Aveo 2004-2005

Transaxle Removal & Installation

Print

  1. Remove the air cleaner assembly.
  2.  
  3. Remove the battery and battery tray.
  4.  
  5. Remove the shift cable pins.
  6.  
  7. Remove the washers.
  8.  
  9. Disconnect the select and the shift cable.
  10.  
  11. Remove the cable E-rings.
  12.  
  13. Disconnect the shift cables from the cable bracket.
  14.  
  15. Remove the engine wiring harness bending strap.
  16.  
  17. Remove the ground wire bolt.
  18.  
  19. Disconnect the ground wire.
  20.  
  21. Disconnect the backup lamp switch connector.
  22.  
  23. Remove the radiator lower hose bolts.
  24.  
  25. Disconnect the radiator lower hose.
  26.  
  27. Remove the Crankshaft Position (CKP) sensor bolt.
  28.  
  29. Disconnect the CKP sensor connector and remove the CKP sensor.
  30.  
  31. Disconnect the Vehicle Speed Sensor (VSS) connector.
  32.  
  33. Remove the VSS.
  34.  
  35. Remove the starter motor.
    CAUTION
    While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

  36.  
  37. Install J 28467-B.
  38.  
  39. Remove the transaxle upper exhaust manifold side bolt and the thermostat housing side bolt.
  40.  
  41. Drain the transaxle fluid.
  42.  
  43. Remove the cable adjust nut.
  44.  
  45. Disconnect the cable from the wire clip.
  46.  
  47. Disconnect the clutch cable from the transaxle mount hole .
  48.  
  49. Remove the front under longitudinal frames and stabilizer.
  50.  
  51. Remove the drive axle, only from the transaxle side.
  52.  
  53. Remove the clutch housing lower plate bolts and lower plate.
    CAUTION
    While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

  54.  
  55. Remove the front exhaust pipe nuts from the exhaust manifold side.
  56.  
  57. Remove the gasket and separate the exhaust manifold pipe.
  58.  
  59. Remove the front exhaust pipe.
  60.  
  61. Remove the 3 transaxle mounting bracket bolts.
  62.  
  63. Support the transaxle with a transaxle support jack.
  64.  
  65. Remove the damping block connection nut and bolt.
  66.  
  67. Remove the 3 rear mounting bracket bolts.
  68.  
  69. Remove the rear mounting bracket from the transaxle.
  70.  
  71. Remove the 2 rear damping block retaining bolts.
  72.  
  73. Remove the rear damping block.
  74.  
  75. Remove the transaxle lower bolts.
    NOTE
    Support the engine in the normal position when removing the transaxle. Damage to related parts can occur.

  76.  
  77. Separate the transaxle, slide the transaxle sideways from the engine block.
  78.  
  79. Lower the transaxle to remove from the vehicle.
  80.  

To install:

  1. Support the transaxle with a transaxle support jack.
  2.  
  3. Install the transaxle by inserting the transaxle input shaft into the clutch disc and sliding the transaxle sideways into the engine block.
  4.  
  5. Install the transaxle lower bolts.
  6.  
  7. Tighten the bolts to 55-65 Nm (41-48 lb ft).
  8.  
  9. Install the 2 rear damping block retaining bolts.
  10.  
  11. Tighten the bolts to 37-44 ft. lbs. (50-60 Nm).
  12.  
  13. Install the bracket, the 3 rear mounting bracket bolts, and the damping block connection nut.

