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Document ID: 1988919

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2008 Saturn Astra

| Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission - F17-5 | Repair Instructions - On Vehicle | Document ID: 1988919

Transmission Fluid Check
Removal Procedure
Important: The transmission fluid level is always below the inspection bolt opening up to 16 mm (0.63 in). Inspect the transmission fluid level only after repair work on transmission and correct if necessary.

1. Inspect the transmission fluid level.

© 2010 General Motors Corporation. All rights reserved.

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9/24/2010

Document ID: 1988919

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2. Disconnect the back up lamp switch wiring harness plug and remove the switch (1).

Installation Procedure

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Document ID: 1988919

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1. Fill up with the recommended transmission fluid. Refer to Lubrication Specifications . 2. Add fluid through the back up lamp switch opening. 3. Fill up with transmission fluid until it emerges at the inspection opening. Notice: Refer to Fastener Notice in the Preface section. 4. Tighten the fluid inspection bolt. Tighten Tighten the bolt to 4 N·m (35 lb in) plus 45-135 degrees.

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Tighten the back up lamp switch (1) 20 N·m (15 lb ft). • Connect the wiring harness plug to the reversing lamp switch. http://localhost:9001/si/showDoc.do?docSyskey=1988919&pubCellSyskey=167687&pub.. 9/24/2010 . • Use a new seal ring.Document ID: 1988919 Page 4 of 4 5..

On Vehicle | Document ID: 2003565 Front Wheel Drive Shaft Seal Replacement Special Tools • KM-446 Installer Drift • KM-557-A Remover Removal Procedure 1.. Refer to Wheel Drive Shaft Replacement . 2. (2) and KM-446 (1) from Installation Procedure © 2010 General Motors Corporation. http://localhost:9001/si/showDoc..do?docSyskey=2003565&pubCellSyskey=167689&pub.Document ID: 2003565 Page 1 of 2 2008 Saturn Astra | Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission . 9/24/2010 . Important: Place a drip pan underneath. Axle shaft remains in wheel hub. transmission fluid will escape. All rights reserved. Remove the affected axle shaft seal ring with KM-557-A transmission housing. Remove the axle shaft affected from transmission.F17-5 | Repair Instructions .

Inspect the transmission fluid level. 3. • Coat the axle shaft seal ring with transmission fluid.. • Install the axle shaft seal ring flush in the transmission. Install the axle shaft in the transmission. http://localhost:9001/si/showDoc.do?docSyskey=2003565&pubCellSyskey=167689&pub. Install the new axle shaft seal ring.. 9/24/2010 . For F17 use KM-446 (1) 2.Document ID: 2003565 Page 2 of 2 1. Refer to Transmission Fluid Check . Refer to Wheel Drive Shaft Replacement .

© 2010 General Motors Corporation. 2.F17-5 | Repair Instructions .On Vehicle | Document ID: 1996069 Transmission Control Replacement Special Tools KM-527-A Adjuster Removal Procedure 1. Remove the front floor console. 3. Loosen the bolt (1) for the relay point clamp.Document ID: 1996069 Page 1 of 6 2008 Saturn Astra | Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission . Refer to Battery Replacement .. Release the gearshift rod. Remove the battery. All rights reserved. 9/24/2010 .do?docSyskey=1996069&pubCellSyskey=169420&pub. http://localhost:9001/si/showDoc.. Important: Do not remove the bolt. Refer to Front Floor Console Replacement .

Remove the transmission control (1). • Pull out transmission control with the gearshift linkage from the bulkhead..do?docSyskey=1996069&pubCellSyskey=169420&pub. Installation Procedure http://localhost:9001/si/showDoc. 9/24/2010 . • Remove the 4 bolts (2-4).Document ID: 1996069 Page 2 of 6 4..

Important: Note gearshift linkage bellows in bulkhead.. Feed the transmission control with the gearshift linkage through the bulkhead. Install the transmission control (1). 2.. http://localhost:9001/si/showDoc. Notice: Refer to Fastener Notice in the Preface section. Tighten Tighten the four bolts (2-4) to 10 N·m (89 lb in) .do?docSyskey=1996069&pubCellSyskey=169420&pub. 9/24/2010 .Document ID: 1996069 Page 3 of 6 1.

9/24/2010 . • Push the transmission control to the left.. Lock the transmission control shaft in the gearbox cover. • Turn the transmission control rod counterclockwise • Direction of third gear . http://localhost:9001/si/showDoc.Document ID: 1996069 Page 4 of 6 3. • Lock the transmission control and shift lever housing with KM-527-A (1).. • Engage the locking pin (1) in the adjusting bore in the gearbox cover (arrow). 4.do?docSyskey=1996069&pubCellSyskey=169420&pub. Lock the transmission control in adjustment position.

