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Home >> Saturn >> 2003 >> VUE L4-2.2L VIN D >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> Overhaul (Unit Repair) >> Transaxle Case Disassemble
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Transaxle Case Disassemble

TRANSAXLE CASE DISASSEMBLY

^ TOOLS REQUIRED
- J 44375 Assembly Pallet
- J 44376 Bearing Pusher/Puller
- J 44377 Input Shaft Anti-Rotation Tool
- J 44380 Differential Bearing Race Puller
- J 44381 Shifter Bearing/Input and Output Bearing Remover
- J 44382 Countershaft Needle Bearing Puller
- J 44385 Differential Bearing Race and Seal Installer
- J 7079-2 Non-Threaded Driver Handle
- J 8092 Threaded Driver Handle
- SA9133T Axle Seal Puller
- SA9133T-I Puller Adapter

DISASSEMBLY

IMPORTANT: Shimming procedures must be performed when at least one of the following has been replaced:
^ Clutch Housing
^ Transaxle Case
^ Differential Case Assembly
^ Differential Bearings
^ Output Shaft Bearings





1. Remove transaxle filler cap.





2. Remove transaxle drain plug and drain fluid.





3. Remove actuator and tube bolts.
4. Remove actuator and tube.





5. Remove shift cable bracket (4), spacers (2), isolators (3) and bolt (1).





6. Remove vehicle speed sensor and bolt.





7. Position transaxle, with transaxle case side facing up, on a bench.
8. Remove bolts from transaxle case side of housing.





9. Turn transaxle over.

NOTICE: Puncture retainer plug in center to prevent damage to transaxle.

10. Remove counter shaft plug using a suitable tool. Discard plug.





11. Remove plastic lube funnel from counter shaft using a suitable tool. Discard lube funnel.





12. Turn transaxle so shifter is on top.
13. Shift transaxle into any gear.





14. Hold input shaft with Input Shaft Anti-Rotation Tool J44377.
15. Remove bolt from counter shaft.





16. Shift transaxle into neutral.
17. Remove shifter guide bolt.





18. Remove shifter retaining bolts.
19. Remove shifter.





20. Remove rear cover bolts.
21. Remove rear cover.
22. Remove oil spout (funnel).





23. Shift transaxle into 4th and 5th gear using a screwdriver in an upward direction.
24. Remove shaft bolts while holding transaxle into 4th and 5th gear with a screwdriver in an upward direction.





25. Turn transaxle over and remove remainder of transaxle bolts from clutch housing side.





IMPORTANT: In line with the counter shaft, use two suitable tools to assist in case separation.

26. Remove clutch housing from transaxle case.





27. Remove differential from transaxle case.





28. Remove roller bearing from output shaft.





29. Remove magnet from transaxle case.





30. Slide outward and unhook shift rod from shift fork.





IMPORTANT: Make sure all the shafts are in the proper slots on holding fixture.

31. Install Assembly Pallet J44375 onto gear shafts and shift forks.





32. Turn transaxle case over on the Assembly Pallet J44375.





33. Remove back-up lamp switch.





IMPORTANT: Alternate tightening of the jack screws on the Bearing Pusher/Puller J44376 to ensure proper removal of transaxle case.

34. Remove transaxle case from shafts using Pusher/Puller Assembly J44376-1, Remover Plug J44376-2, and Forcing Screw J44376-3.





35. Remove oil trough from transaxle case.





36. Remove counter shaft and shift fork from input shaft, output shaft, and Assembly Pallet J44375.





37. Remove remaining gear assemblies from holding fixtures.
38. Remove shift forks from gear assemblies.





39. Using Puller Adapter SA9133T- 1 used with Differential Bearing Race Puller J44380(2), and Axle Sea] Puller SA9133T (1), remove differential bearing outer race from clutch housing. Discard race.





40. Remove drive shaft seal from clutch housing. Discard seal.





41. Remove output shaft bearing race and bolts from clutch housing using Puller Adapter SA9133T-1 used with Differential Bearing Race Puller J44380 (2) and Axle Seal Puller SA9133T (1).





42. Remove input shaft bearing from clutch housing using Shifter Bearing/Input and Output Bearing Remover J44381 and Non-Threaded Driver Handle J7079-2.





43. Remove snap ring and counter shaft bearing from clutch housing using Shifter Bearing/Input and Output Bearing Remover J44381 and the Non-Threaded Driver Handle J7079-2.





44. Remove differential bearing outer race from transaxle case using Puller Adapter SA9133T-I used with Differential Bearing Race Puller J44380 (2) and Axle Sea] Puller SA9133T (1). Discard race.





45. Remove drive shaft seal from transaxle case. Discard seal.





46. Remove bolt, lever and spring from transaxle case.





47. Remove shifter bearing from transaxle case using Output Bearing Remover J44381 and Non-Threaded Driver Handle J7079-2.





48. Remove counter shaft needle bearing from transaxle case using Puller Adapter SA9133T-2 used with Countershaft Needle Bearing Puller J44382 (2) and Axle Seal Puller SA9133T (1).





49. Remove shift shaft bushing and shift shaft from transaxle case.





50. Remove snap ring and input shaft bearing from the transaxle case using Differential Bearing Race and Seal Installer J44385 (2) and Threaded Driver Handle J8092 (1). Discard snap ring.
51. Remove snap ring and output shaft bearing from transaxle case using the Differential Bearing Race and Seal Installer J44385 (2) and Threaded Driver Handle J8092 (1). Discard snap ring.
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