Installation
INSTALL OR CONNECT^ Tools Required:
- J 34860 Clutch Alignment Arbor
- J 28467-A Universal Support Fixture
- J 28467-89 Engine: Support Fixture Adapters (Geo Metro);
- J 28712 Drive Axle Shaft: Boot Protectors
Inspect
- Clutch alignment by inserting J 34860 through the clutch disc and into the crankshaft pilot bearing. If J 34860 does not fit through the clutch disc and into the pilot bearing smoothly, the clutch disc may be misaligned. For clutch disassembly and inspection procedures, refer to Clutch. Align if necessary.
1. Transaxle to engine by raising the transaxle into position and moving the transaxle toward the engine while simultaneously inserting the transaxle input shaft through the pressure plate and clutch disc.
2. Two lower right case-to-engine block mounting bolts.
Tighten
- Two lower right case-to-engine block mounting bolts to 60 N.m (44 lb. ft.).
3. Three bolts into left transaxle mounting bracket.
Tighten
- Three left transaxle mounting bracket bolts to 60 N.m (44 lb. ft.).
4. Rear transaxle mount through bolt and nut into rear transaxle mount.
Tighten
- Rear transaxle mount through bolt and nut to 60 N.m (44 lb. ft.).
5. Starter motor into transaxle; secure with two starter motor retaining bolts.
Tighten
- Starter motor retaining bolts to 28 N.m (21 lb. ft.).
6. Starter motor electrical connections to starter motor.
7. Extension rod onto extension rod mounting stud at transaxle; secure with two washers and one nut.
8. Extension rod to gearshift control lever guide plate; secure with four bolts.
Tighten
- Extension rod retaining nut to 40 N.m (29 lb. ft.).
- Gearshift control lever guide plate bolts to 10 N.m (89 lb. in.).
9. Gearshift control shaft and gearshift control shaft joint to transaxle gearshift shaft; secure with control shaft joint through bolt and nut.
Tighten
- Gearshift control shaft joint through bolt and nut to 20 N.m (15 lb. ft.).
10. Flywheel cover to transaxle; secure with two bolts.
Tighten
- Flywheel cover bolts to 20 N.m (15 lb. ft.).
11. Both drive axles. Refer to Drive Axle Assembly in Drive Axle.
12. Remove J 28712 from the differential-side and the wheel-side joints of both drive axles.
13. Remove hydraulic jack from transaxle.
14. Apply GM P/N 12346004, or equivalent, to the threaded portion of the transaxle drain plug.
15. Transaxle drain plug into transaxle.
Tighten
- Transaxle drain plug to 21 N.m (15 lb. ft.).
16. Add approximately 2.4 liters (2.5 qts.) of Castrol (R) Syntorq Transmission Fluid GM P/N 12346190, or equivalent, into the transaxle oil level/filler plug hole. Oil level should be even with the bottom of the transaxle oil level/filler plug hole.
17. Oil level/filler plug into transaxle after applying GM P/N 12346004, or equivalent, to plug threads.
Tighten
- Transaxle oil level/filler plug to 21 N.m (15 lb. ft.).
18. Lower vehicle.
19. Remove J 28467-A and J 28467-89.
20. Two upper right case-to-engine block mounting bolts.
Tighten
- Right case-to-engine block mounting bolts to 60 N.m (44 lb. ft.).
21. Speedometer cable into speedometer driven gear case; secure with speedometer cable retaining clip.
22. Engine wiring harness bracket and engine wiring harness to gearshift guide case; secure with two bolts.
Tighten
- Gearshift guide case bolts to 12 N.m (106 lb. in.).
23. Transaxle hanger and negative (-) battery cable to transaxle, secure hanger with one bolt.
Tighten
- Transaxle hanger bolt to 12 N.m (106 lb. in.).
24. Clutch cable bracket and clutch cable to transaxle secure with two bolts.
Tighten
- Clutch cable bracket bolts to 28 N.m (21 lb. ft.).
25. Clutch release lever onto clutch release shaft aligning clutch release shaft and lever marks.
Tighten
- Clutch release lever bolt and nut to 23 N.m (17 lb. ft.).
26. Backup lamp switch electrical connector.
27. Negative (-) battery cable. Refer to Steering and Suspension.