GM Corsica/Beretta 1988-1996 Repair Guide

Transaxle

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REMOVAL & INSTALLATION



2.0L and 2.2L Engines

See Figures 1, 2, 3 and 4

  1. Disconnect the negative battery cable. Remove the air cleaner and air intake assembly.
  2.  
  3. Disconnect the TV cable from the throttle lever and the transaxle.
  4.  
  5. Remove the fluid level indicator and the filler tube.
  6.  
  7. Using the Engine Support Fixture tool No. J-28467 or equivalent and the Adapter tool No. J-35953 or equivalent, install them onto the engine.
  8.  
  9. Remove the wiring harness-to-transaxle nut.
  10.  
  11. Label and disconnect the electrical connectors for the speed sensor, TCC connector and the neutral safety/backup light switch.
  12.  
  13. Disconnect the shift linkage from the transaxle.
  14.  
  15. Remove the top 2 transaxle-to-engine bolts, the transaxle mount and bracket assembly.
  16.  
  17. Disconnect the rubber hose that runs from the transaxle to the vent pipe.
  18.  
  19. Raise and support the front of the vehicle.
  20.  
  21. Remove the front wheels and tire assemblies.
  22.  
  23. Disconnect the shift linkage and bracket from the transaxle.
  24.  
  25. Remove the left side splash shield.
  26.  
  27. Using a modified Drive Axle Seal Protector tool No. J-34754 or equivalent, install one on each drive axle to protect the seal from damage and the joint from possible failure.
  28.  
  29. Using care not to damage the halfshaft boots, disconnect the halfshafts from the transaxle.
  30.  
  31. Remove the transaxle strut. Remove the left side stabilizer link pin bolt and bushing clamp nuts from the support.
  32.  
  33. Remove the left frame support bolts and move it out of the way.
  34.  
  35. Disconnect the speedometer wire from the transaxle.
  36.  
  37. Remove the transaxle converter cover and matchmark the torque converter-to-flywheel for reassembly.
  38.  
  39. Disconnect and plug the transaxle cooler pipes.
  40.  
  41. Remove the transaxle-to-engine support.
  42.  
  43. Using a transmission jack, position and secure the jack to the transaxle. Remove the remaining transaxle-to-engine bolts.
  44.  
  45. Making sure the torque converter does not fall out, remove the transaxle from the vehicle.
  46.  

The transaxle cooler and lines should be flushed any time the transaxle is removed for overhaul or replacing the pump, case or converter.

Click image to see an enlarged view

Fig. Fig. 1: Transaxle mount-to-transaxle attachment - 1988-91 2.0L and 2.2L vehicles



Click image to see an enlarged view

Fig. Fig. 2: Location of the transaxle-to-engine bolts - 2.0L and 2.2L engines, except 1990 2.2L engine



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the transaxle-to-engine attachment - 1990 2.2L engine



Click image to see an enlarged view

Fig. Fig. 4: Transaxle-to-engine brace mounting - 2.0L and 2.2L engines

To install:
  1. Put a small amount of grease on the pilot hub of the converter and make sure that the converter is properly engaged with the pump.
  2.  
  3. Raise the transaxle to the engine while guiding the right side halfshaft into the transaxle.
  4.  
  5. Install the lower transaxle mounting bolts and remove the jack.
  6.  
  7. Align the converter with the marks made previously on the flywheel and install the bolts hand tight.
  8.  
  9. Torque the converter bolts to 46 ft. lbs.; retorque the first bolt after the others.
  10.  
  11. Install the transaxle converter cover.
  12.  
  13. Install the speedometer wire connector.
  14.  
  15. Position the left side drive axle shaft into the transaxle.
  16.  
  17. Install the left frame support assembly.
  18.  
  19. Install the left stabilizer shaft frame bushing nuts.
  20.  
  21. Install the left stabilizer bar link pin bolt.
  22.  
  23. Install the transaxle strut.
  24.  
  25. Seat the drive axles in the transaxle.
  26.  
  27. Remove the drive axle seal protectors.
  28.  
  29. Install the splash shield.
  30.  
  31. Install the shift linkage bracket to the transaxle.
  32.  
  33. Install both wheel and tire assemblies.
  34.  
  35. Lower the car and install the upper engine to transaxle bolts.
  36.  
  37. Install the shift linkage to the transaxle.
  38.  
  39. Install the speed sensor, TCC connector and the Park/Neutral and back-up switch wiring connectors.
  40.  
  41. Install the wiring harness and nut securing it to the transaxle.
  42.  
  43. Remove the engine support fixture.
  44.  
  45. Install the fluid level indicator and fill tube.
  46.  
  47. Install the TV cable at the transaxle and throttle lever.
  48.  
  49. Install the rubber hoses to the transaxle vent pipe.
  50.  
  51. Install the air cleaner assembly and the air intake duct.
  52.  
  53. Install the negative battery cable.
  54.  
  55. Fill with fluid and check for leaks.
  56.  