    Tighten the bracket bolts to 41-48 ft. lbs. (55-65 Nm)
     
    Tighten the connection nut and bolt to 55-63 ft. lbs. (75-85 Nm)
     

  14.  
  15. Install the 3 rear transaxle mounting bracket bolts.
  16.  
  17. Tighten the bolts to 33-41 ft. lbs. (45-55 Nm).
  18.  
  19. Install the front exhaust pipe nuts.
  20.  
  21. Tighten the nuts to 18-25 ft. lbs. (25-35 Nm).
  22.  
  23. Install the clutch housing lower plate.
  24.  
  25. Install the clutch housing lower plate bolts.
  26.  
  27. Tighten the bolts to 71-106 inch lbs. (8-12 Nm).
  28.  
  29. Install the drive axle.
  30.  
  31. Install the front under longitudinal frames and stabilizer.
  32.  
  33. Install the clutch cable to the transaxle mount.
  34.  
  35. Install the cable to the wire clip.
  36.  
  37. Install the clutch cable adjusting nut.
  38.  
  39. Install the transaxle upper bolts.
  40.  
  41. Tighten the bolts to 41-48 ft. lbs. (55-65 Nm).
  42.  
  43. Install the starter motor.
  44.  
  45. Remove tool J 28467-B.
  46.  
  47. Install the VSS.
  48.  
  49. Install the VSS mounting bolt.
  50.  
  51. Tighten the bolt to 35-62 inch lbs. (4-7 Nm).
  52.  
  53. Connect the VSS connector.
  54.  
  55. Install the radiator lower hose and CKP sensor.
  56.  
  57. Tighten the connection nut and bolt to 55-63 ft. lbs. (75-85 Nm)
  58.  
  59. Tighten the sensor bolt  to 44-70 inch lbs. (5-8 Nm).
  60.  
  61. Connect the ground wire and the backup lamp switch connector.
  62.  
  63. Install the engine wiring harness bending strap.
  64.  
  65. Tighten the bolt to 7-12 ft. lbs. (10-16 Nm).
  66.  
  67. Connect the shift cables to the cable bracket.
  68.  
  69. Install the cable E-rings.
  70.  
  71. Connect the select and shift cable.
  72.  
  73. Install the washers.
  74.  
  75. Install the shift cable pins.
  76.  
  77. Install the drain plug.
  78.  
  79. Tighten the drain plug to 18-22 ft. lbs. (25-30 Nm).
  80.  
  81. Remove the oil level plug.
  82.  
  83. Fill recommended fluid to the proper level and following specifications:

    The classification is 75W-85
     
    The capacity is 2.1 liters (2.21 quarts). (GL-4)
     

  84.  
  85. Install the oil level plug.
  86.  
  87. Tighten the oil level plug to 18-22 ft. lbs. (25-30 Nm).
  88.  
  89. Adjust the clutch cable.
  90.  

D16 Manual Transaxle



  1. Remove the battery and battery tray.
  2.  
  3. Remove the shift linkage assembly.
  4.  
  5. Remove the drive axle shaft.
  6.  
  7. Disconnect the backup lamp switch electrical connector.
  8.  
  9. Disconnect the speedometer speed sensor electrical connector.
  10.  
  11. Remove the clutch release cylinder retaining bolts and the clutch release cylinder.
  12.  
  13. Remove the damping block connection nut and bolt.
  14.  
  15. Remove the 3 rear mounting bracket bolts.
  16.  
  17. Remove the rear mounting bracket from the transaxle.
  18.  
  19. Remove the 2 rear damping block retaining bolts.
  20.  
  21. Remove the rear damping block from the front cross member.
  22.  
  23. Remove the 2 cage retaining bolts.
  24.  
  25. Remove the 3 transaxle upper mounting bracket bolts.
  26.  
  27. Remove the upper mounting bracket and cage.
  28.  
  29. Remove the 3 transaxle upper retaining bolts.
  30.  
  31. Support the transaxle with a transaxle support jack.
  32.  
  33. Remove the 7 transaxle lower retaining bolts.
    WARNING
    Important: Rest the transaxle only in an upright position

  34.  
  35. Remove the transaxle.
  36.  
  37. Slide the transaxle sideways away from the engine block.
  38.  
  39. Lower the transaxle.
  40.  

To install:

Click image to see an enlarged view

Fig. Support the transaxle with a transaxle support jack

  1. Support the transaxle with a transaxle support jack.
  2.  
  3. Install the transaxle by inserting the transaxle input shaft into the clutch disc and sliding the transaxle sideways into the engine block.

