GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Transaxle

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REMOVAL & INSTALLATION



1982-88 Vehicles

See Figures 1, 2, 3 and 4

On 1982-84 models, whenever the transaxle mount is removed, the alignment bolt M6 x 1 x 65 must be installed in the right front engine mount to prevent powertrain misalignment

  1. Disconnect the negative battery cable.
  2.  
  3. Install tool J-28467-A or equivalent, an engine holding bar/support fixture, so that one end is supported on the cowl tray over the wiper motor and the other end rests on the radiator support. Use padding and be careful not to damage the paint or body work with the bar. Attach a lifting hook to the engine lift ring and to the bar and raise the engine enough to take the pressure off the motor mounts.
  4.  

If a lifting bar and hook is not available, a chain hoist can be used, however, during the procedure the vehicle must be raised, at which time the chain hoist must be adjusted to keep tension on the engine/transaxle assembly.

Click image to see an enlarged view

Fig. Fig. 1: Install a suitable engine support tool to take the pressure off the motor mounts



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Fig. Fig. 2: View of the transaxle mounting points - 1982-85 vehicles equipped with a 4-speed manual transaxle



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Fig. Fig. 3: The front suspension support must be attached in this sequence



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Fig. Fig. 4: Securing the front engine mount on 1982-84 vehicles

  1. Remove the heater hose clamp at the transaxle mount bracket. On 4-cylinder engines, detach the electrical connector and remove the horn assembly.
  2.  
  3. Unfasten the transaxle mount attaching bolts. Discard the bolts attaching the mount to the side frame. Note that new bolts MUST be used during installation.
  4.  
  5. On 1982-84 models, disconnect the clutch cable from the clutch release lever. On 1985-87 models, disconnect the clutch slave cylinder from the transaxle support bracket and lay aside. Remove the transaxle mount bracket attaching bolts and nuts.
  6.  
  7. On 6-cylinder engines remove the following:
    1. Remove the air intake duct from the air cleaner.
    2.  
    3. Unfasten the left fender brace.
    4.  
    5. Detach the M.A.T. sensor lead at the air cleaner.
    6.  
    7. Disconnect the mass air flow sensor lead.
    8.  
    9. Remove the PCV pipe retaining clamp from the air intake duct.
    10.  
    11. Unfasten the clamp retaining the air intake duct to the throttle body.
    12.  
    13. Remove the mass air flow sensor mounting bolt.
    14.  
    15. Unfasten the air cleaner bracket mounting bolts at the battery tray.
    16.  
    17. Remove the air cleaner, mass air flow sensor and air intake duct as an assembly.
    18.  
    19. Remove the heat shield at the crossover pipe and remove the crossover pipe.
    20.  

  8.  
  9. Disconnect the shift cables and retaining clips at the transaxle. Detach the ground cables at the transaxle mounting stud.
  10.  
  11. Unfasten the four upper transaxle-to-engine mounting bolts.
  12.  
  13. Raise the and safely support vehicle and support it on stands. Remove the left front wheel and tire assembly.
  14.  
  15. Remove the left front inner splash shield. Remove the transaxle strut and bracket.
  16.  
  17. Unfasten the clutch housing cover bolts.
  18.  
  19. Detach the speedometer cable at the transaxle.
  20.  
  21. Disconnect the stabilizer bar at the left suspension support and control arm.
  22.  
  23. Disconnect the ball joint from the steering knuckle.
  24.  
  25. Unfasten the left suspension support attaching bolts and remove the support and control arm as an assembly.
  26.  
  27. Install boot protectors and disengage the drive axles at the transaxle. Remove the left side shaft from the transaxle.
  28.  
  29. Position a jack under the transaxle case, unfasten the lower two transaxle-to-engine mounting bolts and remove the transaxle by sliding it towards the driver's side, away from the engine. Carefully lower the jack, guiding the right shaft out the transaxle.
  30.  