2.3L Engine

See Figures 5, 6 and 7

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Detach the heater hoses from the heater core.
  6.  
  7. Disconnect the intake air duct.
  8.  
  9. Remove the cable control cover.
  10.  
  11. Disconnect the throttle and TV cables.
  12.  
  13. Disconnect the shift cable and bracket.
  14.  
  15. Disconnect the throttle cable from the throttle body.
  16.  
  17. Tag and disconnect all vacuum lines and electrical connections.
  18.  
  19. Remove the power steering pump and set aside.
  20.  
  21. Remove the fluid fill tube.
  22.  
  23. Install engine support fixture J 28467-A or equivalent.
  24.  
  25. Remove the 4 top engine to transaxle bolts.
  26.  
  27. Raise and support the vehicle safely.
  28.  
  29. Remove both front tire and wheel assemblies.
  30.  
  31. Disconnect the left inner splash shield from the control arm assembly.
  32.  
  33. Disconnect both lower ball joints.
  34.  
  35. Disconnect the stabilizer shaft links.
  36.  
  37. Remove the front air deflector.
  38.  
  39. Disconnect the left suspension support.
  40.  
  41. Install drive axle seal protectors and remove both drive axles.
  42.  
  43. Disconnect the engine to transaxle brace.
  44.  
  45. Remove the flywheel cover.
  46.  
  47. Remove the flywheel-to-torque converter bolts.
  48.  
  49. Disconnect the transaxle cooler pipes.
  50.  
  51. Disconnect the ground wires from the engine-to-transaxle bolt.
  52.  
  53. Disconnect the cooler pipe brace.
  54.  
  55. Disconnect the exhaust brace.
  56.  
  57. Remove the bolts from the engine and transaxle mount.
  58.  
  59. Remove the transaxle mount to body bolts.
  60.  
  61. Support the transaxle with a jack.
  62.  
  63. Remove the remaining engine-to-transaxle bolts and remove the transaxle.
  64.  



Click image to see an enlarged view

Fig. Fig. 5: Transaxle-to-engine brace - 2.3L engine



Click image to see an enlarged view

Fig. Fig. 6: Location of the transaxle-to-engine mounting bolts - 2.3L engines



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of the transaxle mount, bracket and brace - 2.3L engines

To install:
  1. Put a small amount of grease on the pilot hub of the converter and make sure that the converter is properly engaged with the pump.
  2.  
  3. Raise the transaxle to the engine while guiding the right side halfshaft into the transaxle.
  4.  
  5. Install the lower engine to transaxle bolts.
  6.  
  7. Install the transaxle mount to body bolts.
  8.  
  9. Install the bolts to the engine and transaxle mount.
  10.  
  11. Connect the exhaust brace.
  12.  
  13. Connect the cooler pipe brace.
  14.  
  15. Connect the ground wires to the engine to transaxle bolt.
  16.  
  17. Connect the transaxle cooler pipes.
  18.  
  19. Apply sealant to the bolts and install the flywheel to torque converter bolts.
  20.  
  21. Install the flywheel cover.
  22.  
  23. Install the engine to transaxle brace.
  24.  
  25. Install drive axle seal protectors and install both drive axles, then remove the protectors.
  26.  
  27. Install the left suspension support.
  28.  
  29. Install the front air deflector.
  30.  
  31. Connect the stabilizer shaft links.
  32.  
  33. Connect the lower ball joints.
  34.  
  35. Connect the left inner splash shield to the control arm assembly.
  36.  
  37. Install both front tire and wheel assemblies.
  38.  
  39. Lower the vehicle.
  40.  
  41. Install the top engine to transaxle bolts to their proper location as shown in the illustration.
  42.  
  43. Remove engine support fixture J 28467-A or equivalent.
  44.  
  45. Install the fluid fill tube.
  46.  
  47. Install the power steering pump and adjust the drive belt.
  48.  
  49. Connect all vacuum lines and electrical connections.
  50.  
  51. Connect the throttle cable to the throttle body.
  52.  
  53. Connect the shift cable and bracket.
  54.  
  55. Connect the throttle and TV cable.
  56.  
  57. Install the cable control cover.
  58.  
  59. Connect the intake air duct.
  60.  
  61. Connect the heater hoses to the heater core.
  62.  
  63. Fill the cooling system.
  64.  
  65. Connect the negative battery cable.
  66.  
  67. Fill the transaxle.
  68.  
  69. Adjust the TV cable and shift linkage as necessary.
  70.  

