2000 Saturn SLFACTORY OEM SERVICE PROCEDURE

Transaxle Disassemble

  1. Remove clutch fork and bearing assembly.
    Fig 1: Removing Clutch Fork
    G01033434Courtesy of GENERAL MOTORS CORP.
  2. Remove shift housing bolts, shift housing and discard gasket.
  3. Remove vehicle speed sensor.
    Fig 2: Removing Shift Control Housing & Vehicle Speed Sensor
    G01033435Courtesy of GENERAL MOTORS CORP.
  4. Remove end cover bolts, end cover and discard gasket.
    Fig 3: Removing End Cover
    G01033436Courtesy of GENERAL MOTORS CORP.
  5. Move two shift forks to lock the transaxle in two gears.

    IMPORTANT:  To hold transaxle in place while removing nuts, drill two holes in bench top to align with the two top of transaxle to engine mounting holes and put bolts through the transaxle into the holes.

  6. Remove input shaft nut and retain for clearance measurements.
  7. Remove output shaft nut and retain for clearance measurements.
    Fig 4: Removing 5th Gear & 5th/Reverse Synchronizer Assembly
    G01033437Courtesy of GENERAL MOTORS CORP.
  8. Remove reverse cone, thrust washer, and reverse blocker ring.
  9. Remove 5th/Reverse fork retainer clip and discard.
  10. Remove 5th/Reverse shift fork. 5th/Reverse synchronizer sleeve, 5th/Reverse hub, blocker assembly, and 5th drive gear.
  11. Remove 5th gear bearing assembly.
  12. Remove 5th/Reverse synchronizer.
    Fig 5: Identifying Spline Alignment Marks On Hub & Sleeve (3rd/4th Synchronizer Shown; 5th/Reverse Synchronizer Similar)
    G01033438Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  Synchronizer hub and sleeve must be kept together as a matched set. (3/4 synchronizer shown, 5th/Reverse synchronizer similar.) If alignment marks (indicated by the arrow) are not visible, put new marks on hub and sleeve before they are separated.

    IMPORTANT:  If the 5th/Reverse hub is press fit on the input shaft:

    1. Install Shaft Protector SA9211T-3 on the end of the input shaft with the counter bore in the shaft protector going over the input shaft.
    2. Install the 5th Gear Remover SA9211T-2 on the input shaft. Engage the legs of the puller under the clutching teeth ring on the 5th drive gear and center the forcing screw on the shaft protector.
    3. Tighten the forcing screw to remove the 5th drive gear along with the 5th/Reverse hub.
  13. Remove 5th driven gear.

    IMPORTANT:  If the 5th driven gear is press fit on the input shaft:

    1. Install Shaft Protector, SA9211T-3 on the end of the output shaft with the counter bore in the shaft protector going over the output shaft.
    2. Install the 5th Gear Remover, SA9211T-2 on the output shaft. Engage the legs of the puller under the 5th driven gear and center the forcing screw on the shaft protector.

      IMPORTANT:  It may be necessary to release the bearing snap-ring and pull the shaft out to provide access for the puller under the 5th driven gear.

    3. Tighten the forcing screw on the puller to remove the 5th driven gear.
  14. Remove case-to-clutch housing bolts.
  15. Use snap ring pliers to open output and input shaft bearing snap rings to allow the bearing snap ring grooves to drop below the snap rings. Use pry slots to separate case and clutch housing, and remove case.
  16. Remove the left axle seal retainer (snap ring) and remove the left axle seal from the case using Axle Seal Puller SA9133T.
    Fig 6: Separating Case & Clutch Housing
    G01033439Courtesy of GENERAL MOTORS CORP.
  17. Remove differential selective snap ring from case.
  18. Remove oil trough.
    Fig 7: Removing Oil Trough
    G01033440Courtesy of GENERAL MOTORS CORP.
  19. Remove 5th/Reverse actuator retainer clip and discard.
    Fig 8: Removing 5th/Reverse Actuator Retainer Clip & Shift Fork Shaft
    G01033441Courtesy of GENERAL MOTORS CORP.
  20. Remove shift fork shaft.
  21. Remove 1/2, 3/4 forks and 5th/Reverse actuator.
    Fig 9: Removing 1/2 & 3/4 Forks, & 5th/Reverse Actuator
    G01033442Courtesy of GENERAL MOTORS CORP.
  22. Remove reverse shift lever bolts, and remove reverse idler gear shift lever assembly.
  23. Remove reverse idler gear shaft.
    Fig 10: Removing Reverse Idler Gear Shift Lever & Reverse Idler Gear Shaft
    G01033443Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  Lift shafts out carefully to prevent damage to output shaft machined surface.

  24. Lift input and output shafts out of the clutch housing together.
    Fig 11: Removing Input & Output Shafts
    G01033444Courtesy of GENERAL MOTORS CORP.
  25. Lift differential out of clutch housing.
  26. Remove transaxle magnet.
    Fig 12: Removing Differential & Transaxle Magnet
    G01033445Courtesy of GENERAL MOTORS CORP.
Factory Service Tools

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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.

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