Cavalier, Sunfire 2001-2005

Transaxle Removal & Installation

Print

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable
  4.  
  5. Disconnect the air duct hose from the intake plenum.
  6.  
  7. Install an engine support fixture.
  8.  
  9. Disconnect the wiring harness from the transaxle and the PNP switch.
  10.  
  11. Remove the upper transmission-to-engine bolts and the stud.
  12.  
  13. Remove the front wheels.
  14.  
  15. Remove the left front splash shield.
  16.  
  17. Disconnect the engine strut from the lower engine mount strut bracket.
  18.  
  19. Remove the wiring harness from the retaining clips.
  20.  
  21. Remove the steering gear mounting bolts and secure the steering gear using mechanics wire.
  22.  
  23. Disconnect the wheel speed sensor wires from the both front wheels and from the frame.
  24.  
  25. Separate the ball joints from the steering knuckles
  26.  
  27. Remove the front exhaust pipe.
  28.  
  29. Disconnect both front Anti-lock Brake System (ABS) wheel speed sensors and harness from left suspension support
  30.  
  31. Disconnect both lower ball joints.
  32.  
  33. Remove the tie rods from the steering knuckles.
  34.  
  35. On vehicles with a brake line running along the support frame, remove the brake pipe from the retainers.
  36.  
  37. Remove the front suspension support brace.
  38.  
  39. Lower the vehicle until the front suspension crossmember rests on jackstands.
  40.  
  41. Remove the front suspension crossmember mounting bolts.
  42.  
  43. Raise the vehicle off of the front suspension crossmember.
  44.  
  45. Remove the lower control arms
  46.  
  47. Remove the 2 bolts from the transmission brace.
  48.  
  49. Disconnect the shift cable from the shift linkage.
  50.  
  51. Disconnect the cable from the bracket.
  52.  
  53. Remove the flywheel inspection cover.
  54.  
  55. Remove the starter.
  56.  
  57. Matchmark the position of the flywheel in relation to the torque converter for assembly purposes.
  58.  
  59. Remove the torque converter-to-flywheel bolts.
  60.  
  61. Remove the transmission cooler lines by first removing the nut holding the bracket to the transaxle case.
  62.  
  63. Disconnect the VSS wiring harness from the sensor.
  64.  
  65. Disconnect the halfshafts from the transaxle.
  66.  
  67. Remove the body-to-transmission mount bolts.
  68.  
  69. Lower the transmission and engine with the engine support fixture enough to remove the transmission.
  70.  
  71. Raise the vehicle.
  72.  
  73. Remove the transmission oil pan, drain the fluid from the transmission and reinstall the pan.
  74.  
  75. Support the transmission with a suitable jack.
  76.  
  77. Remove the transaxle-to-engine nut.
  78.  
  79. Separate the engine and the transaxle and remove the transaxle from the vehicle.
  80.  

To install:

  1. Install the transaxle in the vehicle.
  2.  
  3. Install the lower transmission-to-engine bolts and nuts. Tighten to 66 ft. lbs. (90 Nm).
  4.  
  5. Lubricate the transaxle cooler pipes before inserting into seals. Connect the transaxle cooler pipes to the transaxle and tighten the pipes to 71 inch lbs. (8 Nm).
  6.  
  7. Install the torque converter-to-flywheel bolts and tighten to 46 ft. lbs. (62 Nm)
  8.  
  9. Install the halfshafts.
  10.  
  11. Connect the wiring harness to the VSS.
  12.  
  13. Install the starter.
  14.  
  15. Install the flywheel inspection cover bolts and tighten to 89 inch lbs. (10 Nm).
  16.  
  17. Use the engine support fixture to raise the engine and transmission assembly.
  18.  
  19. Install the transaxle mount-to-body bolts and tighten to 66 ft. lbs. (90 Nm).
  20.  
  21. Attach the wiring harness to the clips on the rail.
  22.  
  23. Install the lower control arms.
  24.  
  25. Lower the vehicle on to the front crossmember support.
  26.  
  27. Install the front suspension crossmember mounting bolts and tighten the fasteners as follows:

    Left rear outboard bolt to 71 ft. lbs. (110 Nm)
     
    Right rear outboard bolt to 71 ft. lbs. (110 Nm)
     
    Tighten the front upper bolt to 71 ft. lbs. (110 Nm)
     
    Tighten the rear inboard bolts to 71 ft. lbs. (110 Nm)
     

  28.  
  29. Install the front suspension support brace.
  30.  
  31. Install the power steering gear mounting bolts and tighten to 81 ft. lbs. (110 Nm).
  32.  
  33. On vehicles with the brake line running along the frame, install the brake pipe into the retainers.
  34.  
  35. Install the tie rods to the knuckle.
  36.  
  37. Install the ball joints to the knuckle.
  38.  
  39. Connect the ABS harness to the lower control arms.
  40.  
  41. Install the front exhaust pipe.
  42.  
  43. Install the engine strut to the lower engine mount and frame.
  44.  
  45. Connect the wheel speed sensor wiring into the clips.
  46.  
  47. Install the steering gear to the front suspension crossmember.
  48.  
  49. Install the transmission brace bolts and tighten the bolts to 53 ft. lbs. (72 Nm).
  50.  
  51. Install the left front splash shield.
  52.  
  53. Install the front wheels.
  54.  
  55. Install the upper transmission-to-engine bolts and stud and tighten 66 ft. lbs. (90 Nm.
  56.  
  57. Connect the engine wiring harness.
  58.  
  59. Remove the engine support fixture.
  60.  
  61. Connect the shift linkage to the transmission.
  62.  
  63. Connect the electrical connectors to the PNP switch and transaxle.
  64.  
  65. Connect the air duct hose to the intake plenum.
  66.  
  67. Connect the negative battery cable.
  68.  
  69. Refill the transmission with correct type and amount of fluid.
  70.  

 
label.common.footer.alt.autozoneLogo