To install:
  1. When installing the transaxle, guide the right drive axle into its bore as the transaxle is being raised. The right drive axle CANNOT be readily installed after the transaxle is connected to the engine.
  2.  
  3. Tighten the fasteners as follows:
    1. Tighten the transaxle-to-engine mounting bolts to 55 ft. lbs. (75 Nm).
    2.  
    3. Tighten the suspension support-to-body attaching bolts to 59 ft. lbs. (80 Nm) on 1985-87 models and 65-67 ft. lbs. (88-91 Nm) on all other years.
    4.  
    5. Tighten the clutch housing cover bolts to 10 ft. lbs. (14 Nm).
    6.  
    7. Using new bolts, install and tighten the transaxle mount-to-side frame to 40 ft. lbs. (54 Nm). When installing the bolts attaching the mount-to-transaxle bracket on the 1982-84 models, check the alignment bolt at the engine mount. If excessive effort is required to remove the alignment bolt, realign the powertrain components and tighten the bolts to 40 ft. lbs. (54 Nm), and then remove the alignment bolt.
    8.  

  4.  

1989-91 Vehicles

EXCEPT ISUZU TRANSAXLE

See Figures 5 and 6

  1. Disconnect the negative battery cable.
  2.  
  3. Install an engine holding support fixture (bar), J-28467-A or equivalent.
  4.  

If a lifting bar and hook is not available, a chain hoist can be used, however, during the procedure the vehicle must be raised, at which time the chain hoist must be adjusted to keep tension on the engine/transaxle assembly.

Click image to see an enlarged view

Fig. Fig. 5: Installing a suitable engine support fixture - 3.1L engine shown

  1. Remove the left sound insulator.
  2.  
  3. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  4.  
  5. Remove the air cleaner and air intake duct assembly.
  6.  
  7. Remove the clutch actuator cylinder from the transaxle support bracket and lay it aside.
  8.  
  9. Remove the transaxle mount through-bolt.
  10.  
  11. Raise and support the vehicle safely.
  12.  
  13. Remove the exhaust crossover bolts at the right hand manifold.
  14.  
  15. Carefully lower the vehicle.
  16.  



Click image to see an enlarged view

Fig. Fig. 6: View of the engine-to-transaxle mounting - 5TM40 manual transaxle shown

  1. Disconnect the transaxle mount bracket.
  2.  
  3. Detach the shift cables and linkage.
  4.  
  5. Remove the transaxle vent tube.
  6.  
  7. Unfasten the upper transaxle to engine bolts.
  8.  
  9. Raise and support the vehicle safely.
  10.  
  11. Remove the left front tire and wheel assembly.
  12.  
  13. Remove the left front inner splash shield.
  14.  
  15. Disconnect the transaxle strut and bracket.
  16.  
  17. Drain the transaxle.
  18.  
  19. Unfasten the clutch housing cover bolts.
  20.  
  21. Detach the speedometer cable.
  22.  
  23. Disconnect the stabilizer shaft at the left suspension support and control arm.
  24.  
  25. Remove the left suspension support attaching bolts and swing the suspension support aside.
  26.  
  27. Install drive axle boot protector J-34754 or equivalent and remove the left drive axle from the transaxle.
  28.  
  29. Attach the transaxle case to a jack.
  30.  
  31. Unfasten the remaining transaxle to engine bolts.
  32.  
  33. Remove the transaxle by sliding it away from the engine and carefully lowering the jack while guiding the intermediate shaft out of the transaxle.
  34.  

The engine may need to be lowered for transaxle-to-body clearance.

To install:
  1. Reposition the transaxle and guide the intermediate shaft into the transaxle.
  2.  

The intermediate shaft cannot be easily installed after the transaxle is connected to the engine.

