Transmission Replacement. Geo Prizm 1996

For 1990-2009 cars

## Transmission Replacement Assembly

#### Tools Required

• | J 28467-A Universal Support Fixture

• | J 28467-89 Engine Support Fixture Adapter

• | J 28467-330 Support Fixture Adapter

• | J 28712 Drive Axle Shaft Boot Protectors

### Removal Procedure

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Remove the battery. Refer to Battery Replacement in Engine Electrical.
2. Remove the air cleaner case assembly (3).
3. Remove the 3 bolts from the clutch line bracket.
4. Remove the 2 bolts and clutch release cylinder and line (1).
5. Disconnect the following components:

• | The backup light switch

• | The vehicle speed sensor connectors

6. Disconnect the ground cable (1).

Remove the hex head bolt of the ground cable from the transaxle.

7. Remove the 2 clips and washers.
8. Remove the 2 clips from the cables.
9. Disconnect the 2 control cables from the transaxle.
10. Remove the upper starter bolt from the transaxle upper side.
11. Remove 2 transaxle upper side mounting bolts (1).
12. Install J 28467-A and the J 28467-330 with the J 28467-89 .
13. Remove the engine 3 left mounting bracket bolts (2) and nut.
14. Lower the transaxle side.
15. Remove the engine left mounting bracket (3) and the bolt.
16. Raise the vehicle.
17. Remove the front wheels. Refer to Tire and Wheel Removal and Installation.
18. Remove the left hand and right hand engine under covers.
19. Drain the transaxle oil.
20. Remove the left hand and right hand drive shafts. Refer to Wheel Drive Shaft Replacement.
21. Remove the 2 heat insulator bolts.
22. Remove the heat insulator nut.
23. Remove the heat insulator (1).
24. Remove the front suspension cross-member. Refer to Lower Control Arm Replacement or Stabilizer Shaft Replacement in Front Suspension.
25. Disconnect the connector and the wire from the starter (3).
26. Remove the starter hex head bolt (2) from the lower side (4).
27. Remove the starter (1).
28. Support the transaxle with a suitable jack.
29. Remove the 4 transaxle to engine lower side mounting bolts (1,2).
30. Lower the transaxle left side.
31. Remove the transaxle from the engine.

### Installation Procedure

1. Raise the engine left side. Install the transaxle to the engine.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the 4 transaxle to engine lower side mounting bolts.

Tighten

• | Tighten the bolts (1) to 23 N·m (11 lb ft).

• | Tighten the bolt (2) to 46 N·m (34 lb ft).

3. Lower the jack from the transaxle.
4. Install the starter.
5. Install the starter hex head bolt to the lower side.

Tighten
Tighten the bolt to 39 N·m (29 lb ft).

6. Connect the connector and the wire to the starter (3).
7. Install the front suspension cross-member. Refer to Lower Control Arm Replacement or Stabilizer Shaft Replacement in Front Suspension.
8. Install the heat insulator (1) .
9. Install the 2 bolts and the nut.

Tighten

• | Tighten the bolt to 20 N·m (15 lb ft).

• | Tighten the nut to 20 N·m (15 lb ft).

10. Install the left hand and right hand drive shafts (2) . Refer to Wheel Drive Shaft Replacement in Front Suspension.
11. Fill the transaxle oil (1).

Tighten
Tighten the fill plug to 21 N·m (15 lb ft).

12. Install the left hand and right hand engine under covers.
13. Lower the vehicle.
14. Install the front wheels. Refer to Tire and Wheel Removal and Installation.
15. Raise the transaxle side.
16. Install the engine left mounting bracket and bolt.

Tighten
Tighten the bolt to 28 N·m (21 lb ft).

17. Install the 3 engine left mounting bracket bolts and nuts.

Tighten
Tighten the bolt (2) to 87 N·m (64 lb ft).

18. Remove the J 28467-A and the J 28467-330 with the J 28467-89 .
19. Install the 3 transaxle upper side mounting bolts (1).

Tighten
Tighten the bolt to 64 N·m (47 lb ft).

20. Install the starter set bolt to the transaxle upper side.

Tighten
Tighten the bolt to 39 N·m (29 lb ft).

21. Connect the 2 control cables to the transaxle.
22. Connect the 2 clips to the cables (1).
23. Connect the 2 clips and washers.
24. Connect the set bolt of the ground cable to the transaxle.
25. Connect the following components:

• | The backup light switch

• | The vehicle speed sensor connectors

26. Install the clutch release cylinder and line.
27. Install the 2 bolts (1).

Tighten
Tighten the bolts to 12 N·m (106 lb in).

28. Connect the 3 hex head bolts to the clutch line bracket.

Tighten
Tighten the bolts to 12 N·m (106 lb in).

29. Install the air cleaner case assembly (3).
30. Install the battery.

## Transmission Replacement Side Cover

### Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the 6 left splash shield screws.
3. Remove the left splash shield.
4. Remove the 9 side cover bolts.
5. Remove the side cover.

### Installation Procedure

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Install the side cover and the 9 side cover bolts.

Tighten
Tighten the side cover bolts to 18 N·m (13 lb ft).

2. Install the left splash shield.
3. Install the 6 left splash shield screws.
4. Lower the vehicle.