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Transaxle Removal: Removal

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
  1. Position vehicle on hoist.
    Fig 1: Identifying Vehicle Support Positions
    G01033401Courtesy of GENERAL MOTORS CORP.
  2. Remove air cleaner and duct assembly. Refer to AIR CLEANER HOUSING AND DUCT ASSEMBLY  .
    Fig 2: Removing Air Cleaner Housing & Duct Assembly
    G01033402Courtesy of GENERAL MOTORS CORP.
  3. Disconnect negative battery cable from battery.
  4. Disconnect positive battery cable from battery.
  5. Remove hold-down retaining nut and screws, and lift off battery hold-down retainer.
  6. Lift battery out of vehicle, and place in a safe location.
    Fig 3: Removing Battery
    G01033403Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  The PCM J1 (black 80-way) harness connector does not need to be disconnected.

  7. Disconnect PCM J2 (black 28-way) harness connector by moving locking device outward toward fender.
  8. Remove PCM attachment bolts and move PCM out of way.
  9. Remove battery tray bolts and tray.
    Fig 4: Removing PCM & Battery Tray
    G01033404Courtesy of GENERAL MOTORS CORP.
    1. One bolt is located in the fender well.
  10. Remove transaxle strut-to-midrail bracket fastener.
    Fig 5: Removing Transaxle Strut-To-Midrail Bracket Fastener
    G01033405Courtesy of GENERAL MOTORS CORP.
  11. Loosen transaxle strut to transaxle bracket fastener and flip transaxle strut out of the way.
  12. Disconnect all electrical connectors from transaxle.
    1. Back-up lamp switch.
    2. Vehicle speed sensor.
    3. Two ground terminals from top two clutch housing bolts.
  13. Remove vent tube retaining clip if equipped.
    Fig 6: Disconnecting Transaxle Electrical Connectors
    G01033406Courtesy of GENERAL MOTORS CORP.
  14. Remove top two clutch housing-to-engine bolts. (Automatic shown, manual similar).
    Fig 7: Removing Top Two Clutch Housing-To-Engine Bolts (Automatic Shown; Manual Similar)
    G01033407Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  Note which spark plug wire is removed from which coil tower. The spark plug wires must be connected to the correct coil towers.

  15. Disconnect spark plug wires from coil towers.
  16. Disconnect electrical connectors at the electronic ignition module.
  17. Remove bolts from electronic ignition module. Remove electronic ignition module.
    Fig 8: Removing Ignition Module/Coil Assembly
    G01033408Courtesy of GENERAL MOTORS CORP.
  18. Remove shifter cables from shift arms and from clutch housing. Use care not to damage cable boot.
    Fig 9: Disconnecting Shifter Cables At Transaxle
    G01033409Courtesy of GENERAL MOTORS CORP.
    NOTE: Removal of the hydraulic damper with a power tool prior to removal of the actuator could result in breaking off the hydraulic line.

    IMPORTANT:  Prior to removing the slave cylinder from the clutch housing, make sure that the clutch hydraulic system has sufficient fluid. Refer to CLUTCH HYDRAULIC FLUID LEVEL CHECK .

  19. Rotate clutch slave cylinder 1/4 turn counter-clockwise while pushing into clutch housing. Remove cylinder from housing.
  20. Remove two clutch hydraulic dampener to clutch housing fasteners. Wire the actuator cylinder and the dampener to the upper radiator hose.
    Fig 10: Removing Clutch Slave Cylinder
    G01033410Courtesy of GENERAL MOTORS CORP.
  21. Wire the radiator to the upper radiator support to hold the radiator in place when frame is removed.
    Fig 11: Wiring Radiator To Radiator Support
    G01033411Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  The two cross bars on the engine support have two settings, one for the SOHC (L24) (1) and one for the DOHC (LLO) (2) engine. The setting locations are marked on the bars as shown.