    Click image to see an enlarged view

    Fig. Install the 7 transaxle lower retaining bolts

  4.  
  5. Install the 7 transaxle lower retaining bolts.

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

  6.  
  7. Install the three transaxle upper retaining bolts.
  8.  
  9. Tighten the transaxle upper retaining bolts to 54 ft. lbs. (73 Nm).
  10.  
  11. Install the cage retaining bolt and cage.
  12.  
  13. Install the three transaxle upper mounting bracket bolts and bracket.
  14.  
  15. Tighten the transaxle upper mounting bracket bolts to 44 ft. lbs. (60 Nm).
  16.  
  17. Install the 2 rear damping block retaining bolts.
  18.  
  19. Tighten the rear damping block retaining bolts to 41 ft. lbs. (55 Nm).
  20.  
  21. Install the rear damping block from the front cross member.
  22.  
  23. Install the 3 rear mounting bracket bolts and the bracket.
  24.  
  25. Tighten the rear mounting bracket bolts to 59 ft. lbs. (80 Nm).
  26.  
  27. Install the damping block connection nut and bolt.
  28.  
  29. Tighten the damping block connection nut and bolt to 59 ft. lbs. (80 Nm).
  30.  
  31. Install the clutch release cylinder retaining bolts and the clutch release cylinder.
  32.  
  33. Tighten the clutch release cylinder retaining bolts to 15 ft. lbs. (20 Nm).
  34.  
  35. Connect the speedometer speed sensor electrical connector.
  36.  
  37. Connect the backup lamp switch electrical connector.
  38.  
  39. Install the drive axle shaft.
  40.  
  41. Install the shift linkage assembly.
  42.  
  43. Install the battery and battery tray.
  44.  
  45. Inspect the fluid level.
  46.  

Y4m Manual Transaxle



  1. Remove the air cleaner assembly.
  2.  
  3. Remove the battery and battery tray.
  4.  
  5. Remove the shift cable pins.
  6.  
  7. Remove the washers.
  8.  
  9. Disconnect the select and the shift cable.
  10.  
  11. Remove the cable E-rings.
  12.  
  13. Disconnect the shift cables from the cable bracket.
  14.  
  15. Remove the engine wiring harness bending strap.
  16.  
  17. Remove the ground wire bolt.
  18.  
  19. Disconnect the ground wire.
  20.  
  21. Disconnect the backup lamp switch connector.
  22.  
  23. Remove the radiator lower hose bolts.
  24.  
  25. Disconnect the radiator lower hose.
  26.  
  27. Remove the Crankshaft Position (CKP) sensor bolt.
  28.  
  29. Disconnect the CKP sensor connector and remove the CKP sensor.
  30.  
  31. Disconnect the Vehicle Speed Sensor (VSS) connector.
  32.  
  33. Remove the VSS.
  34.  
  35. Remove the starter motor.
    CAUTION
    While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

  36.  
  37. Install J 28467-B.
  38.  
  39. Remove the transaxle upper exhaust manifold side bolt and the thermostat housing side bolt.
  40.  
  41. Drain the transaxle fluid.
  42.  
  43. Remove the cable adjust nut.
  44.  
  45. Disconnect the cable from the wire clip.
  46.  
  47. Disconnect the clutch cable from the transaxle mount hole .
  48.  
  49. Remove the front under longitudinal frames and stabilizer.
  50.  
  51. Remove the drive axle, only from the transaxle side.
  52.  
  53. Remove the clutch housing lower plate bolts and lower plate.
    CAUTION
    While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

  54.  
  55. Remove the front exhaust pipe nuts from the exhaust manifold side.
  56.  
  57. Remove the gasket and separate the exhaust manifold pipe.
  58.  
  59. Remove the front exhaust pipe.
  60.  
  61. Remove the 3 transaxle mounting bracket bolts.
  62.  
  63. Support the transaxle with a transaxle support jack.
  64.  
  65. Remove the damping block connection nut and bolt.
  66.  
  67. Remove the 3 rear mounting bracket bolts.
  68.  
  69. Remove the rear mounting bracket from the transaxle.
  70.  
  71. Remove the 2 rear damping block retaining bolts.
  72.  
  73. Remove the rear damping block.
  74.  
  75. Remove the transaxle lower bolts.
    NOTE
    Support the engine in the normal position when removing the transaxle. Damage to related parts can occur.