9/24/2010 .. 6. Tighten Tighten the bolt (1) to 12 N·m (106 lb in) plus 180-225 degrees. Detach the KM-527-A (1). http://localhost:9001/si/showDoc..Document ID: 1996069 Page 5 of 6 Important: Do not change the position of the transmission control rod.do?docSyskey=1996069&pubCellSyskey=169420&pub. 5. Release the transmission control lock. Install the transmission control rod.

do?docSyskey=1996069&pubCellSyskey=169420&pub. 8. • With vehicle standing • With engine running • With clutch disengaged 9. Inspect the ease of gear shifting. Refer to Front Floor Console Replacement .Document ID: 1996069 Page 6 of 6 Important: The locking pin in the adjusting bore hole releases automatically when first shifted in the "R" direction. 9/24/2010 . http://localhost:9001/si/showDoc.. refer to Control Module References . 10. Refer to Battery Replacement . 11. Install the front floor console. Release the locking pin in the gearbox cover. 7. if necessary release the locking pin by hand.. Install the battery. For programming procedures.

do?docSyskey=2002490&pubCellSyskey=170400&pub. http://localhost:9001/si/showDoc.F17-5 | Repair Instructions . Release the selector lever link.On Vehicle | Document ID: 2002490 Selector Lever Link Adjustment Special Tools KM-527-A Adjuster Removal Procedure 1. Important: Do not remove the bolt. Refer to Battery Tray Replacement . • Release the cover of the transmission control lever at the front (arrows) from the front floor console.. All rights reserved. Remove battery tray. 2. Detach the over of the transmission control lever (1). 9/24/2010 .. 3. • Prop up the cover of the transmission control lever with the cover frame.Document ID: 2002490 Page 1 of 5 2008 Saturn Astra | Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission . © 2010 General Motors Corporation. Loosen the bolt (1) for the relay point clamp.

do?docSyskey=2002490&pubCellSyskey=170400&pub.Document ID: 2002490 Page 2 of 5 4. http://localhost:9001/si/showDoc. Lock the transmission control lever in adjustment position. 9/24/2010 .. • Push the transmission control lever to the left. • Lock the transmission control lever and transmission control lever housing with the KM527-A (1)..

Installation Procedure Notice: Refer to Fastener Notice in the Preface section. • Turn the selector lever link counterclockwise.do?docSyskey=2002490&pubCellSyskey=170400&pub... Lock the selector lever link shaft in the transmission cover. Important: Do not change the position of the gearshift rod. http://localhost:9001/si/showDoc.Document ID: 2002490 Page 3 of 5 5. • Direction of the 3rd gear • Engage the locking pin (1) in the adjusting bore in the transmission cover (arrow). 9/24/2010 .

http://localhost:9001/si/showDoc. Release the transmission control lever lock. Detach the KM-527-A (1). 2.Document ID: 2002490 Page 4 of 5 1. Attach the cover of the transmission control lever (1).. • Insert the cover of the transmission control lever at the rear in the front floor console.do?docSyskey=2002490&pubCellSyskey=170400&pub. 9/24/2010 . Tighten Tighten the bolt (1) to 12 N·m (106 lb in) plus 180-225 degrees. Install the selector lever link. 3..

if necessary release the locking pin by hand.do?docSyskey=2002490&pubCellSyskey=170400&pub. For programming procedures. Important: The locking pin in the adjusting bore hole releases automatically when first shifted in "R" direction. 5. Release the locking pin in the transmission cover.. 4. http://localhost:9001/si/showDoc. 9/24/2010 .Document ID: 2002490 Page 5 of 5 • Clip the cover of the transmission control lever into the front floor console at the front (arrows). 7. Inspect ease of gear shifting. refer to Control Module References . • With vehicle standing • With engine running • With clutch disengaged 6.. Refer to Battery Tray Replacement . Install battery tray .

2.On Vehicle | Document ID: 2002492 Selector Lever Link Replacement Special Tools KM-527-A Adjuster Removal Procedure 1.do?docSyskey=2002492&pubCellSyskey=170401&pub. Loosen the bolt (1) for relay point clamp.F17-5 | Repair Instructions . Release the selector lever link.. 3.Document ID: 2002492 Page 1 of 6 2008 Saturn Astra | Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission . Refer to Battery Replacement . Refer to Front Floor Console Replacement . Remove the front floor console.. Remove the battery. Important: Do not remove the bolt. 9/24/2010 . © 2010 General Motors Corporation. All rights reserved. http://localhost:9001/si/showDoc.

. 9/24/2010 ..do?docSyskey=2002492&pubCellSyskey=170401&pub.Document ID: 2002492 Page 2 of 6 4. Remove the transmission control lever assembly (1). • Pull out the transmission control lever assembly with selector lever link from the bulkhead. Installation Procedure http://localhost:9001/si/showDoc. • Remove the 4 bolts (2).

. Important: Note selector lever link bellows in bulkhead.do?docSyskey=2002492&pubCellSyskey=170401&pub. http://localhost:9001/si/showDoc.Document ID: 2002492 Page 3 of 6 1.. 2. Tighten Tighten the 4 bolts (2) to 10 N·m (89 lb in). Feed the transmission control lever assembly with selector lever link through the bulkhead. Notice: Refer to Fastener Notice in the Preface section. Install the transmission control lever assembly (1). 9/24/2010 .

Lock the transmission control lever in adjustment position. http://localhost:9001/si/showDoc. • Engage the locking pin (1) in the adjusting bore in the transmission cover (arrow). 4. • Push the transmission control lever to the left. • Turn the selector lever link counterclockwise.Document ID: 2002492 Page 4 of 6 3. • Direction of 3rd gear. Lock the selector lever link in the gearbox cover.do?docSyskey=2002492&pubCellSyskey=170401&pub... 9/24/2010 . • Lock the transmission control lever and shift lever housing with KM-527-A (1).

do?docSyskey=2002492&pubCellSyskey=170401&pub. Tighten Tighten bolt (1) to 12 N·m (106 lb in) plus 180-225 degrees. Install the selector lever link... 9/24/2010 . Release the transmission control lever lock.Document ID: 2002492 Page 5 of 6 Important: Do not change position of selector lever link. 6. Detach KM-527-A (1) http://localhost:9001/si/showDoc. 5.