  1. Install the transaxle to engine mounting bolts to 55 ft. lbs (75 Nm).
  2.  
  3. Install the left drive axle into its bore at the transaxle and seat the driveaxle at the transaxle.
  4.  
  5. Remove the drive axle boot protector.
  6.  
  7. Fasten the suspension support to body bolts and tighten to 65 ft. lbs. (88 Nm).
  8.  
  9. Install the stabilizer shaft at the left suspension support and control arm.
  10.  
  11. Attach the speedometer cable.
  12.  
  13. Install the clutch/flywheel housing cover bolts and tighten to 115 inch lbs. (13 Nm).
  14.  
  15. Fasten the strut bracket to the transaxle.
  16.  
  17. Install the strut.
  18.  
  19. Attach the inner splash shield.
  20.  
  21. Install the wheel and tire assembly and tighten the wheel nuts to 100 ft. lbs. (136 Nm).
  22.  
  23. Carefully lower the vehicle.
  24.  
  25. Install the upper engine to transaxle bolts and tighten to 55 ft. lbs. (75 Nm).
  26.  
  27. Install the transaxle vent tube.
  28.  
  29. Attach the shift cables.
  30.  
  31. Install the transaxle mount bracket.
  32.  
  33. Fasten the left exhaust crossover bolts.
  34.  
  35. Raise and support the vehicle safely.
  36.  
  37. Install the exhaust crossover bolts at the right hand manifold.
  38.  
  39. Carefully lower the vehicle.
  40.  
  41. Install the transaxle mount through-bolt.
  42.  
  43. Install the clutch actuator cylinder to the transaxle support bracket.
  44.  
  45. Install the air cleaner and air intake duct assembly.
  46.  
  47. Remove the engine holding support fixture (bar), J-28467-A or equivalent.
  48.  
  49. Connect the clutch master cylinder pushrod to the clutch pedal.
  50.  
  51. Install the left sound insulator.
  52.  
  53. Check the transaxle fluid level and add as necessary.
  54.  
  55. Connect the negative battery cable.
  56.  

ISUZU TRANSAXLE

See Figures 7 and 8

  1. Disconnect the negative battery cable.
  2.  
  3. Install an engine holding support fixture (bar), J-28467-A or equivalent and raise the engine enough to take the pressure off the motor mounts.
  4.  



Click image to see an enlarged view

Fig. Fig. 7: Installing the engine support tool on the 1991 2.0L (VIN K) engine

  1. Remove the left sound insulator.
  2.  
  3. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  4.  
  5. Remove the clutch actuator cylinder from the transaxle support bracket and lay it aside.
  6.  
  7. Disconnect the wire harness at the mount bracket.
  8.  
  9. Unfasten the transaxle mount attaching bolts.
  10.  
  11. Remove the transaxle mount bracket attaching bolts and nuts.
  12.  
  13. Remove the shift cables and retaining clamp at the transaxle.
  14.  



Click image to see an enlarged view

Fig. Fig. 8: Isuzu transaxle mounting - 1991 2.0L (VIN K) engine shown

  1. Detach the ground cables at the transaxle mounting studs.
  2.  
  3. Detach the back-up switch connector.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Drain the transaxle.
  8.  
  9. Remove the left front wheel assembly.
  10.  
  11. Detach the left front inner splash shield.
  12.  
  13. Disconnect the transaxle strut and bracket.
  14.  
  15. Remove the clutch housing cover bolts.
  16.  
  17. Detach the Vehicle Speed Sensor (VSS) at the transaxle.
  18.  
  19. Disconnect the stabilizer shaft at the left suspension support and control arm.
  20.  
  21. Remove the left suspension support attaching bolts and swing the suspension support aside.
  22.  
  23. Install drive axle boot protector J-34754 or equivalent, disconnect the drive axles and remove the left shaft from the transaxle.
  24.  
  25. Attach the transaxle case to a jack.
  26.  
  27. Remove the transaxle to engine bolts.
  28.  
  29. Remove the transaxle by sliding it away from the engine and carefully lowering the jack while guiding the right drive axle out of the transaxle.
  30.  

To install:
  1. Reposition the transaxle and guide the right drive axle into its bore as the transaxle is being raised.
  2.  

