Aveo 2004-2005

Transaxle Removal & Installation

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  1. Remove the battery and battery tray.
  2.  
  3. Drain the transaxle fluid. Remove the left and right drive axle assemblies.
  4.  
  5. Disconnect the fluid cooler inlet and outlet hoses from the transaxle.
  6.  
  7. Disconnect the shift control cable from the transaxle. Install the J 28467-B  to support the engine.
  8.  
  9. Disconnect the Input Shaft Speed (ISS) sensor electrical connector. Disconnect the output shaft speed (OSS) sensor electrical connector.
  10.  
  11. Disconnect the Park/Neutral Position (PNP) sensor electrical connector.
  12.  
  13. Disconnect the transaxle electrical connector.
  14.  
  15. Remove the service hall cover.
  16.  
  17. Remove the torque converter bolts.
  18.  
  19. Remove the damping block connection nut and bolt.
  20.  
  21. Remove the rear mounting bracket bolts and rear mounting bracket.
  22.  
  23. Remove the 3 upper transaxle mounting bracket bolts.
  24.  
  25. Remove the 3 upper transaxle-to-engine mounting bolts.
  26.  
  27. Secure the transaxle to a transaxle jack and DW 260-120.  
  28.  
  29. Remove the 7 lower transaxle-to-engine retaining bolts.
  30.  
  31. Carefully remove the transaxle from the vehicle with the transaxle secured in the DW 260-120.
  32.  

To install:

  1. Secure the transaxle to the transaxle jack, then carefully position in the vehicle with the transaxle secured in the DW 260-120.
  2.  
  3. Install the 7 lower transaxle-to-engine retaining bolts.

    Tighten the bolts to 54 ft. lbs. (73 Nm).
     
    Tighten the bolts to 23 ft. lbs. (31 Nm).
     
    Tighten the bolts to 15 ft. lbs. (21 Nm).
     

  4.  
  5. Install the 3 upper transaxle-to-engine mounting bolts. Tighten the 3 upper transaxle-to-engine mounting bolts to 54 ft. lbs. (73 Nm).
  6.  
  7. Install the 3 upper transaxle mounting bracket bolts and the bracket. Tighten the 3 upper transaxle mounting bracket bolts to 44 ft. lbs. (60 Nm).
  8.  
  9. Install the rear mounting bracket bolts and the bracket. Tighten the rear mounting bracket bolts to 44 ft. lbs. (60 Nm).
  10.  
  11. Install the damping block connection nut and bolt. Tighten the damping block connection nut and bolt to 59 ft. lbs. (80 Nm).
  12.  
  13. Install the torque converter bolts. Tighten the torque converter bolts to 33 ft. lbs. (45 Nm).
  14.  
  15. Install the service hall cover.

    Connect the transaxle electrical connector.
     
    Connect the PNP sensor electrical connector.
     
    Connect the OSS sensor electrical connector.
     
    Connect the ISS sensor electrical connector.
     

  16.  
  17. Remove the J 28467-B .
  18.  
  19. Connect the shift control cable into the transaxle.
  20.  
  21. Connect the fluid cooler inlet and outlet hose into the transaxle.
  22.  
  23. Install the left and right drive axle assemblies.
  24.  
  25. Install the battery and battery tray
  26.  
  27. Fill the transaxle with fluid.
  28.  
  29. Measure the fluid level.
  30.  

  1. Disconnect the battery cables.
  2.  
  3. Remove the battery and battery tray.
  4.  
  5. Drain the transaxle fluid. Remove the left and right drive axle assemblies.
  6.  
  7. Disconnect the fluid cooler inlet and outlet hoses from the transaxle.
  8.  
  9. Disconnect the shift control cable from the transaxle. Install the J 28467-B  to support the engine.
  10.  
  11. Disconnect the Input Shaft Speed (ISS) sensor electrical connector. Disconnect the output shaft speed (OSS) sensor electrical connector.
  12.  
  13. Disconnect the Park/Neutral Position (PNP) sensor electrical connector.
  14.  
  15. Disconnect the transaxle electrical connector.
  16.  
  17. Remove the service hall cover.
  18.  
  19. Remove the torque converter bolts.
  20.  
  21. Remove the damping block connection nut and bolt.
  22.  
  23. Remove the rear mounting bracket bolts and rear mounting bracket.
  24.  
  25. Remove the 3 upper transaxle mounting bracket bolts.
  26.  
  27. Remove the 3 upper transaxle-to-engine mounting bolts.
  28.  
  29. Secure the transaxle to a transaxle jack and DW 260-120.  
  30.  
  31. Remove the 7 lower transaxle-to-engine retaining bolts.
  32.  
  33. Carefully remove the transaxle from the vehicle with the transaxle secured in the DW 260-120.
  34.  

To install:

  1. Secure the transaxle to the transaxle jack, then carefully position in the vehicle with the transaxle secured in the DW 260-120.
  2.  
  3. Install the 7 lower transaxle-to-engine retaining bolts.

    Tighten the bolts to 54 ft. lbs. (73 Nm).
     
    Tighten the bolts to 23 ft. lbs. (31 Nm).
     
    Tighten the bolts to 15 ft. lbs. (21 Nm).
     

  4.  
  5. Install the 3 upper transaxle-to-engine mounting bolts. Tighten the 3 upper transaxle-to-engine mounting bolts to 54 ft. lbs. (73 Nm).
  6.  
  7. Install the 3 upper transaxle mounting bracket bolts and the bracket. Tighten the 3 upper transaxle mounting bracket bolts to 44 ft. lbs. (60 Nm).
  8.  
  9. Install the rear mounting bracket bolts and the bracket. Tighten the rear mounting bracket bolts to 44 ft. lbs. (60 Nm).
  10.  
  11. Install the damping block connection nut and bolt. Tighten the damping block connection nut and bolt to 59 ft. lbs. (80 Nm).
  12.  
  13. Install the torque converter bolts. Tighten the torque converter bolts to 33 ft. lbs. (45 Nm).
  14.  
  15. Install the service hall cover.

    Connect the transaxle electrical connector.
     
    Connect the PNP sensor electrical connector.
     
    Connect the OSS sensor electrical connector.
     
    Connect the ISS sensor electrical connector.
     

  16.  
  17. Remove the J 28467-B .
  18.  
  19. Connect the shift control cable into the transaxle.
  20.  
  21. Connect the fluid cooler inlet and outlet hose into the transaxle.
  22.  
  23. Install the left and right drive axle assemblies.
  24.  
  25. Install the battery and battery tray
  26.  
  27. Fill the transaxle with fluid.
  28.  
  29. Measure the fluid level.
  30.  

 
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