  22. Install Engine Support Bar Assembly SA9105E.
    Fig 12: Identifying Engine Support Cross Bar Settings
    G01033412Courtesy of GENERAL MOTORS CORP.
    1. Place engine support bar in vehicle as shown. Place the support bar feet on the outer edge of the shock tower.
      Fig 13: Installing Engine Support
      G01033413Courtesy of GENERAL MOTORS CORP.
    2. Connect bar hooks to engine support brackets.
    3. Position stabilizer foot on engine block to the right of the engine oil dipstick.
    4. Adjust hooks and stabilizer to remove looseness.
    Fig 14: Connecting Engine Support Bar Hooks To Engine Support Brackets
    G01033414Courtesy of GENERAL MOTORS CORP.
    CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
  23. Raise vehicle and drain transaxle fluid.
    Fig 15: Removing Transaxle Drain Plug
    G01033415Courtesy of GENERAL MOTORS CORP.
  24. Remove front wheels.
  25. Remove left and right front inner fender splash shields.
    Fig 16: Removing Front Inner Fender Splash Shields
    G01033416Courtesy of GENERAL MOTORS CORP.
  26. Remove front engine splash shield from vehicle.
    Fig 17: Removing Front Engine Splash Shield
    G01033417Courtesy of GENERAL MOTORS CORP.
  27. Remove engine strut frame bracket-to-frame fasteners.
    Fig 18: Removing Engine Strut Frame Bracket-To-Frame Fasteners
    G01033418Courtesy of GENERAL MOTORS CORP.
  28. Remove transaxle mount-to-frame fastener.
    Fig 19: Removing Transaxle Mount-To-Frame Fastener
    G01033419Courtesy of GENERAL MOTORS CORP.
  29. Remove front exhaust pipe-to-manifold fasteners.
    Fig 20: Removing Front Exhaust Pipe-To-Manifold Fasteners
    G01033420Courtesy of GENERAL MOTORS CORP.
  30. Remove front exhaust pipe-to-catalytic converter nuts.
    Fig 21: Removing Front Exhaust Pipe-To-Catalytic Converter Nuts
    G01033421Courtesy of GENERAL MOTORS CORP.
  31. Remove exhaust pipe support bracket-to-exhaust pipe fasteners.
  32. Remove front exhaust pipe from vehicle.
    Fig 22: Removing Exhaust Pipe Support Bracket-To-Exhaust Pipe Fasteners
    G01033422Courtesy of GENERAL MOTORS CORP.
  33. Remove steering gear to frame fasteners. (Power steering gear shown, manual steering gear similar.)
  34. Support steering gear with safety wire.
    Fig 23: Removing Steering Gear-To-Frame Fasteners
    G01033423Courtesy of GENERAL MOTORS CORP.
  35. Remove brake pipe bracket push pin at rear of frame.
    Fig 24: Removing Brake Pipe Bracket Push Pin
    G01033424Courtesy of GENERAL MOTORS CORP.
  36. Remove engine to transaxle stiffening brace bolts and remove brace.
    Fig 25: Removing Engine-To-Transaxle Stiffening Brace
    G01033425Courtesy of GENERAL MOTORS CORP.
  37. Remove dust cover to clutch housing bolts and remove dust cover.
    Fig 26: Removing Clutch Housing Dust Cover
    G01033426Courtesy of GENERAL MOTORS CORP.
  38. Remove cotter pin from lower ball joints and discard. Loosen nut and back off until top of nut is even with top of threads.
  39. Repeat for opposite side.
    Fig 27: Removing Lower Ball Joint Cotter Pin & Nut (Left Side Shown)
    G01033427Courtesy of GENERAL MOTORS CORP.
    NOTE: On ABS equipped vehicles, the outer CV joint has a speed sensor ring. Using the incorrect tool or procedure to separate the control arm from the knuckle can damage the ring, resulting in a loss of ABS operation.
    NOTE: Do not attempt to separate the joint using a wedge type tool because the boot may be damaged.

    IMPORTANT:  It will be necessary to pull down on lower control arm to remove castle nut.

  40. Separate ball joint from lower control arm using Lower Control Arm Ball Stud Separator SA9132S and remove nut.
  41. Repeat for opposite side.
    Fig 28: Separating Ball Joint From Lower Control Arm
    G01033428Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not allow screwdriver to contact axle seal or damage to the seal may occur.
  42. Separate left side axle from transaxle using a large screwdriver or appropriate pry bar.
    Fig 29: Separating Left Side Axle From Transaxle
    G01033429Courtesy of GENERAL MOTORS CORP.
  43. Remove axle only part way and install Axle Seal Protector SA91112T. Use seal protector that was previously used or open up protector at split line and install around axle and into seal. This will protect the seal from being cut by the shaft spline.
  44. Separate right side axle from intermediate shaft.
  45. On DOHC (LLO) vehicles, remove intake bracket to intake manifold bolt.
  46. Remove intake bracket to intermediate shaft support bolt, and remove support bracket.
  47. Remove two intermediate shaft to engine block bolts.
  48. Carefully slide intermediate shaft out of transaxle.
    Fig 30: Removing Intermediate Shaft
    G01033430Courtesy of GENERAL MOTORS CORP.
  49. Use the powertrain support dolly and two 4 in. x 4 in. x 36 in. pieces of lumber to support the frame on the dolly.
    Fig 31: Supporting Frame On Powertrain Support Dolly
    G01033431Courtesy of GENERAL MOTORS CORP.
  50. Remove the four frame-to-body bolts. Carefully lower the frame from the vehicle with the powertrain support dolly.
    Fig 32: Removing Four Frame-To-Body Bolts
    G01033432Courtesy of GENERAL MOTORS CORP.
  51. Support transaxle securely with jack.
    Fig 33: Supporting Transaxle
    G01033433Courtesy of GENERAL MOTORS CORP.
  52. Remove two bottom clutch housing to engine bolts, and install guide bolt into bottom rear clutch housing bolt hole.
  53. Separate transaxle from engine and lower transaxle.
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