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HOMESERVICE MANUALSSATURN2003ION 3 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 5 (AUTOMATIC TRANSMISSION - VT25-E)REPAIR INSTRUCTIONSTRANSMISSION REPLACEMENTINSTALLATION PROCEDURE
2003 Saturn Ion 3 4D Sedan, Standard

Installation Procedure

2003 Saturn Ion 3 4D Sedan, StandardSECTION Installation Procedure
WARNING: This page is about a different variant/trim than selected.
  1. Install the rear transmission mount to the transmission. Refer to Transmission Mount Replacement - Rear .
  2. Install the front transmission mount to the transmission. Refer to Transmission Mount Replacement - Front .
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the shift cable bracket.

    Tighten 

    Tighten the bolts to 23 N.m (17 lb ft).

  4. Install the PNP switch. Refer to Park/Neutral Position Switch Replacement .
  5. Use a transmission jack to position the transmission to the vehicle.

    Important:  The number three position does not require a bolt.

  6. Secure the transmission to the engine.

    Tighten 

    Tighten the bolts to 75 N.m (55 lb ft).

    Fig 1: Tightening Transmission To Engine Bolts
    G02126172Courtesy of GENERAL MOTORS CORP.
  7. Connect the shift cable to the transmission. Refer to Shift Cable Replacement .
  8. Install the torque converter to flywheel bolts.

    Tighten 

    Tighten the bolts to 65 N.m (48 lb ft).

  9. Install the starter. Refer to STARTER in Starters.
    Fig 2: Installing Torque Converter To Flywheel Bolts
    G02126173Courtesy of GENERAL MOTORS CORP.
  10. Connect the drive axles to the transmission. Refer to WHEEL DRIVE SHAFT REPLACEMENT in Wheel Drive Shafts.

    Important:  Lubricate the transmission cooler pipes in order to prevent damage to the seals.

  11. Connect the transmission cooler lines to the transmission.

    Tighten 

    Tighten the nut to 7 N.m (62 lb in).

  12. Lower the vehicle.
  13. Use the engine support fixture in order to raise the powertrain assembly.
  14. Install the transmission side mount. Refer to Transmission Mount Replacement - Side .
  15. Install the frame. Refer to FRAME REPLACEMENT in Frame and Underbody.
  16. Remove the engine support fixture.
  17. Install the top engine to transmission bolt

    Tighten 

    Tighten the bolt to 75 N.m (55 lb ft).

    Fig 3: Connecting Transmission Cooler Lines To Transmission
    G02126174Courtesy of GENERAL MOTORS CORP.
  18. Connect the park/neutral position switch harness connector.
  19. Release the cooling module from the upper body structure.
    Fig 4: Connecting Park/Neutral Position Switch Harness Connector
    G02126175Courtesy of GENERAL MOTORS CORP.
  20. Position the under hood junction block to the original mounting.
  21. Install the surge tank inlet hose to the surge tank.
    Fig 5: Positioning Underhood Junction Block
    G02126176Courtesy of GENERAL MOTORS CORP.
  22. Install the front wiring harness to the junction block bracket.
  23. Connect the positive battery cables to the junction block bracket (1).
  24. Install positive battery post to the junction block bracket (2).
    Fig 6: Installing Positive Battery Cables & Positive Battery Post To Junction Block Bracket
    G02126177Courtesy of GENERAL MOTORS CORP.
  25. Install the junction block bracket, bolt and nuts.

    Tighten 

    • Tighten the nuts to 10 N.m (89 lb in).
    • Tighten the bolt to 25 N.m (18 lb ft).
  26. Install the transmission control module. Refer to Transmission Control Module Replacement .
  27. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  28. Fill the transmission to the proper level. Refer to Transmission Fluid Replacement .
    Fig 7: Installing Junction Block Bracket, Bolt & Nuts
    G02126178Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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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.