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

Removal Procedure

2003 Saturn Ion 3 4D Sedan, StandardSECTION Removal Procedure
WARNING: This page is about a different variant/trim than selected.
  1. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  2. Remove the transmission control module (TCM). Refer to Transmission Control Module Replacement .
  3. Remove the positive battery post from the underhood junction block (2).
  4. Disconnect the positive battery cables from the underhood junction block (1).
  5. Disconnect the surge tank inlet hose from the surge tank.
    Fig 1: Removing Positive Battery Post & Positive Battery Cables From Underhood Junction Block
    G02126165Courtesy of GENERAL MOTORS CORP.
  6. Remove the underhood junction block bracket nuts (1,2).
  7. Loosen the underhood junction block bracket bolt (3).
  8. Disconnect the front wiring harness from the underhood junction block bracket.
    Fig 2: Removing Underhood Junction Block Bracket Nuts & Bolt
    G02126166Courtesy of GENERAL MOTORS CORP.
  9. Reposition the underhood junction block bracket aside.
    Fig 3: Repositioning Underhood Junction Block Bracket Aside
    G02126167Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the park/neutral position switch harness connector.
  11. Install the engine support fixture. Refer to ENGINE SUPPORT FIXTURE in Engine Mechanical 2.2L (L61).
  12. Secure the cooling module to the upper body structure.
    Fig 4: Disconnecting Park/Neutral Position Switch Harness Connector
    G02126168Courtesy of GENERAL MOTORS CORP.
  13. Remove the upper transmission to mount bolts.
  14. Remove the upper transmission to engine bolt.
  15. Remove the frame. Refer to FRAME REPLACEMENT in Frame and Underbody.
  16. Drain the transmission. Refer to Transmission Fluid Replacement .
    Fig 5: Removing Upper Transmission To Mount Bolts
    G02126169Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the transmission cooler lines from the transmission.
  18. Disconnect the drive axles from the transmission and secure out of the way. Refer to WHEEL DRIVE SHAFT REPLACEMENT in Wheel Drive Shafts.
  19. Remove the starter. Refer to STARTER in Starters.
    Fig 6: Disconnecting Transmission Cooler Lines From Transmission
    G02126170Courtesy of GENERAL MOTORS CORP.
  20. Remove the torque converter to flywheel bolts.
  21. Disconnect the shift cable from the transmission. Refer to Shift Cable Replacement .
  22. Lower the vehicle.
  23. Use the engine support fixture rear hook to lower the powertrain approximately 2-3 inches. This will allow clearance between the side rail and powertrain.
  24. Raise the vehicle.
  25. Use a transmission jack to secure the transmission, and remove the transmission to engine bolts.
  26. Remove the transmission from the vehicle.
    Fig 7: Removing Torque Converter To Flywheel Bolts
    G02126171Courtesy of GENERAL MOTORS CORP.
  27. Remove the PNP switch. Refer to Park/Neutral Position Switch Replacement .
  28. Remove the shift cable bracket.
  29. Remove the front transmission mount from the transmission. Refer to Transmission Mount Replacement - Front .
  30. Remove the rear transmission mount and bracket from the transmission. Refer to Transmission Mount Replacement - Rear .
  31. Flush the transmission cooler lines. Refer to Automatic Transmission Oil Cooler Flushing .
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.