For 1990-2009 cars

### Removal Procedure

#### Tools Required

• | J 28467-A Universal Support Fixture

• | J 28467-90 Engine Support Fixture Adapters

• | J 28712 Drive Axle Shaft Boot Protectors

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. Disconnect the negative battery cable.
2. Disconnect the electrical connector for the backup lamp switch.
3. Loosen the clutch release lever bolt and the nut (1).
4. Remove the clutch release lever (2) from the clutch release shaft (3).
5. Remove the 2 clutch cable bracket bolts (1) from the clutch cable bracket (2).

Set aside the clutch cable and the clutch cable bracket.

6. Remove the following components from the transaxle:

• | The transaxle hanger bolt

• | The transaxle hanger (4)

• | The negative battery cable (5)

7. Remove the 2 bolts (2) from the gearshift guide case (1).

Set aside the engine wiring harness and the engine wiring harness bracket (3).

8. Remove the harness from the bracket.
9. Remove the following components from the speedometer driven gear case:

• | The speedometer cable retaining clip.

• | The speedometer cable (1) .

• | Disconnect the starter motor electrical connectors from the starter motor. Refer to Starter Motor Replacement in Engine Electrical.

• | Disconnect the 2 starter motor retaining bolts.

• | Remove the starter motor from the transaxle.

• | Remove the 2 upper right mounting bolts that attach the case to the engine block.

10. Use the J 28467-A with the J 28467-90 in order to support the engine.
11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
12. Place a drain pan, or another suitable container, under the transaxle.
13. Remove the transaxle oil level/filler plug (1) from the transaxle.
14. Drain the transaxle oil.
15. Remove the drain pan from under the transaxle.
16. Support the transaxle with a suitable hydraulic jack.
17. Install the J 28712 on the differential-side joints and on the wheel-side joints of both drive axles.
18. Remove both of the drive axles. Refer to Wheel Drive Shaft Replacement in Driveline/Axle.
19. Remove the 2 flywheel cover bolts from the transaxle.
20. Remove the flywheel cover.
21. Remove the control joint shaft through-bolt and the nut (4) at the transaxle gear shift shaft (5).
22. Separate the following components from the transaxle:

• | The gearshift control joint (3)

• | The gearshift control shaft (6)

23. Remove the 4 bolts (2) that attach the gearshift control lever guide plate, and separate the extension rod (1) from the gearshift control lever guide plate (4).
24. Remove the 1 nut and the 2 washers at the extension rod mounting stud (3).
25. Separate the extension rod from the transaxle.
26. Remove the rear transaxle mount through-bolt (6) and the nut (5) from the rear transaxle mount (2).
27. For 1.3-liter vehicles, remove the coolant pipe from the side cover.Set the pipe aside.
28. Remove the 3 bolts (1) from the left transaxle mounting bracket (2).
29. Remove the 2 lower right mounting nuts and the studs that attach the case to the engine block.
30. Carefully move the transaxle away from the engine toward the left side of the engine compartment until the input shaft is clear of the clutch pressure plate cover.
31. Inspect carefully for obstructions. If you do not find any obstructions, slowly lower the transaxle jack. Remove the transaxle from the engine.

### Installation Procedure

#### Tools Required

• | J 34860 Clutch Alignment Arbor

• | J 28467-A Universal Support Fixture

• | J 28467-90 Engine Support Fixture Adapters

• | J 28712 Drive Axle Shaft Boot Protectors

1. Inspect the clutch alignment by inserting J 34860 through the clutch disc and into the crankshaft pilot bearing.

If the J 34860 does not fit through the clutch disc and into the pilot bearing smoothly, the clutch disc may be misaligned. For clutch disassembly procedures and for inspection procedures, Clutch Assembly Replacement refer to in Clutch. Align the clutch disc, if necessary.

2. Raise the transaxle into the installation position.
3. Gradually move the transaxle toward the engine while inserting the transaxle input shaft through the pressure plate (1) and through the clutch disc.

