GM Corsica/Beretta 1988-1996 Repair Guide

Manual Transaxle

Print

REMOVAL & INSTALLATION



See Figures 1 through 18

Before performing any maintenance that requires the removal of the slave cylinder, transaxle or clutch housing, the clutch master cylinder push rod must first be disconnected from the clutch pedal. Failure to disconnect the push rod will result in permanent damage to the slave cylinder if the clutch pedal is depressed with the slave cylinder disconnected.

Except Isuzu Transaxle
  1. Disconnect the negative terminal from the battery.
  2.  
  3. Using the Engine Support Fixture tool No. J-28467 or equivalent and Adapter tool No. J-35953 or equivalent, install them on the engine and raise the engine enough to take the engine weight off of the engine mounts.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Installed view of the engine support tool - 2.0L and 2.2L engines



Click image to see an enlarged view

Fig. Fig. 2: Whenever you install an engine support device, make sure to follow all of the manufacturers directions - 2.3L engine shown



Click image to see an enlarged view

Fig. Fig. 3: Engine support fixture mounting - 2.8L and 3.1L engines

  1. Remove the left side sound insulator.
  2.  
  3. Disconnect the clutch master cylinder push rod from the clutch pedal.
  4.  
  5. Remove the air cleaner and duct assembly.
  6.  
  7. Disconnect the clutch slave cylinder-to-transaxle support bolts and position the cylinder aside.
  8.  
  9. Remove the transaxle-to-mount through bolt.
  10.  
  11. Raise and support the front of the vehicle.
  12.  
  13. Remove the 2 exhaust crossover bolts at the right side manifold.
  14.  
  15. Lower the vehicle. Remove the left side exhaust manifold.
  16.  
  17. Disconnect the transaxle mounting bracket.
  18.  
  19. Disconnect the shifter cables.
  20.  
  21. Remove the upper transaxle-to-engine bolts.
  22.  
  23. Raise and support the front of the vehicle.
  24.  
  25. Remove the left front tire assembly and the left side inner splash shield.
  26.  
  27. Remove the transaxle strut and bracket.
  28.  
  29. Place a drain pan under the transaxle, remove the drain plug and drain the fluid from the transaxle.
  30.  
  31. Remove the clutch housing cover bolts.
  32.  
  33. Disconnect the speedometer wire.
  34.  
  35. From the left suspension support and control arm, disconnect the stabilizer shaft.
  36.  
  37. Remove the left suspension support mounting bolts and move the support aside.
  38.  
  39. Disconnect both halfshafts from the transaxle and remove the left halfshaft from the vehicle.
  40.  
  41. Using a transmission jack, attach it to and support the transaxle.
  42.  
  43. Remove the remaining transaxle-to-engine bolts.
  44.  
  45. Slide the transaxle away from the engine, lower it and remove the right side halfshaft.
  46.  

To install:
  1. When installing, guide the right side halfshaft into the transaxle while it is being installed in the vehicle.
  2.  
  3. Torque the transaxle-to-engine bolts to 60 ft. lbs. (81 Nm), the transaxle mount-to-body bolt to 80 ft. lbs. (108 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 4: Transaxle strut installation and bolt tightening specifications - 1988-89 2.0L and 2.8L engines and 1991 2.2L and 3.1L engines



Click image to see an enlarged view

Fig. Fig. 5: Transaxle mount installation and tightening values - 1988-91 vehicles, except the 2.3L engine

  1. Install the left halfshaft into its bore at the transaxle then seat both halfshafts at the transaxle.
  2.  
  3. Install the left suspension support mounting bolts.
  4.  
  5. Connect the stabilizer shaft to the left suspension support and control arm.
  6.  



Click image to see an enlarged view

Fig. Fig. 6: Transaxle roll bumper mounting and tightening specifications - 1990-91 3.1L engines



Click image to see an enlarged view

Fig. Fig. 7: Rear transaxle mount and bolt tightening values-1992-96 vehicles

  1. Connect the speedometer wire.
  2.  
  3. Connect the clutch housing cover bolts.
  4.  
  5. Install the transaxle strut and bracket.
  6.  



Click image to see an enlarged view

Fig. Fig. 8: Transaxle strut installation - 1990 vehicles



Click image to see an enlarged view

Fig. Fig. 9: Transaxle mount installation and bolt tightening specifications - 1990 vehicles, except 2.3L engine

  1. Install the left front tire assembly and the left side inner splash shield.
  2.  
  3. Lower the car.
  4.  
  5. Install the upper transaxle to engine bolts and torque to 55 ft. lbs. (75 Nm).
  6.  
  7. Install the shift cables.
  8.  
  9. Install the transaxle mount bracket and torque to the specifications illustrated.
  10.  
  11. Install the left side exhaust manifold.
  12.  
  13. Raise the car and install the exhaust crossover bolts at the right side exhaust manifold.
  14.  
  15. Lower the car.
  16.  
  17. Install the transaxle mount through bolt and torque to the specifications illustrated.
  18.  
  19. Install the clutch slave cylinder to the support bracket.
  20.  
  21. Install the air cleaner and the air intake duct assembly.
  22.  
  23. Remove the engine support fixture.
  24.  
  25. Connect the clutch master cylinder push rod to the clutch pedal.
  26.  
  27. Install the left side sound insulator.
  28.  
  29. Install the negative battery cable.
  30.  

