adjust as needed. See appropriate OVERHAUL article.
  1. If the vehicle is equipped with AWD, install the transfer case. See appropriate REMOVAL & INSTALLATION article in TRANSFER CASES.
  2. Position the flex plate alignment hole to the 7 o'clock position.
  3. Align the transaxle filler tube to the transmission and install the transaxle into the vehicle.
  4. Install the lower transaxle bolt (6) and stud (1). (Scheme 258) Tighten the lower transaxle to engine and engine to transaxle bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154467-S06512389272003051500000).
  5. Install the transaxle/transfer case brace. (Scheme 262) Tighten brace bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154467-S06512389272003051500000).
  6. Install the transmission cooler hoses.
  7. Install the right and left axle shafts into the transaxle.
  8. Connect the VSS electrical connector.
  9. Install the torque converter bolts. (Scheme 260) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154467-S06512389272003051500000).
  10. Install the torque converter cover. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154467-S06512389272003051500000).
  11. Install the filler tube bracket bolt. Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154467-S06512389272003051500000).
  12. Install the frame. See «FRAME REPLACEMENT»(ref-154467-S17144872012003051600000).
  13. If the vehicle is equipped with AWD, perform the following steps: Install the drive shaft. (Scheme 259) For additional information, see appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Install the transfer case brace.
  14. Install the front wheels.
  15. Lower the vehicle.
  16. Remove the engine support fixture. See «ENGINE SUPPORT FIXTURE»(ref-154467-S32997825102003051500000).
  17. Install the right side engine strut.
  18. Install the upper transaxle bolts (3, 4 and 5), and stud (2). (Scheme 258) Tighten the upper transaxle bolts and stud to specification. See «TORQUE SPECIFICATIONS»(ref-154467-S06512389272003051500000).
  19. Connect the wiring harness to the transaxle. (Scheme 257)
  20. Install the transmission range selector cable bracket. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-154467-S06512389272003051500000).
  21. Install the automatic transmission range selector cable to the automatic transmission range selector lever.
  22. Install the air cleaner assembly.
  23. Install the coolant recovery bottle. (Scheme 256)
  24. Inspect and adjust the transaxle fluid level as needed. Refer to the following information.

Scheme 263

Scheme 263: Removal
Scheme 263: Removal

Scheme 264

Scheme 264
Scheme 264
  1. Remove the bolt and nut from the engine mount strut at the right engine mount strut bracket on the engine. (Scheme 263)
  2. Remove the bolt and the nut from the engine mount strut at the engine mount strut bracket on the upper radiator support.
  3. Remove the engine mount strut. (Scheme 264)
  4. Inspect the rubber in the engine mount strut for the following conditions: Hardness Splitting Cracking
  1. Install the engine mount strut.
  2. Install the bolt and the nut to the engine mount strut at the engine mount strut at the engine mount strut bracket on the upper radiator support. Tighten engine mount strut bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154467-S06512389272003051500000) .
  3. Install the bolt and the nut to the engine mount strut at the right engine mount strut bracket on the engine. Tighten engine mount strut nut to specification. See «TORQUE SPECIFICATIONS»(ref-154467-S06512389272003051500000) .

