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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 205 (AUTOMATIC TRANSAXLE SERVICING)REMOVAL & INSTALLATIONCASE SIDE COVERINSTALLATION
2003 Chevrolet TrailBlazer 4.2 S, 4WD

Case Side Cover: Installation

2003 Chevrolet TrailBlazer 4.2 S, 4WDSECTION Installation
WARNING: This page is about a different car, the 2003 Buick Regal and 2003 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the case side cover gasket (54). See Figure . Install the case side cover pan (53). Install the case side cover bolts (56-58). Tighten case side cover bolts to specification. See TORQUE SPECIFICATIONS  .
  2. Remove the drain pan from under the transaxle. Adjust the jackstand to raise the left side of the frame. Install the left and right side frame bolts.
  3. Install the engine mount lower nuts. Install the transaxle mount. See TRANSAXLE MOUNT  . Remove the jackstands from the frame. Install the 3-way catalytic converter pipe to the right exhaust manifold.
    4. CAUTION: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the 2 mating shafts may disengage. Disengagement of the 2 mating shafts will cause loss of steering control which could result in personal injury.
  4. Install the intermediate shaft to the steering gear and the pinch bolt. See appropriate POWER RACK & PINION article in STEERING. Install the left drive axle to the transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Lower the vehicle. Connect the transaxle wiring harness connector.
  5. Install the engine mount struts. See appropriate REMOVAL & INSTALLATION article. Remove the engine support fixture. Install the throttle body air inlet duct. Connect the negative battery cable.
  6. DO NOT overfill the transaxle. Overfilling will result in foaming, loss of fluid, and possible damage to the transaxle. Fill transaxle with appropriate fluid to proper level. See LUBRICATION  . Inspect for fluid leaks.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.