Document ID: 2002492

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Important: The locking pin in the adjusting bore hole releases automatically when first shifted in R direction. If necessary, release the locking pin by hand. 7. Release the locking pin in the transmission cover. 8. Inspect the ease of gear shifting. • With vehicle standing • With engine running • With clutch disengaged 9. Install the battery. Refer to Battery Replacement . 10. For programming procedures, refer to Control Module References . 11. Install the front floor console. Refer to Front Floor Console Replacement .

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Document ID: 2002468

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2008 Saturn Astra

| Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission - F17-5 | Repair Instructions - On Vehicle | Document ID: 2002468

Shift Lever Rod Universal Joint Replacement
Special Tools
KM-569-A Plug Remover

Removal Procedure
1. Position the transmission control lever into 4th gear. 2. Remove the battery tray. Refer to Battery Tray Replacement .

3. Release the selector lever. Important: Do not remove the bolt. 4. Loosen the bolt (1) for the relay point clamp. 5. Disconnect the transmission rocker arm from the relay point bracket. 6. Disconnect the 2 retaining clamps (1, 2) from the transmission rocker arm.

© 2010 General Motors Corporation. All rights reserved.

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7. Disconnect the selector lever from the universal joint. • Press in retaining spring (arrow) of the hollow pin (3). • Detach the hollow pin with KM-569-A .

Installation Procedure
Important: Use new retaining clamps. 1. Connect the transmission rocker arm to the relay point bracket. Connect the 2 retaining clamps (1, 2) to the transmission rocker arm.

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Retaining spring (arrow) of hollow pin (3) must engage. For programming procedures. refer to Control Module References . Refer to Selector Lever Link Adjustment . 3. Connect the selector lever to the universal joint.Document ID: 2002468 Page 3 of 3 Important: Use a new hollow pin. Refer to Battery Tray Replacement . Connect the selector lever to relay point.do?docSyskey=2002468&pubCellSyskey=170402&pub. 9/24/2010 . Adjust the transmission shift linkage. 4. Install battery tray. 5. 6.. Important: Do not tighten bolt (1) yet. 2. Connect a hollow pin. http://localhost:9001/si/showDoc..

1..On Vehicle | Document ID: 1988923 Transmission Control Lever Boot Replacement Removal Procedure 1. Disconnect the relay point from the selector lever lever. 2. 2. 3.Document ID: 1988923 Page 1 of 2 2008 Saturn Astra | Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission . Important: Do not tighten the clamping screw (1). Installation Procedure Important: Push the lever boot onto the gearshift rod without twisting it. Disconnect the selector lever boot (2) from the bulkhead. Release the bolt (1) for the relay point clamp. Attach the selector lever boot (2) to the bulkhead. Attach the transmission relay point to the selector lever.do?docSyskey=1988923&pubCellSyskey=167698&pub.. All rights reserved. http://localhost:9001/si/showDoc. Position the transmission control lever into 4th gear. 9/24/2010 .F17-5 | Repair Instructions . © 2010 General Motors Corporation.

Adjust the transmission selector lever link.Document ID: 1988923 Page 2 of 2 3..do?docSyskey=1988923&pubCellSyskey=167698&pub. Refer to Selector Lever Link Adjustment .. 9/24/2010 . http://localhost:9001/si/showDoc.

2. 1. 4. Remove the battery tray. 3. Remove the gearbox cover. reversing lamp switch.. Refer to Battery Tray Replacement . All rights reserved. Remove the reversing lamp switch (1). Refer to Front Frame Replacement . © 2010 General Motors Corporation. Remove the upper engine cover.Document ID: 2010078 Page 1 of 5 2008 Saturn Astra | Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission . 5.On Vehicle | Document ID: 2010078 Rear Shield Cover Replacement Special Tools • KM-6155 Guide Pins • SA9105E /MKM-883-1A Engine Support Fixture (3-Bar) Removal Procedure Caution: Refer to Battery Disconnect Caution in the Preface section.F17-5 | Repair Instructions .do?docSyskey=2010078&pubCellSyskey=171325&pub.. 9/24/2010 . http://localhost:9001/si/showDoc. if equipped. Remove the front frame. Disconnect the wiring harness plug.

7. Remove the left engine damping block. 9/24/2010 .. Lower the engine and transmission SA9105E /MKM-883-1A approximately 5 cm. Important: When dismantling the end shield (1) it is essential to use KM-6155 (2) as otherwise the shaft seal ring of the central release will be damaged. • Remove the 3 bolts (1)..Document ID: 2010078 Page 2 of 5 6.do?docSyskey=2010078&pubCellSyskey=171325&pub. 8. http://localhost:9001/si/showDoc. 9. Remove the end shield cover. Remove the front left wheel. Important: Do not damage the wiring harnesses and attaching parts. • Remove from the left engine damping block bracket.