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.

4. Install the 1 bolt and the 1 nut that attach the lower right case to the engine block.

Tighten
Tighten the mounting bolts to 60 N·m (44 lb ft).

5. Install the left transaxle mounting bracket (2).
6. Install the bolts (1) that attach the left transaxle mounting bracket.

Tighten
Tighten the 3 bolts to 60 N·m (44 lb ft).

7. Install the rear transaxle through-bolt (6) and the nut (5) into the rear transaxle mount (2).

Tighten
Tighten the through-bolt and the nut to 60 N·m (44 lb ft).

8. Install the starter motor into the transaxle. Refer to Starter Motor Replacement in Engine Electrical.

Tighten
Tighten the 2 starter motor retaining bolts to 28 N·m (21 lb ft).

9. Install the starter motor electrical connectors to the starter motor.
10. Install the extension rod (1) into the mounting stud at the transaxle.

Tighten
Tighten the extension rod nut (2) with the 2 washers to 40 N·m (29 lb ft).

11. Install the extension rod (1) into the gearshift control lever guide plate.

Tighten
Tighten the bolts that attach the extension rod to the guide plate to 10 N·m (89 lb in).

12. Install the following components to the transaxle gear shift shaft (5):

12.1. | The gearshift control shaft (3)

12.2. | The gearshift control shaft joint (6).

12.3. | The control shaft joint through-bolt and the nut (4).

Tighten
Tighten the control shaft joint through-bolt and the nut to 20 N·m (15 lb ft).

12.4. | Install the flywheel cover to the transaxle.

Tighten
Tighten the 2 flywheel cover bolts to 20 N·m (15 lb ft).

12.5. | Install both of the drive axles. Refer to Wheel Drive Shaft Replacement in Driveline/Axle.

12.6. | Remove the J 28712 from the differential-side joint and from the wheel-side joint of each drive axle.

Remove the hydraulic jack from the transaxle.

13. Apply GM P/N 12346004, or the equivalent, to the threaded portion of the transaxle drain plug (2).
14. Install the transaxle drain plug into the transaxle.

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

15. Add approximately 2.4 liters (2.5 qts) of Castrol® Syntorq Transmission Fluid GM P/N 12346190, or the equivalent, into the transaxle oil level/filler plug hole (1).

The oil level should be even with the bottom of the transaxle oil level/filler plug hole.

16. Apply GM P/N 12346004, or the equivalent, to the oil level/filler plug threads.
17. Install the oil level/filler plug to the transaxle.

Tighten
Tighten the oil level/filler plug to 21 N·m (15 lb ft).

18. Lower the vehicle.
19. Remove the J 28467-A and the J 28467-90 .
20. Install the 2 upper right mounting bolts that attach the case to the engine block .

Tighten
Tighten the case-to-engine block mounting bolts to 60 N·m (44 lb ft).

21. Install the speedometer cable (1) into the speedometer driven gear case.
22. Install the speedometer cable retaining clip.
23. Install the following components to the gearshift guide case (1):

• | The engine wiring harness

• | The gear shift guide bolts 2

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

24. Install the following components to the transaxle:

24.1. | The negative battery cable (5)

24.2. | The transaxle hanger (4)

24.3. | The transaxle hanger bolt

Tighten
Tighten the transaxle hanger bolt to 12 N·m (106 lb in).

24.4. | The clutch cable bracket (2)

24.5. | The clutch cable bracket bolts (1)

Tighten
Tighten the 2 clutch cable bracket bolts to 28 N·m (21 lb ft).

25. Install the clutch release shaft on the clutch release lever (1) by aligning the clutch release shaft and the clutch release lever marks (2,3).

Tighten
Tighten the clutch release lever bolt and the nut to 23 N·m (17 lb ft).

26. Connect the electrical connector (2) for the backup lamp switch .
27. Connect the negative battery cable.