For 1990-2009 cars

# SERVICE MANUAL UPDATE-SEC. 7A TRANSAXLE REMOVAL/INSTALL PROC

#### Subject: SERVICE MANUAL UPDATE - SECTION 7A TRANSAXLE REMOVAL AND INSTALLATION PROCEDURE CHANGE

#### Models Affected: 1990-92 TRANS SPORT MODELS W/3.1L ENGINE

APPLICATION: 1990-91 Pontiac Trans Sport Section 7A1-Pg. 15, 16 1992 Pontiac Trans Sport Section 7A-Pg. 21

Engine: 3.1L VIN D (RPO LG6), Transaxle: 3T40

The following procedure is to be used in place of the Service Manual Sections 7A and 7A1.

#### 3T40 Transaxle Assembly

#### Remove or Disconnect

1. Battery negative cable.

2. Air cleaner assembly.

3. Electrical connectors at transaxle.

4. Electrical wiring harness retainer to transaxle shift cable bracket.

5. Transaxle shift cable bracket and heat shield assembly, wire cable/bracket assembly to body wire cable/bracket assembly to body.

6. Vacuum supply to modulator at transaxle.

7. Retaining bolt to transaxle indicator tube assembly.

8. Retaining bolt at T.V. cable, cable from T.V. link.

9. Battery ground cable to engine/transaxle stud and stud from engine/transaxle.

10. Install engine/transaxle support assembly.

11. Raise vehicle and suitably support, Refer to General Information (Section OA).

12. Both front tires and wheels, refer to Tire and Wheels (Section 3E).

13. Retainers at front engine wiring and power steering cooler lines to frame.

14. Both tie rod ends to steering knuckles, refer to Front Suspension (Section 3E).

15. Power steering gear heat shield from gear assembly.

16. Power steering gear assembly to frame retaining bolts.

17. Power steering gear assembly from frame and secure with wire to vehicle.

18. Front engine mount to frame retaining nuts and washers.

19. Front and rear transaxle mount nuts and washers.

20. Both lower ball joint retaining bolts and nuts.

21. Flywheel covers from engine/transaxle.

22. Rotate engine flywheel to access torque converter bolts, bolts from torque converter/flywheel.

23. Drain and remove transaxle fluid pan.

24. Transaxle cooler lines at transaxle and bracket.

25. Both RH and LH drive axles from transaxle, secure to steering knuckle/strut assembly.

26. Electrical connector to speed sensor at transaxle.

27. Support transaxle/frame assembly with transaxle table.

28. Engine to transaxle bracket and bolts.

29. Retaining bolt from transaxle to engine.

30. Frame retaining bolts from body to frame.

31. Lower transaxle/frame assembly from vehicle.

32. Transaxle from frame to bench.

#### Install or Connect

1. Transaxle to frame assembly.

2. Raise transaxle/frame assembly and position to engine.

3. Retaining bolt from transaxle to engine.

TIGHTEN

. Bolt to 75 N.m (55 lb.ft.).

4. Engine to transaxle bracket and bolts.

TIGHTEN

. Bolts to 50 N.m (37 lb.ft.).

5. Remove transaxle support table.

6. Connect electrical connector to transaxle speed sensor.

7. Both RH and LH axles into transaxle assembly.

8. Transaxle cooler line bracket and lines to transaxle.

TIGHTEN

. Bracket bolt to 55 N.m (41 lb.ft.).

9. Flywheel to torque converter bolts.

TIGHTEN

. Bolts to 47 N.m (35 lb.ft.).

10. Flywheel covers and bolts.

TIGHTEN

. Bolts to 13 N.m (115 lb.in.).

11. Position both lower ball joints to steering knuckles, retaining bolts to ball joints.

TIGHTEN

. Ball joint retaining bolts and nuts to 45 N.m (33 lb.ft.).

12. Position frame to body, frame retaining bolts.

TIGHTEN

. Frame bolts to 140 N.m (103 lb.ft.).

13. Front and rear transaxle mount to frame, washers and retaining bolts.

TIGHTEN

. Transaxle mount nuts to 30 N.m (22 lb.ft.).

14. Front engine mount to frame.

TIGHTEN

. Washers and retaining nuts to 45 N.m (33 lb.ft.).

15. Power steering gear for support wire, position gear assembly to mounts on frame.

16. Retaining bolts and nuts to power steering gear assembly.

TIGHTEN

. Bolts and nuts to 95 N.m (70 lb.ft.).

17. Power steering gear heat shield and retaining screws.

TIGHTEN

. Screws to 10 N.m (89 lb.in.).

18. Both LH and RH tie rod ends to steering knuckles.

TIGHTEN

. Tie rod end retaining bolts to 70 N.m (52 lb.ft.).

19. Power steering cooler lines and engine wiring harness to frame and retainers.

20. Both LH and RH tire and wheel assemblies, refer to Tire and Wheels (Section 3E).

21. Lower vehicle.

22. Remove engine support fixture.

23. Retaining bolts to transaxle to engine.

TIGHTEN

. Bolts to 75 N.m (55 lb.ft.).

24. Battery cable negative to engine stud, washer and nut.

TIGHTEN

. Retaining nut to 33 N.m (24 lb.ft.).

25. Retaining bolt to transaxle indicator tube to transaxle.

TIGHTEN

. Bolts to 20 N.m (15 lb.ft.).

26. Vacuum supply to modulator at transaxle.

27. Shift cable and bracket assembly to transaxle.

28. Shift cable heat shield and retaining bolt to heatshield bracket, cable assembly.

TIGHTEN

. Bolts to 33 N.m (24 lb.ft.).

29. T.V. cable to link at transaxle and retaining bolt.

30. Electrical connector retainer to shift cable bracket.

31. Electrical connectors at transaxle.

32. Air cleaner assembly.

33. Battery negative cable.

INSPECT

. Transaxle fluid.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.