.Document ID: 2010078 Page 3 of 5 Important: Be careful of the guide sleeves. 11.. Install a new end shield gasket to the transmission with roller bearing grease. are correctly seated.do?docSyskey=2010078&pubCellSyskey=171325&pub. Install the end shield (4). • Use new bolts. Check all parts for damage. Remove the 4 bolts (arrows). Clean the sealing surfaces. Carefully insert the end shield into the transmission housing. Important: • Check that the magnet (1) and friction washer (2). Installation Procedure 1. 12. Notice: Refer to Fastener Notice in the Preface section. Screw the KM-6155 into the threaded bores. http://localhost:9001/si/showDoc. Remove the end shield. Important: Replace damaged components. 10. 2. 13. magnet (3) and spacer washer (4) for axle reverse idler gear. 9/24/2010 .

Install the left front wheel. 7.. Refer to Front Frame Replacement . • Attach to the left support for engine damping block. 6.. Lift the engine and transmission with SA9105E /MKM-883-1A. Tighten Tighten the left front wheel to 110 N·m (81 lb ft). Install the end shield cover. Install the front frame. 9/24/2010 . 5.do?docSyskey=2010078&pubCellSyskey=171325&pub.Document ID: 2010078 Page 4 of 5 Tighten Tighten the 4 new bolts to 22 N·m (16 lb ft). 3. Tighten Tighten the 3 bolts to 55 N·m (41 lb ft). http://localhost:9001/si/showDoc. Remove KM-6155 (3) 4. Install the left engine damping block. 8.

.. Attach the gearbox cover to the transmission. 14. Install the batter tray. Install the reversing lamp switch. Install the upper engine cover. http://localhost:9001/si/showDoc. • Connect the wiring harness plug for the reversing lamp switch. Tighten Tighten to 7 N·m (62 lb in). 13. 11. 12. 9/24/2010 .do?docSyskey=2010078&pubCellSyskey=171325&pub. Inspect the transmission fluid level. refer to Control Module References . • Using new seal ring.Document ID: 2010078 Page 5 of 5 9. Refer to Front Wheel Drive Shaft Seal Replacement . Tighten Tighten the reversing lamp switch to 20 N·m (15 lb ft). For reprogramming procedures. Refer to Battery Tray Replacement . if present. 10.

9/24/2010 .On Vehicle | Document ID: 2010079 Rear Shield Cover Gasket Replacement Removal Procedure Important: Place collecting pan underneath--transmission fluid will escape. Remove sealant residues. Clean sealing surfaces. Important: If necessary. Important: Replace damaged components. 2.. All rights reserved. 6. Installation Procedure © 2010 General Motors Corporation. remove the end shield cover seal. Remove the end shield cover. Remove the 9 bolts.Document ID: 2010079 Page 1 of 2 2008 Saturn Astra | Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission .do?docSyskey=2010079&pubCellSyskey=171326&pub. release the end shield cover by striking it gently with a rubber mallet. 4. 3. Inspect all the components for damage. Only for metal cover with separate seal. http://localhost:9001/si/showDoc.F17-5 | Repair Instructions . 5.. 1.

1. Only for metal cover with separate seal. For plastic cover with integral seal. 3. 4. attach a new end shield cover. Notice: Refer to Fastener Notice in the Preface section. 2. http://localhost:9001/si/showDoc. Inspect transmission fluid level. Tighten • Tighten the 4 bolts M7 to 15 N·m (11 lb ft)... Tighten • Tighten the 4 bolts M6 to 8 N·m (70 lb in).Document ID: 2010079 Page 2 of 2 Important: Note close tolerance bolts. • Tighten the 5 bolts M8 to 20 N·m (15 lb ft).do?docSyskey=2010079&pubCellSyskey=171326&pub. Install the end shield cover to transmission housing with a new gasket. 9/24/2010 . Refer to Front Wheel Drive Shaft Seal Replacement . attach the end shield cover seal. • Tighten the 5 bolts M8 to 20 N·m (15 lb ft).

9/24/2010 . Installation Procedure Notice: Refer to Fastener Notice in the Preface section. © 2010 General Motors Corporation. All rights reserved.do?docSyskey=1988929&pubCellSyskey=167699&pub.On Vehicle | Document ID: 1988929 Backup Lamp Switch Replacement Removal Procedure Remove the backup lamp switch (1)..F17-5 | Repair Instructions . http://localhost:9001/si/showDoc. • Remove the backup lamp switch.. • Disconnect the wiring harness plug from the backup lamp switch.Document ID: 1988929 Page 1 of 2 2008 Saturn Astra | Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission .

. • Tighten the backup lamp switch (1).. 1. Tighten Tighten to 20 N·m (15 lb ft).Document ID: 1988929 Page 2 of 2 Important: Use a new seal ring. http://localhost:9001/si/showDoc. Install the backup lamp switch.do?docSyskey=1988929&pubCellSyskey=167699&pub. Refer to Transmission Fluid Check . 9/24/2010 . 2. Inspect the transmission fluid level. • Connect the wiring harness plug to the backup lamp switch.

Document ID: 1987437 Page 1 of 15 2008 Saturn Astra | Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission .On Vehicle | Document ID: 1987437 Transmission Replacement (Transmission Only) Special Tools • KM-569-A Plug Remover • KM-6001-A Engine Mount • MKM-883-1 Engine Bridge • DT-47648 Transmission Holder • KM-904 Base Frame Removal Procedure Important: If the transmission is replaced..do?docSyskey=1987437&pubCellSyskey=167702&pub. All rights reserved. 9/24/2010 . Place a drain pan underneath. 3.F17-5 | Repair Instructions . Connection piece for clutch actuation. http://localhost:9001/si/showDoc. Refer to Battery Tray Replacement 2. Shift Bowden cable bracket. • Remove the clutch pressure hose. 4. the following parts must be transferred: 1. 1. Engine damping block bracket. • Open the retaining clamp (3).. 2. Remove the clutch pressure hose (4) from the connection piece (2). backup lamp switch (1). Disconnect the wiring harness plug. Remove the battery tray. • Close the retaining clamp. 3. © 2010 General Motors Corporation.