2.8L and 3.1L Engines

See Figures 8, 9, 10, 11 and 12

  1. Disconnect the negative battery cable. Remove the air cleaner, bracket, mass air flow (MAF) sensor and air tube as an assembly.
  2.  
  3. Disconnect the exhaust crossover from the right side manifold and remove the left side exhaust manifold. Raise and support the manifold/crossover assembly.
  4.  
  5. Disconnect the TV cable from the throttle lever and the transaxle.
  6.  
  7. Remove the vent hose and the shift cable from the transaxle.
  8.  
  9. Remove the fluid level indicator and the filler tube.
  10.  
  11. Using the Engine Support Fixture tool No. J-28467 or equivalent and the Adapter tool No. J-35953 or equivalent, install them on the engine.
  12.  
  13. Remove the wiring harness-to-transaxle nut.
  14.  
  15. Label and disconnect the wires for the speed sensor, TCC connector and the neutral safety/backup light switch.
  16.  
  17. Remove the upper transaxle-to-engine bolts.
  18.  
  19. Remove the transaxle-to-mount through bolt, the transaxle mount bracket and the mount.
  20.  
  21. Raise and support the vehicle.
  22.  
  23. Remove the front wheel and tire assemblies.
  24.  
  25. Disconnect the shift cable bracket from the transaxle.
  26.  
  27. Remove the left side splash shield.
  28.  
  29. Using a modified Drive Axle Seal Protector tool No. J-34754 or equivalent, install one on each drive axle to protect the seal from damage and the joint from possible failure.
  30.  
  31. Using care not to damage the halfshaft boots, disconnect the halfshafts from the transaxle.
  32.  
  33. Remove the torsional and lateral strut from the transaxle. Remove the left side stabilizer link pin bolt.
  34.  
  35. Remove the left frame support bolts and move it out of the way.
  36.  
  37. Disconnect the speedometer wire from the transaxle.
  38.  
  39. Remove the transaxle converter cover and matchmark the converter-to-flywheel for assembly.
  40.  
  41. Disconnect and plug the transaxle cooler pipes.
  42.  
  43. Remove the transaxle-to-engine support.
  44.  
  45. Using a transmission jack, position and secure it to the transaxle. Remove the remaining transaxle-to-engine bolts.
  46.  
  47. Make sure that the torque converter does not fall out and remove the transaxle from the vehicle.
  48.  

The transaxle cooler and lines should be flushed any time the transaxle is removed for overhaul, to replace the pump, case or converter.

Click image to see an enlarged view

Fig. Fig. 8: Exploded view of the transaxle-to-engine brace - 1988-91 2.8L and 3.1L engines



Click image to see an enlarged view

Fig. Fig. 9: Transaxle-to-engine brace mounting - 1992-96 3.1L engines



Click image to see an enlarged view

Fig. Fig. 10: Transaxle lateral strut mounting - 1988-89 2.8L engines



Click image to see an enlarged view

Fig. Fig. 11: Exploded view of the transaxle lateral strut mounting - 1990 3.1L engine



Click image to see an enlarged view

Fig. Fig. 12: Transaxle lateral strut attachment - 1991 3.1L engine

To install:
  1. Put a small amount of grease on the pilot hub of the converter and make sure that the converter is properly engaged with the pump.
  2.  
  3. Raise the transaxle to the engine while guiding the right side halfshaft into the transaxle.
  4.  
  5. Install the lower transaxle mounting bolts and remove the jack.
  6.  
  7. Install the cooler lines at the transmission.
  8.  
  9. Position the left side drive axle shaft into the transaxle.
  10.  
  11. Install the left frame support bolts.
  12.  
  13. Install the left stabilizer shaft bushing clamp nuts at the support.
  14.  
  15. Install the left stabilizer bar link pin bolt.
  16.  
  17. Seat the drive axles in the transaxle.
  18.  
  19. Remove the drive axle seal protectors.
  20.  
  21. Install the shift linkage bracket to the transaxle.
  22.  
  23. Install the speedometer wire connector.
  24.  
  25. Install the transaxle brace bolts.
  26.  
  27. Install the transaxle lateral strut.
  28.  
  29. Install the transaxle torsional strut.
  30.  
  31. Align the converter with the marks made previously on the flywheel and install the bolts hand tight.
  32.  
  33. Torque the converter bolts to 46 ft. lbs.; retorque the first bolt after the others.
  34.  
  35. Install the transaxle converter cover.
  36.  
  37. Install the splash shield.
  38.  
  39. Install both wheel and tire assemblies.
  40.  
  41. Lower the car.
  42.  
  43. Install the transaxle mount.
  44.  
  45. Install the transaxle mount through bolt.
  46.  
  47. Install the wiring harness and nut securing it to the transaxle.
  48.  
  49. Remove the engine support fixture.
  50.  
  51. Install the fluid level indicator and fill tube.
  52.  
  53. Install the neutral start and TCC connectors.
  54.  
  55. Install the shift cable.
  56.  
  57. Install the TV cable at the transaxle and throttle lever.
  58.  
  59. Install the rubber hoses to the transaxle vent pipe.
  60.  
  61. Install the left side exhaust manifold bolts and exhaust crossover bolts.
  62.  
  63. Install the air cleaner mounting bracket, MAF sensor and air tube as an assembly.
  64.  
  65. Install the negative battery cable.
  66.  
  67. Fill with fluid and check for leaks.
  68.  

 
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