The right drive axle cannot be easily installed after the transaxle is connected to the engine.

  1. Install the transaxle to engine mounting bolts to 55 ft. lbs (75 Nm).
  2.  
  3. Install the left drive axle into its bore at the transaxle and seat both drive axles at the transaxle.
  4.  
  5. Remove the drive axle boot protector.
  6.  
  7. Install the suspension support to body bolts and tighten to 65 ft. lbs. (88 Nm).
  8.  
  9. Install the stabilizer shaft at the suspension support and control arm.
  10.  
  11. Install the vehicle speed sensor at the transaxle.
  12.  
  13. Install the flywheel/clutch housing cover bolts and tighten to 115 inch lbs. (13 Nm).
  14.  
  15. Install the strut bracket to the transaxle.
  16.  
  17. Install the strut.
  18.  
  19. Install the inner splash shield.
  20.  
  21. Install the wheel and tighten the wheel nuts to 100 ft. lbs. (140 Nm).
  22.  
  23. Lower the vehicle.
  24.  
  25. Install the ground cables at the transaxle mounting studs.
  26.  
  27. Install the back-up switch connector.
  28.  
  29. Install the actuator cylinder to the transaxle bracket aligning the pushrod into the pocket of the clutch release lever and install the retaining nuts and tighten evenly to prevent damage to the cylinder.
  30.  
  31. Install the transaxle mount bracket.
  32.  
  33. Install the transaxle mount to side frame and install the bolts.
  34.  
  35. Install the wiring harness at the transaxle mount bracket.
  36.  
  37. Install the bolt attaching the mount to the transaxle bracket and tighten to 88 ft. lbs. (120 Nm).
  38.  
  39. Remove the engine holding support fixture (bar), J-28467-A or equivalent.
  40.  
  41. Install the shift cables.
  42.  
  43. Check the transaxle fluid level and add as necessary.
  44.  
  45. Connect the negative battery cable.
  46.  

1992-94 Vehicles
NVG-T550 TRANSAXLES

See Figures 9 and 10

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the left sound insulator.
  4.  
  5. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  6.  
  7. Remove the air cleaner assembly and the bracket.
  8.  
  9. Unfasten the exhaust crossover pipe.
  10.  
  11. Disconnect the hydraulic line from the clutch slave cylinder.
  12.  
  13. Remove the transaxle shift cables by snapping them off.
  14.  
  15. Remove the shift cable mount bracket.
  16.  
  17. Detach the back-up light switch connector.
  18.  
  19. Disconnect the transaxle vent tube from the transaxle.
  20.  
  21. Unfasten the top two transaxle-to-engine bolts.
  22.  
  23. Install engine support fixture J 28467-A, or equivalent, and raise the engine enough to remove the weight from the engine mounts.
  24.  



Click image to see an enlarged view

Fig. Fig. 9: Installation of the engine support fixture on the 3.1L engine

  1. Raise and support the vehicle safely, then drain the transaxle fluid.
  2.  
  3. Remove the front tire and wheel assemblies.
  4.  
  5. Remove the left side splash shield.
  6.  
  7. Unfasten the front air deflector.
  8.  
  9. Remove the right side splash shield.
  10.  
  11. Detach the ABS Wheel Speed Sensor (WSS) connectors from the WSS and harness from the left side suspension support.
  12.  



Click image to see an enlarged view

Fig. Fig. 10: Engine-to-transaxle mounting - NVG-550 manual transaxle shown

  1. Remove the left and right ball joint nuts.
  2.  
  3. Unfasten the left stabilizer link.
  4.  
  5. Remove the transaxle strut bracket from the transaxle bolts.
  6.  
  7. Remove the stabilizer bat and left side U-bolt.
  8.  
  9. Unfasten the left suspension support attaching bolts.
  10.  
  11. Remove the intermediate shaft and housing.
  12.  
  13. Remove the left and drive drive axles (halfshafts), as outlined later in this section.
  14.  
  15. Unfasten the rear engine mount through-bolts.
  16.  
  17. Remove the rear engine mount bracket.
  18.  
  19. Detach the following electrical connectors:

    Vehicle Speed Sensor (VSS)
     
    Back-up light switch
     

  20.  
  21. Remove the starter motor.
  22.  
  23. Unfasten and remove the flywheel cover.
  24.  
  25. Lower the engine with engine support fixture J-28476-A, or equivalent, to ease removal of the transaxle, but be sure to count the number of turns for installation.
  26.  
  27. Detach the ground wires from the lower engine-to-transaxle bolts.
  28.  
  29. Install a transaxle jack, then unfasten the lower engine-to-transaxle bolts. Remove the transaxle.
  30.  

To install:
  1. Reposition the transaxle and install the lower transaxle bolts. tighten the bolts to 55 ft. lbs. (75 Nm).
  2.  
  3. Attach the ground wires to the lower engine-to-transaxle bolts.
  4.  
  5. Install the flywheel cover, then tighten the retaining bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Install the starter motor.
  8.  
  9. Raise the engine with the support fixture to install the powertrain mounts.
  10.  
  11. Install the rear engine mount bracket, then install the rear engine mount and through-bolts.
  12.  
  13. Attach the VSS and back-up light switch electrical connectors.
  14.  
  15. Install the intermediate shaft and housing.
  16.  
  17. Fasten the right and left drive axles to the transaxle.
  18.  
  19. Install the left suspension support and attaching bolts.
  20.  
  21. Fasten the transaxle strut bracket and the bolt to the transaxle. Tighten the strut bracket bolts to 40 ft. lbs. (54 Nm).
  22.  
  23. Install the left side stabilizer U-bolt.
  24.  
  25. Install both ball joints and cotter pins.
  26.  
  27. Fasten the stabilizer link.
  28.  
  29. Attach the left side ABS WSS harness and attach both ABS wheel speed sensor connectors.
  30.  
  31. Fasten the right side splash shield, front air deflector and the left side splash shield.
  32.  
  33. Install both front wheel and tire assemblies.
  34.  
  35. Carefully lower the vehicle.
  36.  
  37. Install the upper transaxle mount and bracket, as an assembly. Tighten the mount nuts to 23 ft. lbs. (31 Nm) and the bolts to 38 ft. lbs. (52 Nm).
  38.  
  39. Remove the engine support fixture.
  40.  
  41. Attach the fluid line to the clutch slave cylinder.
  42.  
  43. Install the top two upper transaxle bolt, then tighten to 55 ft. lbs. (75 Nm).
  44.  
  45. Fasten the exhaust crossover pipe.
  46.  
  47. Attach the transaxle vent tube to the transaxle.
  48.  
  49. Fasten the back-up light switch and VSS electrical connectors.
  50.  
  51. Install the transaxle shift cable bracket, then snap on the shift cables.
  52.  
  53. Fasten the exhaust crossover pipe.
  54.  
  55. Install the air cleaner bracket and assembly.
  56.  
  57. Install the left sound insulator, then connect the clutch master cylinder pushrod to the clutch pedal.
  58.  
  59. Connect the negative battery cable.
  60.  
  61. Fill the transaxle with GM fluid 123455349, or equivalent.
  62.  

ISUZU TRANSAXLE

See Figures 11 and 12

  1. Disconnect the negative battery cable.
  2.  
  3. Install an engine holding support fixture (bar), J-28467-A or equivalent and raise the engine enough to take the pressure off the motor mounts.
  4.  



Click image to see an enlarged view

Fig. Fig. 11: Installation of the engine support fixture - 1994 2.0L engine shown

  1. Remove the left sound insulator.
  2.  
  3. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  4.  
  5. Remove the clutch actuator cylinder from the transaxle support bracket and lay it aside.
  6.  