Scheme 265

Scheme 265: Installation
Scheme 265: Installation

Scheme 266

Scheme 266
Scheme 266

Scheme 267

Scheme 267
Scheme 267

Scheme 268

Scheme 268
Scheme 268

Scheme 269

Scheme 269
Scheme 269

Scheme 270

Scheme 270
Scheme 270

Scheme 271

Scheme 271
Scheme 271

Scheme 272

Scheme 272
Scheme 272
  1. Remove the right engine mount strut. See «ENGINE MOUNT STRUT»(ref-154467-S27775689902003051900000).
  2. Install the Engine Support Bar Assembly (J-45057) to the right engine mount strut bracket (1). (Scheme 265)
  3. Install the engine support bar assembly to the left side engine lift bracket. (Scheme 266)
  4. Install the engine support bar assembly to the right rear engine lift bracket. (Scheme 267)
  5. On Rendezvous, remove the headlamps.
  6. On all models, disconnect the hood strut assist rods from the fenders.
  7. Carefully open and secure the hood in 90-degree position.
  8. Install the Side Rail Support Bracket (J-28467-B). (Scheme 268)
  9. Install the Bolt Hook (J-28467-7A) (1) and the Lift Hook Wing Nut and Washer (J-28467-34) to the Engine Support Fixture (J-28467-500) and the rear hole on the right side of the engine support bar assembly (2). (Scheme 269)
  10. Install the bolt hook (1) and the lift hook wing nut and washer to the engine support fixture and the left side of the engine support bar assembly (2). (Scheme 270)
  11. Gently tighten the lift hook wing nuts.
  12. Raise the vehicle.
  13. Remove the lower air baffle.
  14. Remove the engine mount left bolt.
  15. Install the Lower Support Bar (J-45057-2) to the radiator core support. (Scheme 271)
  16. Use the engine mount bolt to install the lower support bar to the engine.
  17. Ensure that the lower support bar is assembled properly and hand tighten the fasteners. (Scheme 272)

Scheme 273

Scheme 273: Removal
Scheme 273: Removal

Scheme 274

Scheme 274
Scheme 274
  1. Install the engine support fixture. See «ENGINE SUPPORT FIXTURE»(ref-154467-S32997825102003051500000).
  2. Raise and support the vehicle.
  3. Remove the front tires and wheels.
  4. Remove the inner fender liner enough to gain access to the front frame bolts.
  5. Remove both outer tie rod ends from the steering knuckles.
  6. Remove the stabilizer shaft.
  7. For AWD models, remove the drive shaft.
  8. For AWD models, remove the catalytic converter pipe.
  9. Remove the power steering gear heat shield.
  10. Remove the power steering gear bolts.
  11. Remove the power steering gear from the frame.
  12. Use mechanics wire to secure the power steering gear to the exhaust manifold.
  13. Remove the front engine splash shield.
  14. Remove the power steering cooler pipe from the frame.
  15. Use utility wire in order to secure the power steering cooler line out of the way.
  16. Disconnect the front wheel speed sensor connectors.
  17. Remove the front wheel speed sensor wiring harnesses from the lower control arms.
  18. Remove the lower ball joints from the steering knuckles.
  19. Remove the engine mount nuts. See «ENGINE SUPPORT FIXTURE»(ref-154467-S32997825102003051500000).
  20. Remove the transaxle mount nuts.
  21. Lower the vehicle until the frame contacts the Universal Engine Support Table (J-39580). (Scheme 273)
  22. Remove frame front bolts. (Scheme 274)
  23. Remove the frame rear bolts. (Scheme 274)
  24. Raise the vehicle in order to separate the frame from the vehicle.
  25. If you are replacing the frame, perform the following steps: Remove the frame insulators from the frame. Remove the lower control arms from the frame. See appropriate FRONT article in SUSPENSION.
  1. If you are replacing the frame, perform the following steps: Install the lower control arms to the frame. See appropriate FRONT article in SUSPENSION. Install the frame insulators to the frame.
  2. Position the transaxle table with the frame under the vehicle. (Scheme 273)
  3. Lower the vehicle until the frame is close to the vehicle.
  4. Insert two 0.75" (19 mm) diameter x 8.0" (203 mm) long guide pins or drill bits into the frame right side alignment holes in order to align the frame.
  5. Install the frame front bolts. (Scheme 274) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154467-S06512389272003051500000).
  6. Install the frame rear bolts. (Scheme 274) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154467-S06512389272003051500000).
  7. Remove the alignment pins from the frame.
  8. Install the transaxle mount nuts.
  9. Install the engine mount nuts.
  10. Install the wheel speed sensor wiring harnesses to the lower control arms.
  11. Connect the wheel speed sensor electrical connectors.
  12. Install the lower ball joints to the steering knuckles.
  13. Install the power steering cooler pipe to the frame.
  14. Install the front engine splash shield.
  15. Remove the mechanics wire and install the power steering gear to the frame.
  16. Install the power steering gear bolts.
  17. Install the power steering gear bolts.
  18. For AWD models, install the drive shaft.
  19. For AWD models, install the catalytic converter pipe.
  20. Install the stabilizer shaft.
  21. Install both tie rod ends to the steering knuckles.
  22. Install front fender liner.
  23. Install the front tires and wheels.
  24. Lower the vehicle.
  25. Remove the engine support fixture. See «ENGINE SUPPORT FIXTURE»(ref-154467-S32997825102003051500000).

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