6. Remove the 4 bolts (arrows). • Press in the retaining spring (arrow) of the hollow pin. Notice: Refer to Fastener Notice in the Preface section. • Lever out roll pin with KM-569-A .Document ID: 1987437 Page 2 of 15 5. 9/24/2010 . Release the transmission at the top.. Remove the selector lever link (1) from the transmission cover (2).do?docSyskey=1987437&pubCellSyskey=167702&pub.. http://localhost:9001/si/showDoc.

. Important: Two journals (2) and (5) must sit flush in the guide holes of the front frame. Attach KM-6001-A to the front frame. • Adjust the front support bearing (4) until in contact with the guide pin of the front engine damping block. http://localhost:9001/si/showDoc.. Important: The guide pins must sit in the support bearings with no play. • Remove the 2 bolts (arrows) for the adjustment rails on KM-6001-A (1). Tighten Tighten the 2 bolts for the adjustment rails.do?docSyskey=1987437&pubCellSyskey=167702&pub. 9/24/2010 . • Insert KM-6001-A as shown.Document ID: 1987437 Page 3 of 15 7. Important: The guide pins must sit in the support bearings with no play.

8. 9. 11. Remove the 2 axle shafts from the transmission. 9/24/2010 . Remove the 3 bolts (1).. Refer to Front Frame Replacement . Remove the transmission from the left engine damping block. 10. Refer to Wheel Drive Shaft Replacement . • Seal the 2 openings for the 2 axle shafts with a plug. Use MKM-883-1 . Important: Axle shafts remain in the wheel hubs. http://localhost:9001/si/showDoc.. Remove the front frame. • Attach the axle shafts to the vehicle underbody.do?docSyskey=1987437&pubCellSyskey=167702&pub. Lower the engine and transmission on the left-hand side.Document ID: 1987437 Page 4 of 15 • Adjust the rear support bearing (3) until in contact with the guide pin of the rear engine damping block bracket. Important: Do not damage wiring harnesses and attaching parts.

Remove the rear engine damping block bracket. Remove the 3 bolts (2). http://localhost:9001/si/showDoc.. Remove the 2 bolts (1). Remove the front engine damping block bracket.Document ID: 1987437 Page 5 of 15 12. 9/24/2010 .do?docSyskey=1987437&pubCellSyskey=167702&pub. 13..

DT-47648 (2) • Position on Base Plate-14 • Designation-Transmission housing support 14.Document ID: 1987437 Page 6 of 15 14.3.. 9/24/2010 . DT-47648 (1) • Position on Base Plate-A • Designation-Support with rear transmission swivel arm 14. DT-47648 (4) • Position on Base Plate-2 • Designation-Clutch housing support 14.2.do?docSyskey=1987437&pubCellSyskey=167702&pub. DT-47648 (3) • Position on Base Plate-F • Designation-Support with rear transmission swivel arm http://localhost:9001/si/showDoc.. Place the transmission holder DT-47648 on KM-904 and pre-install as shown in the illustration: 14.1.4.

15.Document ID: 1987437 Page 7 of 15 Important: It is essential to follow the manufacturer's instructions for transmission holder DT-47648 . http://localhost:9001/si/showDoc. • Tighten the bolt connections of the supports • Attach the swivel arm (1) and (2) to the transmission. Adjust the supports using the spindles until they are as low as possible.. Attach the transmission holder DT-47648 to the transmission. slacken all bolt connections of the swivel arms and supports as far as the base plate.. • Place the transmission holder DT-47648 with supports in position under the transmission. Important: Before placing in position.do?docSyskey=1987437&pubCellSyskey=167702&pub. 9/24/2010 .

16. Important: Note differing bolt lengths.do?docSyskey=1987437&pubCellSyskey=167702&pub. http://localhost:9001/si/showDoc.Document ID: 1987437 Page 8 of 15 Important: Align the swivel arms so that as little leverage as possible is created. • Remove the 3 bolts (1) and (3). transmission to cylinder block. • Remove the 3 bolts (2). • Tighten the bolt connections of the swivel arms starting from the transmission and going as far as the base plate Important: Do not damage attaching parts when putting the transmission down.. transmission to oil pan. Important: Do not damage attaching parts.. Remove the transmission. 9/24/2010 .