Isuzu Transaxle
  1. Disconnect the negative terminal from the battery.
  2.  
  3. Using the Engine Support Fixture tool No. J-28467 or equivalent and Adapter tool No. J-35953 or equivalent, install them on the engine and raise the engine enough to take the engine weight off of the engine mounts.
  4.  
  5. Remove the left side sound insulator.
  6.  
  7. Disconnect the clutch master cylinder push rod from the clutch pedal.
  8.  
  9. Disconnect the clutch slave cylinder-to-transaxle support bolts and position the cylinder aside.
  10.  
  11. Remove the wiring harness from the transaxle mount bracket and the shift wire electrical connector.
  12.  
  13. Remove the transaxle-to-mount bolts and the transaxle mount bracket-to-chassis nuts/bolts.
  14.  
  15. Disconnect the shift cables and remove the retaining clamp from the transaxle. Remove the ground cables from the transaxle mounting studs.
  16.  
  17. Raise and support the front of the vehicle.
  18.  
  19. Remove the left front tire assembly and the left side inner splash shield.
  20.  
  21. Remove the transaxle front strut and bracket.
  22.  
  23. Remove the clutch housing cover bolts. Disconnect the speedometer wire connector.
  24.  
  25. From the left suspension support and control arm, disconnect the stabilizer shaft.
  26.  
  27. Remove the left suspension support mounting bolts and move the support aside.
  28.  
  29. Disconnect both halfshafts from the transaxle and remove the left halfshaft from the vehicle.
  30.  
  31. Place a drain pan under the transaxle, remove the drain plug and drain the fluid from the transaxle.
  32.  
  33. Using a transmission jack, attach it to and support the transaxle.
  34.  
  35. Remove the transaxle-to-engine bolts.
  36.  
  37. Slide the transaxle away from the engine, lower it and remove the right side halfshaft.
  38.  

To install:
  1. When installing, guide the right side halfshaft into the transaxle while it is being installed in the vehicle.
  2.  
  3. Install and torque the transaxle-to-engine bolts to 55 ft. lbs. (75 Nm)
  4.  
  5. Install the left halfshaft into its bore at the transaxle then seat both halfshafts at the transaxle.
  6.  
  7. Install the left suspension support mounting bolts.
  8.  



Click image to see an enlarged view

Fig. Fig. 10: Exploded view of the transaxle mount installation - 1990-91 2.3L engines

  1. Connect the stabilizer shaft to the left suspension support and control arm.
  2.  
  3. Connect the speedometer wire.
  4.  
  5. Connect the clutch housing cover bolts and tighten to 89 inch lbs. (10 Nm).
  6.  



Click image to see an enlarged view

Fig. Fig. 11: Transaxle mount-to-body attachment - 1992-96 vehicles



Click image to see an enlarged view

Fig. Fig. 12: Transaxle-to-engine attachments - 1988-89 vehicles, except Isuzu transaxles



Click image to see an enlarged view

Fig. Fig. 13: Transaxle-to-engine attachments - 1988-89 Isuzu transaxles

  1. Install the transaxle strut and bracket. Torque the transaxle strut to body bolt to 40 ft. lbs. (54 Nm) and the transaxle strut to transaxle to 50 ft. lbs. (68 Nm). See applicable illustration.
  2.  
  3. Install the left front tire assembly and the left side inner splash shield.
  4.  



Click image to see an enlarged view

Fig. Fig. 14: Front transaxle mount-to-transaxle attachment and bolt torques



Click image to see an enlarged view

Fig. Fig. 15: Transaxle-to-engine attachment - 1990-96 vehicles, except 2.3L engine



Click image to see an enlarged view

Fig. Fig. 16: Transaxle-to-engine attachment and bolt tightening specifications - 2.3L engine

  1. Lower the car.
  2.  
  3. Install the ground cables at the transaxle mounting studs.
  4.  
  5. Install the wires for the shift light.
  6.  



Click image to see an enlarged view

Fig. Fig. 17: Transaxle retaining bolt sizes - 2.3L engine



Click image to see an enlarged view

Fig. Fig. 18: Transaxle stud and bolt location - 2.3L engine

  1. Install the slave cylinder to the transaxle bracket aligning the push rod into the pocket of the clutch release lever and installing the retaining nuts and tighten evenly.
  2.  
  3. Install the transaxle mount bracket. Tighten the rear mount bracket to transaxle to 40 ft. lbs. (54 Nm). See applicable illustration.
  4.  
  5. Install the transaxle mount to side frame and tighten to 23 ft. lbs. (30 Nm). See applicable illustration.
  6.  
  7. Install the wire harness at the mount bracket.
  8.  
  9. Install the bolt attaching the mount to the transaxle bracket and tighten to 88 ft. lbs. (120 Nm). See applicable illustration.
  10.  
  11. Remove the engine support.
  12.  
  13. Install the shift cables.
  14.  
  15. Connect the negative cable at the battery.
  16.  

 
label.common.footer.alt.autozoneLogo