GM Cavalier/Sunfire 1995-2000 Repair Guide

Manual Transaxle Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Support the engine using the proper device



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Fig. Fig. 2: Remove the flywheel cover



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Fig. Fig. 3: The transaxle-to-engine bolt locations

  1. Disconnect the negative battery cable.
  2.  
  3. Install a suitable engine support device, and raise the engine enough to take the pressure off the transaxle mounts.
  4.  
  5. Remove the left side hush panel.
  6.  
  7. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  8.  
  9. Remove the air cleaner and duct assembly from the throttle body.
  10.  
  11. Remove the wiring harness from the mount bracket.
  12.  
  13. Remove the upper transaxle mount-to-transaxle bolts.
  14.  
  15. Remove the clutch master cylinder from the clutch actuator.
  16.  
  17. Disconnect the ground cables from the transaxle mounting studs.
  18.  
  19. Detach the back-up light switch connector.
  20.  
  21. Disconnect the transaxle vent tube.
  22.  
  23. Remove the rear transaxle-to-engine bolts.
  24.  
  25. Lower the engine support fixture enough to ease removal and installation of the transaxle.
  26.  
  27. Raise and safely support the vehicle.
  28.  
  29. Drain the transaxle fluid into a suitable container.
  30.  
  31. Remove the tire and wheel assemblies.
  32.  
  33. Remove the left side splash shield.
  34.  
  35. Disconnect both front ABS wheel speed sensor harness and move out of the way.
  36.  
  37. Remove the flywheel cover.
  38.  
  39. Disconnect the vehicle speed sensor at the transaxle.
  40.  
  41. Remove the left and right ball joint nuts and separate them from the steering knuckle.
  42.  
  43. Remove the left stabilizer link pin.
  44.  
  45. Remove the left side U-bolt from the stabilizer bar.
  46.  
  47. Remove the left side suspension support attaching bolts.
  48.  
  49. Remove the drive axles from the transaxle.
  50.  
  51. Remove the front lower transaxle mount.
  52.  
  53. Position a suitable jack under the transaxle.
  54.  
  55. Remove the transaxle-to-engine mounting bolts (noting their location).
  56.  
  57. Remove the transaxle away from the engine by carefully lowering the jack.
  58.  

To install:
  1. Position the transaxle on the jack and move it into place.
  2.  
  3. Install the transaxle-to-engine mounting bolts and tighten them to 55 ft. lbs. (75 Nm).
  4.  
  5. Install the front transaxle mount.
  6.  
  7. Install the flywheel cover.
  8.  
  9. Install the drive axles into the transaxle assembly.
  10.  
  11. Install the left side suspension support and attaching bolts.
  12.  
  13. Install the left side U-bolt to the stabilizer bar.
  14.  
  15. Connect the ball joints to the steering knuckle and install the nuts, tighten to 41 ft. lbs. (55 Nm).
  16.  
  17. Install the left side stabilizer link pin assembly.
  18.  
  19. Route the left side ABS wheel speed sensor wiring harness and connect both front wheel speed sensor connectors.
  20.  
  21. Install the inner splash shield.
  22.  
  23. Connect the vehicle speed sensor to the transaxle.
  24.  
  25. Install both tire and wheel assemblies.
  26.  
  27. Lower the vehicle.
  28.  
  29. Install the ground cables to the transaxle mounting studs.
  30.  
  31. Install the vent tube to the transaxle.
  32.  
  33. Attach the back-up light switch connector.
  34.  
  35. Install the upper transaxle mounting bolts and tighten to 55 ft. lbs. (75 Nm).
  36.  
  37. Install the clutch master cylinder to clutch actuator cylinder.
  38.  
  39. Install the rear transaxle mount. Tighten the bolts to 55 ft. lbs. (75 Nm).
  40.  
  41. Clip the wiring harness to the mount bracket.
  42.  
  43. Remove the engine support fixture.
  44.  
  45. Connect the shift cables clamp and nut. Tighten the nut to 89 inch lbs. (10 Nm).
  46.  
  47. Install the air cleaner and duct assembly to the throttle body.
  48.  
  49. Connect the pushrod to the clutch pedal.
  50.  
  51. Install the left side hush panel.
  52.  
  53. Connect the negative battery cable.
  54.  
  55. Fill the transaxle with Synchromesh® Transaxle Fluid.
  56.  
  57. Road test the vehicle and verify proper operation.
  58.  

 
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