• Carefully lower the transmission with the hydraulic jack and extend the hydraulic jack. Installation Procedure Notice: Refer to Fastener Notice in the Preface section.Document ID: 1987437 Page 9 of 15 • Pry the transmission away from the engine. • Place the transmission so that it is in even contact with the engine.do?docSyskey=1987437&pubCellSyskey=167702&pub. Install the transmission with DT-47648 • Raise the transmission and align it. 17. 2. Important: Ensure that no cables and brackets get trapped between the transmission and engine. http://localhost:9001/si/showDoc. 9/24/2010 . With the aid of an assistant. • Remove the 2 bolts.. remove the transmission from DT-47648 . 1.. attach the transmission to DT-47648 . Important: Ensure it is seated perfectly. • Put the transmission down carefully. Tighten the 2 bolts. With the aid of an assistant.

do?docSyskey=1987437&pubCellSyskey=167702&pub. Raise the engine and transmission on the left hand side. Remove the transmission holder DT-47648 from the transmission. Important: Do not damage wiring harnesses and attaching parts. http://localhost:9001/si/showDoc.. Install the transmission. 9/24/2010 . • Tighten the 2 transmission to oil pan bolts (2) to 40 N·m (30 lb ft) . Raise with MKM-883-1 . Tighten • Tighten the 3 transmission to cylinder block bolts (1) and (3) to 60 N·m (44 lb ft) . • Remove the 2 bolts.Document ID: 1987437 Page 10 of 15 3. 4.. • Lower and extend the hydraulic jack. Install the wiring harness bracket with the front bolt. 5.

.. 9/24/2010 . 6.Document ID: 1987437 Page 11 of 15 Important: Do not tighten bolts yet. Tighten Tighten the 3 bolts (1) to 80 N·m (59 lb ft).do?docSyskey=1987437&pubCellSyskey=167702&pub. http://localhost:9001/si/showDoc. Attach the transmission to left hand engine damping block.

. http://localhost:9001/si/showDoc. 8. Install the front engine damping block bracket. 9/24/2010 . Install the 2 axle shafts to the transmission. Tighten Tighten the 3 bolts (2) to 80 N·m (59 lb ft). Important: Do not detach MKM-883-1 yet.do?docSyskey=1987437&pubCellSyskey=167702&pub. Install the rear engine damping block bracket.. Refer to Wheel Drive Shaft Replacement . 9.Document ID: 1987437 Page 12 of 15 7. Tighten Tighten the 2 bolts (1) to 80 N·m (59 lb ft).

do?docSyskey=1987437&pubCellSyskey=167702&pub. Tighten Tighten the 4 bolts (arrows) to 60 N·m (44 lb ft). Remove KM-6001-A from the front frame. 13. 9/24/2010 . Refer to Front Frame Replacement .. Install the front frame. Attach the transmission to left hand engine damping block. Fasten the transmission at the top. Tighten Tighten the 3 bolts (1) to 55 N·m (41 lb ft). 11. http://localhost:9001/si/showDoc.. 12.Document ID: 1987437 Page 13 of 15 10.

http://localhost:9001/si/showDoc. Insert a new roll pin (arrow)... 15. Attach the clutch pressure hose (3) to the connection piece (2).do?docSyskey=1987437&pubCellSyskey=167702&pub. 16. Important: The clutch pressure hose must audibly engage. Attach the selector lever link (1) to the transmission cover (2). • Coat the roll pin with grease. 9/24/2010 .Document ID: 1987437 Page 14 of 15 14. Connect the wiring harness plug for the reversing lamp switch (1). • Depress the roll pin until retaining spring engages.

For reprogramming procedures. 9/24/2010 . http://localhost:9001/si/showDoc. . Refer to Selector Lever Link Adjustment . 18.Document ID: 1987437 Page 15 of 15 17. Refer to Transmission Fluid Check . Refer to Battery Tray Replacement .do?docSyskey=1987437&pubCellSyskey=167702&pub. 21.. Adjust the transmission selector lever link. refer to Control Module References . 19. 20. Bleed the hydraulic clutch actuation. Refer to Hydraulic Clutch Bleeding . Install the battery tray. Inspect for correct transmission fluid level..

9/24/2010 . © 2010 General Motors Corporation. Remove the coolant return hose. throttle valve pre-heating (1) from the coolant surge tank. 1.do?docSyskey=2003248&pubCellSyskey=167702&pub. • Unclip from the bracket.Document ID: 2003248 Page 1 of 20 2008 Saturn Astra | Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission . All rights reserved.. http://localhost:9001/si/showDoc.F17-5 | Repair Instructions .On Vehicle | Document ID: 2003248 Transmission Replacement (Engine and Transmission) Special Tools • KM-313 Sliding Hammer • OTC 1726 / KM-412-31-1/KM-412-31-2 Engine Overhaul Stand • KM-460-B Axle Shaft Remover • KM-6003 Remover • KM-6349 Fixing Rod Removal Procedure Important: Engine with manual transmission removed.. • Release the clamp.

9/24/2010 .Document ID: 2003248 Page 2 of 20 2. • Unclip from the bracket.. 4. • Release the clamp. Release the clamp. Remove the upper radiator hose (1) from the thermostat (2). 3.. Remove the lower radiator hose from the coolant pump. Remove the bolt (2). http://localhost:9001/si/showDoc. Remove the refrigerant lines (1) from the air conditioning (A/C) compressor.do?docSyskey=2003248&pubCellSyskey=167702&pub.

9/24/2010 . • Temperature sensor. Disconnect the 3 wiring harness plugs. radiator (3) http://localhost:9001/si/showDoc..Document ID: 2003248 Page 3 of 20 5.do?docSyskey=2003248&pubCellSyskey=167702&pub.. • Compressor (1) • Manometric switch. condenser (2) • Disconnect the wiring harness.