Click image to see an enlarged view

Fig. Fig. 12: Isuzu transaxle mounting - 1994 2.0L engine shown

  1. Disconnect the wire harness at the mount bracket.
  2.  
  3. Unfasten the transaxle mount attaching bolts.
  4.  
  5. Remove the transaxle mount bracket attaching bolts and nuts.
  6.  
  7. Remove the shift cables and retaining clamp at the transaxle.
  8.  
  9. Detach the ground cables at the transaxle mounting studs.
  10.  
  11. Detach the back-up switch connector.
  12.  
  13. Raise and support the vehicle safely.
  14.  
  15. Drain the transaxle.
  16.  
  17. Remove the left front wheel assembly.
  18.  
  19. Detach the left front inner splash shield.
  20.  
  21. Remove the transaxle front strut and bracket.
  22.  
  23. Unfasten the clutch housing cover bolts.
  24.  
  25. Detach the Vehicle Speed Sensor (VSS) electrical connector at the transaxle.
  26.  
  27. Unfasten the left and right drive axle nuts and the left and right ball joint nuts.
  28.  
  29. Unfasten the left and right stabilizer links.
  30.  
  31. Remove the drive axles (halfshafts).
  32.  
  33. Unfasten the left side U-bolt and remove it from the stabilizer bar.
  34.  
  35. Remove the left suspension support attaching bolts and swing the suspension support aside.
  36.  
  37. Attach the transaxle case to a suitable jack.
  38.  
  39. Unfasten the transaxle-to-engine bolts.
  40.  
  41. Remove the transaxle by sliding it away from the engine and carefully lowering the jack.
  42.  

To install:
  1. Reposition the transaxle, then install the transaxle to engine mounting bolts and tighten to 55 ft. lbs (75 Nm).
  2.  
  3. Install the flywheel housing cover, then tighten the retaining bolts to 89 inch lbs. (10 Nm).
  4.  
  5. Install the left suspension support and secure with the attaching bolts.
  6.  
  7. Fasten the left U-bolt to the stabilizer bar.
  8.  
  9. Install the left and right drive axles (halfshafts). Fasten the left and right drive axle, ball joint and stabilizer link nuts.
  10.  
  11. Attach the vehicle speed sensor connector at the transaxle.
  12.  
  13. Instal the front strut bracket to the transaxle. Tighten the bracket bolts to 38 ft. lbs. (52 Nm). Install the front strut. Tighten the mounting bolt and nut to 38 ft. lbs. (52 Nm).
  14.  
  15. Install the inner splash shield.
  16.  
  17. Install the wheel and tire assembly, then tighten the wheel nuts to 100 ft. lbs. (136 Nm).
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Fasten the ground cables at the transaxle mounting studs.
  22.  
  23. Attach the back-up switch connector.
  24.  
  25. Install the actuator cylinder to the transaxle bracket aligning the pushrod into the pocket of the clutch release lever and install the retaining nuts and tighten evenly to prevent damage to the cylinder.
  26.  
  27. Fasten the transaxle mount bracket. Tighten the bracket-to-transaxle mounting bolts to 55 ft. lbs. (75 Nm). Tighten the bracket-to-clutch cylinder support bolts to 38 ft. lbs. (52 Nm).
  28.  
  29. Install the transaxle mount-to-side frame and install the bolts. Tighten the mount nuts to 23 ft. lbs. (31 Nm) and the bolt to 38 ft. lbs. (52 Nm).
  30.  
  31. Attach the wiring harness at the transaxle mount bracket.
  32.  
  33. Install the bolt attaching the mount to the transaxle bracket and tighten to 83 ft. lbs. (113 Nm).
  34.  
  35. Remove the engine holding support fixture (bar), J-28467-A or equivalent.
  36.  
  37. Install the shift cables, clamp and nut. Tighten the nut to 89 inch lbs. (10 Nm).
  38.  
  39. Attach the clutch pushrod to the clutch pedal.
  40.  
  41. Install the left sound insulator.
  42.  
  43. Connect the negative battery cable.
  44.  
  45. Fill the transaxle with GM fluid 123455349, or equivalent.
  46.  

 
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