Cavalier, Sunfire 2001-2005

Transaxle Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the windshield washer fluid reservoir.
  4.  
  5. Raise the engine enough to take pressure off of the transaxle mounts.
  6.  
  7. Install an engine support fixture and raise the engine enough to take the pressure off the transaxle mounts.
  8.  
  9. Remove or disconnect the following:

    Battery
     
    Air cleaner and duct assembly
     

  10.  
  11. Drain the cooling system and disconnect the upper radiator hose.

    Wiring harness from the upper transmission mount bracket
     
    Upper transaxle mount-to-transaxle bolts
     
    Negative battery cable from the transmission
     
    Starter motor
     
    Pressure line from the clutch actuator cylinder
     
    Back-up light switch connector
     
    Rear transmission mount bolts
     
    Vehicle Speed Sensor (VSS) electrical connector
     
    Upper transmission mounting bolts
     
    Shift cables
     
    Cable bracket
     
    Rack and pinion mounting bolts
     
    Front wheels
     
    Splash shields
     
    Engine strut
     
    Front exhaust pipe
     
    Both front Anti-lock Brake System (ABS) wheel speed sensor harness
     
    Intermediate steering shaft
     
    Ball joints from the steering knuckles
     
    Tie rod ends from the steering knuckles
     
    Brake lines from the support frame
     
    Power steering hoses from the rack and pinion
     

  12.  
  13. Support the suspension crossmember.
  14.  
  15. Remove or disconnect the following:

    Left side suspension support bolts
     
    Flywheel cover
     
    Halfshafts from the transaxle
     
    Front lower transaxle mount
     

  16.  
  17. Position a suitable jack under the transaxle.
  18.  
  19. Remove or disconnect the following:

    Transaxle-to-engine mounting bolts (noting their location)
     
    Transaxle from the engine
     

  20.  

To install:

  1. Install or connect the following:

    Transaxle
     
    Transaxle-to-engine mounting bolts. Torque the bolts to 55 ft. lbs. (75 Nm).
     
    Front transaxle mount. Torque the bolt to 44 ft. lbs. (60 Nm).
     
    Flywheel cover
     
    Halfshafts into the transaxle
     
    Suspension support. Torque the bolts to 81 ft. lbs. (110 Nm).
     
    Power steering hoses to the rack and pinion
     
    Brake lines to the support frame
     
    Ball joints to the steering knuckle. Torque the nuts to 48 ft. lbs. (65 Nm).
     
    Tie rod ends to the steering knuckles. Torque the nuts to 33 ft. lbs. (45 Nm).
     
    Intermediate steering shaft. Torque the pinch bolt to 12 ft. lbs. (17 Nm).
     
    ABS wheel speed sensor wiring harness connectors
     
    Front exhaust pipe. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Engine strut. Torque the bolts to 74 ft. lbs. (100 Nm) plus an additional turn of 90 degrees.
     
    Inner splash shield
     
    Front wheels
     
    Rack and pinion mounting bolts. Torque the bolts to 89 ft. lbs. (120 Nm).
     
    Starter motor. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Upper transaxle bolts. Torque the bolts to 71 ft. lbs. (96 Nm).
     
    Pressure line to clutch actuator cylinder
     
    VSS electrical connector
     
    Back-up light switch connector
     
    Rear transaxle mount. Torque the bolts to 55 ft. lbs. (75 Nm).
     
    Wiring harness to the mount bracket
     

  2.  
  3. Remove the engine support fixture.
  4.  
  5. Install or connect the following:

    Shift cable clamp. Torque the nut to 89 inch lbs. (10 Nm).
     
    Shift cables
     
    Negative battery cable to the transmission
     
    Air cleaner and duct assembly to the throttle body
     
    Upper radiator hose
     
    Battery
     

  6.  
  7. Refill the transaxle and cooling system.
  8.  
  9. Refill and bleed the clutch hydraulic system.
  10.  
  11. Road test the vehicle and verify proper operation.
  12.  

 
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