7. • Seal the opening in differential with the sealing plug. Remove the right-hand axle body. • Remove the axle body with KM-460-B (1) from the differential gear. Place the collecting basin underneath.. 8. Remove the radiator (1).do?docSyskey=2003248&pubCellSyskey=167702&pub.. http://localhost:9001/si/showDoc.Document ID: 2003248 Page 4 of 20 6. 9/24/2010 . Remove from the lower radiator brackets.

http://localhost:9001/si/showDoc... 9/24/2010 . • Seal the opening in the differential with the sealing plug.Document ID: 2003248 Page 5 of 20 9.do?docSyskey=2003248&pubCellSyskey=167702&pub. Remove the left-hand axle body. • Remove the axle body with KM-313 and KM-6003 (1) from the differential gear.

11.Document ID: 2003248 Page 6 of 20 10. • Disconnect the wiring harness connector. • Remove the bolt (1).. • Apply tension to the ribbed V-belt tensioner in the direction of the arrow at the projection (1) and lock with KM-6349 (2). • Remove the ribbed-V-belt. Remove the ribbed V-belt. • Remove the oil dipstick guide tube upward.. Remove the wiring harness plug of the catalytic converter control oxygen sensor.do?docSyskey=2003248&pubCellSyskey=167702&pub. 12. Remove the oil dipstick guide tube (2). • Unclip from the bracket. http://localhost:9001/si/showDoc. 9/24/2010 .

Remove the 3 bolts. Remove the exhaust manifold heat shield. 3). Remove the bracket for the catalytic converter (1) from the cylinder block.do?docSyskey=2003248&pubCellSyskey=167702&pub. Remove the 2 bolts (2. 14.. 9/24/2010 . http://localhost:9001/si/showDoc..Document ID: 2003248 Page 7 of 20 13.

. Remove the 9 nuts (1).do?docSyskey=2003248&pubCellSyskey=167702&pub. Remove the exhaust manifold. 16.Document ID: 2003248 Page 8 of 20 15. 9/24/2010 . Remove the 3 bolts (1). Remove the compressor. http://localhost:9001/si/showDoc..

http://localhost:9001/si/showDoc. • Release the coolant pipe (1) and push into the oil filter housing. • Remove the bolt (2). 18.do?docSyskey=2003248&pubCellSyskey=167702&pub. Remove the coolant pipe (1) from the coolant pump. • Push the coolant pipe into the oil filter housing. • Remove the 2 bolts (2).Document ID: 2003248 Page 9 of 20 17. • Remove the 2 bolts (2).. 9/24/2010 .. Remove the oil filter housing (3). 19. Remove the coolant pipe (1) between the thermostat housing and the oil filter housing. • Draw out of the oil filter housing.

.Document ID: 2003248 Page 10 of 20 • Remove the 4 bolts (4). • Disconnect the wiring harness plug of the catalytic converter control oxygen sensor. http://localhost:9001/si/showDoc.. • Remove the 2 bolts (3).do?docSyskey=2003248&pubCellSyskey=167702&pub. 9/24/2010 . 20. Remove the intake manifold support (2). • Unclip the wiring harness plug (1) from the bracket.

Remove the 2 nuts (1. http://localhost:9001/si/showDoc. 9/24/2010 . Disconnect the generator from the power supply.Document ID: 2003248 Page 11 of 20 21.. Remove the generator.. 4). 22.do?docSyskey=2003248&pubCellSyskey=167702&pub. Remove the 2 bolts (3. 2).

Remove the nut. Remove the 2 nuts. 24. 9/24/2010 . Remove the 2 positive cables (2) from the starter.. Remove the negative cable (1) from the starter..Document ID: 2003248 Page 12 of 20 23.do?docSyskey=2003248&pubCellSyskey=167702&pub. http://localhost:9001/si/showDoc.

.Document ID: 2003248 Page 13 of 20 25. • Unclip the wiring harness plug for the oxygen sensor of the catalytic converter control from the bracket. 26. Tighten the 3 bolts (2) http://localhost:9001/si/showDoc. 9/24/2010 .do?docSyskey=2003248&pubCellSyskey=167702&pub. 2).. Remove the starter. Attach OTC 1726 (1). • Remove the 2 bolts (1.

28. Attach the engine up to the workshop crane.do?docSyskey=2003248&pubCellSyskey=167702&pub.. http://localhost:9001/si/showDoc. Install OTC 1726 (1). Install the holding ropes to the engine transport shackles. Tighten the 3 bolts..Document ID: 2003248 Page 14 of 20 27. 9/24/2010 .

31.Document ID: 2003248 Page 15 of 20 29.do?docSyskey=2003248&pubCellSyskey=167702&pub. Remove the screwed connection (1).. 32. Remove the holding ropes from the engine transport shackles.. Lift the motor away from the front frame. Remove the front engine damping block. http://localhost:9001/si/showDoc. Install the engine on the engine overhaul stand OTC 1726 . 30. Remove the rear engine damping block. Remove the screwed connection (2). 9/24/2010 .

Notice: Refer to Fastener Notice in the Preface section. Remove the transmission (1) from the engine. • Install the transmission to the cylinder block. 34. 9/24/2010 . • Install the holding ropes. Remove 8 bolts. 33. • Attach the transmission up to the workshop crane. • Install the transmission to the engine. • Remove the bolt. Remove the transmission. • Attach the transmission up to the workshop crane. Important: Ensure that the attached parts and the wiring harnesses are undamaged.do?docSyskey=2003248&pubCellSyskey=167702&pub. • Disconnect the workshop crane. Installation Procedure 1. Install the transmission.Document ID: 2003248 Page 16 of 20 Important: One bolt remains as a retaining device. Install the transmission to the engine. • Remove the holding ropes. • Install the bolt... http://localhost:9001/si/showDoc. 2.

