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Home >> Saturn >> 2003 >> Ion 1 Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle - AF23-5 >> Repair Instructions >> Control Valve Body Replacement >> Installation Procedure

Installation Procedure

  1. Install new case fluid passage seals (86).
    Fig 1: Installing Case Fluid Passage Seals
    G02125363Courtesy of GENERAL MOTORS CORP.
  2. While holding the valve body assembly (39), connect the manual shift detent lever assembly (710) to the manual valve link (710).
    Fig 2: Connecting Manual Shift Detent Lever Assembly To Manual Valve Link
    G02125364Courtesy of GENERAL MOTORS CORP.
  3. Install the valve body assembly to transaxle case bolts (34, 35, 47) hand tight.
    Fig 3: Installing Valve Body Assembly To Transaxle Case Bolts
    G02125365Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Tighten the valve body assembly-to-transaxle case bolts in the sequence shown.

    Tighten 

    Tighten the bolts to 10 N.m (89 lb in).

    Fig 4: Tightening Valve Body Assembly-To-Transaxle Case Bolts In Sequence
    G02125366Courtesy of GENERAL MOTORS CORP.
  5. Install a new valve body fluid passage cover gasket (38).
  6. Install a new control valve body fluid passage cover (37).
  7. Install the control valve body fluid passage cover bolts (31).

    Tighten 

    Tighten the bolts to 10 N.m (89 lb in).

    Fig 5: Installing Control Valve Body Fluid Passage Cover, Bolts & Gasket
    G02125367Courtesy of GENERAL MOTORS CORP.

    Important:  Apply transaxle fluid to the new fluid temperature sensor O-ring.

  8. Install a new O-ring (32) into the groove of the transaxle fluid temperature sensor (36).
  9. Install the temperature fluid sensor (36) into the valve body.
  10. Install the fluid temperature sensor clamp (49).
  11. Install the fluid temperature sensor bolt (31).

    Tighten 

    Tighten the bolt to 10 N.m (89 lb in).

    Fig 6: Installing Fluid Temperature Sensor, O-Ring, Clamp & Bolt
    G02125368Courtesy of GENERAL MOTORS CORP.
  12. Connect the solenoid harness connectors in the following order:
    1. 12.1. Blue (1)
    2. 12.2. Black (2)
    3. 12.3. Green (3)
    4. 12.4. Black (4)
    5. 12.5. Blue (5)
    6. 12.6. Gray (6)
    7. 12.7. Green (7)
    8. 12.8. Gray (8)
    Fig 7: Connecting Solenoid Harness Connectors
    G02125369Courtesy of GENERAL MOTORS CORP.

    Important:  The cover and transaxle must be free of dirt, gasket material and debris in order to seal properly.

  13. Clean and inspect the valve body cover and transaxle gasket surfaces for gasket material and debris.
    Fig 8: Inspecting Valve Body Cover & Transaxle Gasket Surfaces
    G02125370Courtesy of GENERAL MOTORS CORP.
  14. Install RTV sealer Saturn P/N 89020326 onto the control valve body cover and install the control valve body cover.
  15. Apply threadlocker Saturn P/N 21485277 to the bolts. Hand tighten the bolts.
    Fig 9: Installing Control Valve Body Cover & Bolts
    G02125371Courtesy of GENERAL MOTORS CORP.
  16. Tighten the valve body cover bolts using the sequence shown.

    Tighten 

    Tighten the bolts to 13 N.m (115 lb in).

    Fig 10: Tightening Valve Body Cover Bolts In Sequence
    G02125372Courtesy of GENERAL MOTORS CORP.
  17. Install the transaxle cooler lines to the transaxle. Refer to Oil Cooler Line Replacement .
  18. Lower the vehicle.

    Important:  Do not use AF P/N 21005966 or P/N 21019223, these fluids are not compatible with this transaxle. Use Saturn T-IV P/N 22689186.

  19. Add fluid to the transaxle as necessary. Refer to Transmission Fluid Checking Procedure .
  20. Start the engine and check for leaks.
    Fig 11: Installing Transaxle Cooler Lines
    G02125373Courtesy of GENERAL MOTORS CORP.
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