  76.  
  77. Remove the transaxle.
  78.  
  79. Slide the transaxle sideways from the engine block.
  80.  
  81. Lower the transaxle.
  82.  
  83. Support the transaxle with a transaxle support jack.
  84.  
  85. Install the transaxle by inserting the transaxle input shaft into the clutch disc and sliding the transaxle sideways into the engine block.
  86.  
  87. Install the transaxle lower bolts.
  88.  
  89. Tighten the bolts to 55-65 Nm (41-48 lb ft).
  90.  
  91. Install the 2 rear damping block retaining bolts.
  92.  
  93. Tighten the bolts to 37-44 ft. lbs. (50-60 Nm).
  94.  
  95. Install the bracket, the 3 rear mounting bracket bolts, and the damping block connection nut.

    Tighten the bracket bolts to 41-48 ft. lbs. (55-65 Nm)
     
    Tighten the connection nut and bolt to 55-63 ft. lbs. (75-85 Nm)
     

  96.  
  97. Install the 3 rear transaxle mounting bracket bolts.
  98.  
  99. Tighten the bolts to 33-41 ft. lbs. (45-55 Nm).
  100.  
  101. Install the front exhaust pipe nuts.
  102.  
  103. Tighten the nuts to 18-25 ft. lbs. (25-35 Nm).
  104.  
  105. Install the clutch housing lower plate.
  106.  
  107. Install the clutch housing lower plate bolts.
  108.  
  109. Tighten the bolts to 71-106 inch lbs. (8-12 Nm).
  110.  
  111. Install the drive axle.
  112.  
  113. Install the front under longitudinal frames and stabilizer.
  114.  
  115. Install the clutch cable to the transaxle mount.
  116.  
  117. Install the cable to the wire clip.
  118.  
  119. Install the clutch cable adjusting nut.
  120.  
  121. Install the transaxle upper bolts.
  122.  
  123. Tighten the bolts to 41-48 ft. lbs. (55-65 Nm).
  124.  
  125. Install the starter motor.
  126.  
  127. Remove tool J 28467-B.
  128.  
  129. Install the VSS.
  130.  
  131. Install the VSS mounting bolt.
  132.  
  133. Tighten the bolt to 35-62 inch lbs. (4-7 Nm).
  134.  
  135. Connect the VSS connector.
  136.  
  137. Install the radiator lower hose and CKP sensor.
  138.  
  139. Tighten the connection nut and bolt to 55-63 ft. lbs. (75-85 Nm)
  140.  
  141. Tighten the sensor bolt  to 44-70 inch lbs. (5-8 Nm).
  142.  
  143. Connect the ground wire and the backup lamp switch connector.
  144.  
  145. Install the engine wiring harness bending strap.
  146.  
  147. Tighten the bolt to 7-12 ft. lbs. (10-16 Nm).
  148.  
  149. Connect the shift cables to the cable bracket.
  150.  
  151. Install the cable E-rings.
  152.  
  153. Connect the select and shift cable.
  154.  
  155. Install the washers.
  156.  
  157. Install the shift cable pins.
  158.  
  159. Install the drain plug.
  160.  
  161. Tighten the drain plug to 18-22 ft. lbs. (25-30 Nm).
  162.  
  163. Remove the oil level plug.
  164.  
  165. Fill recommended fluid to the proper level and following specifications:

    The classification is 75W-85
     
    The capacity is 2.1 liters (2.21 quarts). (GL-4)
     

  166.  
  167. Install the oil level plug.
  168.  
  169. Tighten the oil level plug to 18-22 ft. lbs. (25-30 Nm).
  170.  
  171. Adjust the clutch cable.
  172.  

 
label.common.footer.alt.autozoneLogo