Remove the engine from the engine overhaul stand OTC 1726 .do?docSyskey=2003248&pubCellSyskey=167702&pub. 12. Install the rear engine damping block. 11. Tighten Tighten the screwed joint to 55 N·m (40 lb ft). • Install the ground cable. Raise the engine carefully. 5. Fit the starter. 13. front frame. Install the starter wiring harness. Tighten Tighten the screwed joint to 55 N·m (40 lb ft). Remove the 6 bolts.. Clip in the wiring harness plug for the oxygen sensor of the catalytic converter control to bracket. 9/24/2010 . 8. Tighten Tighten the 2 bolts to 35 N·m (26 lb ft). Tighten Tighten the 2 bolts to 25 N·m (18 lb ft). 9. Use new nuts. Tighten Tighten the 3 bolts to 40 N·m (30 lb ft). 4. Remove OTC 1726 and OTC 1726 from the cylinder block. Tighten Tighten the 2 nuts to 12.5 N·m (110 lb in). 6. • Install the transmission to the oil pan. Use new nuts.. Hitch the engine up to the workshop crane. 7. Install holding ropes to the engine transport shackles. Install the generator. 10.Document ID: 2003248 Page 17 of 20 Tighten Tighten the 4 bolts to 60 N·m (44 lb ft). 3. Install the front engine damping block to the front frame. Tighten http://localhost:9001/si/showDoc.

Tighten Tighten the 2 bolts to 8 N·m (70 lb in). Install the oil filter adapter. 22. Tighten Tighten the 2 bolts to 8 N·m (70 lb in). Tighten Tighten the bolt to 25 N·m (18 lb ft). Tighten Tighten the 4 bolts to 25 N·m (18 lb ft).. Connect the alternator wiring harness. • Install the 2 coolant pipes in the oil filter adapter. • Replace the 2 gaskets. 18. Install the intake manifold bracket. 20. • Connect the wiring harness plug into the bracket. • Install the coolant pipe to the oil filter adapter. http://localhost:9001/si/showDoc. Install the coolant pipe to the coolant module. • Clip in 2x. • Push into the oil filter housing. • Connect to the thermostat housing. 14. • Remove the 2 coolant pipes from the oil filter adapter. 9/24/2010 . oil filter housing to the thermostat housing. Tighten Tighten the 2 bolts to 25 N·m(18 lb ft) . • Install 3 new gaskets. Remove the coolant pipe. 15. Install the coolant pipe to the coolant module. Tighten Tighten the 2 nuts to 7 N·m (67 lb in). • O-rings with white silicone grease 19. 16. 21.. Install the compressor. • Connect the wiring harness plug for the catalytic converter control oxygen sensor. • Draw the coolant pipe out of the oil filter adapter.do?docSyskey=2003248&pubCellSyskey=167702&pub. Draw the coolant pipe out of the oil pump housing. Clean the sealing surface. Replace the 4 coolant pipe seal rings.Document ID: 2003248 Page 18 of 20 Tighten the nut to 5 N·m (44 lb in). 17.

• Use a new gasket.. • Install the wiring harness plug.. 9/24/2010 . • Install the bracket to the cylinder block. Install the heat shield. Tighten Tighten the 9 new nuts to 20 N·m (15 lb ft). • Insert the guide tube into the oil pan.Document ID: 2003248 Page 19 of 20 Tighten Tighten the 3 bolts to 22 N·m (16 lb ft). Tighten Tighten the 2 bolts to 20 N·m (15 lb ft). 25. Tighten Tighten the bolt to 8 N·m (70 lb in). Tighten Tighten the 3 bolts to 8 N·m (70 lb in). http://localhost:9001/si/showDoc. 27. 26. 23. 24. Install the dipstick guide tube. Install the exhaust manifold with the catalytic converter. Clean the sealing surface.do?docSyskey=2003248&pubCellSyskey=167702&pub. Important: Be careful of the wiring harness bracket. • Clip in. • Use a new gasket. Install the wiring harness plug of the catalytic converter control oxygen sensor.

Tighten Tighten the bolt to 20 N·m (15 lb ft). http://localhost:9001/si/showDoc. Install the refrigerant line to the compressor. • Push the axle body into the transmission until the circlip engages. Install the coolant return hose. 35. • Attach the new circlip (1) to the axle body. • Lubricate the teeth and the bearing points with engine oil. • Clip into the bracket. 33. 30. • Fasten the clamp. throttle valve pre-heating to coolant surge tank.do?docSyskey=2003248&pubCellSyskey=167702&pub. 29. Install the left-hand axle body. • Push the axle body into the transmission until the circlip engages. 36. • Fasten the clamp. Install the lower radiator hose to the radiator. 34. Use a new gasket. Install the upper radiator hose to the thermostat. 32. • Attach the new circlip to the front frame. Install the right-hand axle body. Fasten the clamp. Inspect and correct the transmission fluid level. 9/24/2010 . Refer to Front Wheel Drive Shaft Seal Replacement . • Lubricate the teeth and the bearing points with engine oil. • Temperature sensor. • Clip into the bracket. condenser • Install the wiring harness. radiator • Compressor • Manometric switch.Document ID: 2003248 Page 20 of 20 28.. 31. Connect the 3 wiring harness plugs.. Place the cooling module in position.