GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1999 🢒 Sunfire 🢒 Body and Accessories 🢒 Body Front End 🢒 Transmission Replacement

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. Disconnect the negative battery cable.
  2. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 2.4L.
  3. Raise the engine enough to take pressure off of the transaxle mounts.
  4. Remove the air cleaner and duct assembly from the throttle body. Refer to Air Cleaner Assembly Replacement in Engine Controls - 2.2 or Air Cleaner Assembly Replacement in Engine Controls - 2.4.
  5. Remove the wire harness from the upper transaxle mount bracket.
  6. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  7. Remove the upper radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
  8. Remove the upper transaxle mount to transaxle bolts.

    9. Object Number: 414943 Size: SH
  9. Remove the vent tube at the shifter housing.

    10. Object Number: 414940 Size: SH
  10. Remove the shift control bolts.
  11. Remove the ground straps.

    12. Object Number: 439868 Size: SH
  12. Remove the negative battery cable from the transaxle housing.
  13. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.

    14. Object Number: 439878 Size: SH
  14. Disconnect the pressure line from the clutch actuator cylinder.
  15. Disconnect the backup light switch connector.
  16. Remove the rear transaxle mount bolts.

    17. Object Number: 414901 Size: SH
  17. Disconnect the vehicle speed sensor (VSS).

    18. Object Number: 414938 Size: SH
  18. Remove the upper upper transaxle mounting bolts.
  19. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  20. Drain the transaxle.

    21. Object Number: 414934 Size: SH
  21. Remove the rack and pinion mounting bolts.
  22. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  23. Remove the front splash shields. Refer to Wheelhouse Splash Shield Replacement in Body Front End.

    24. Object Number: 414402 Size: SH
  24. Remove the front Antilock Brake System (ABS) Wheel Speed Sensor (WSS) connectors.

    25. Object Number: 414399 Size: SH
  25. Unroute the left side ABS WSS harnesses.

    26. Object Number: 414928 Size: SH
  26. Unroute the right side ABS WSS harnesses.

    27. Object Number: 414920 Size: SH
  27. Remove the front frame brace bolt at the radiator.

    28. Object Number: 414930 Size: SH
  28. Remove the front frame brace bolt at the frame.
  29. Remove the brace.
  30. Remove the following components from the retainers below the rack and pinion:
    31. • The metal evap.
    • The brake tubes

    Object Number: 414909 Size: SH
  31. Remove the following components:
    32. • The axle shaft nuts
    • The axle shaft washers
  32. Remove the flywheel housing cover bolts.
  33. Remove the flywheel housing cover.

    34. Object Number: 414956 Size: SH
  34. Remove the following components:
    35. • The left ball joint cotter pin
    • The right ball joint cotter pin
    • The left ball joint nut
    • The right ball joint nut
  35. Separate the joints.
  36. Remove the drive axles. Refer to Wheel Drive Shaft Replacement in Driveline/Axle.

    37. Object Number: 414902 Size: SH
  37. Remove the following components:
    38. • The left lower transaxle mount bolts
    • The right lower transaxle mount bolts

    Object Number: 414951 Size: SH
  38. Remove the following components:
    39. • The left upper transaxle mounting bolts
    • The right upper transaxle mounting bolts

    Object Number: 414932 Size: SH
  39. Remove the center transaxle mount bolts.
  40. Remove the suspension support from the vehicle.

    41. Object Number: 414910 Size: SH
  41. Remove the engine strut from the bracket.

    42. Object Number: 414972 Size: SH
  42. Remove the front lower tranaxle mount thru-bolt.

    43. Object Number: 414959 Size: SH
  43. Attach the transaxle case to the support stand.

    44. Object Number: 414963 Size: SH
  44. Support the engine with a jack stand.

    45. Object Number: 414961 Size: SH
  45. Remove the transaxle-to-engine mount bolts.

    46. Object Number: 414956 Size: SH
  46. Remove the left front fascia splash shield.
  47. Use the following procedure in order to remove the transmission:
    48. 47.1. Slide the transaxle away from the engine.
    47.2. Carefully lower the support stand.

Installation Procedure
  1. Install the transaxle.

    2. Object Number: 414961 Size: SH

    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 transaxle-to-engine lower mounting bolts.

    3. Tighten
    Tighten the transaxle-to-engine lower mounting bolts to 75 N·m (55 lb ft).


    Object Number: 414959 Size: SH
  3. Remove the following components from the jackstand:
    4. • The safety strap
    • The transaxle jack
  4. Install the front transaxle mount-thru bolt.

    5. Tighten
    Tighten the front transaxle mount-thru bolt to 60 N·m (44 lb ft).


    Object Number: 414956 Size: SH
  5. Install the left fascia splash shield.
  6. Install the rear transaxle mount-thru bolt.

    7. Tighten
    Tighten the rear transaxle mount-thru bolt to 60 N·m (44 lb ft).

  7. Install the flywheel inspection cover.

    8. Object Number: 414963 Size: SH
  8. Remove the jackstand supporting the engine.
  9. Install the splash shields. Refer to Wheelhouse Splash Shield Replacement in Body Front End.
  10. Install the drive axles. Refer to Wheel Drive Shaft Replacement in Driveline/Axle.

    11. Object Number: 414932 Size: SH
  11. Install the following components:
    12. • The frame bolts
    • The center bolts

    Object Number: 414902 Size: SH
  12. Install the following components:
    13. • The left side bolts
    • The right side bolts

    Object Number: 414951 Size: SH
  13. Install the frame upper bolts.

    14. Object Number: 414906 Size: SH
  14. Install the ball joints to the steering knuckles.

    15. Object Number: 414399 Size: SH
  15. Install the wheel speed harness in the retainer.

    16. Object Number: 414402 Size: SH
  16. Connect the wheel speed sensors.

    17. Object Number: 414910 Size: SH
  17. Install the engine strut-to-strut bracket.

    18. Object Number: 414920 Size: SH
  18. Install the following components:
    19. • The front frame brace
    • The front frame bolt

    Object Number: 414930 Size: SH
  19. Install the rear frame brace bolt.

    20. Object Number: 414934 Size: SH
  20. Install the rack and pinion mounting bolts.

    21. Tighten
    Tighten the rack and pinion mounting bolts to 120 N·m (89 lb ft).

  21. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  22. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
  23. Lower the vehicle.

    24. Object Number: 414938 Size: SH
  24. Install the upper transaxle mounting bolts

    25. Tighten
    Tighten the upper transaxle mounting bolts to 96 N·m (71 lb ft).


    Object Number: 439878 Size: SH
  25. Connect the clutch master cylinder line.

    26. Object Number: 414901 Size: SH
  26. Connect the vehicle speed sensor.

    27. Object Number: 12405 Size: SH
  27. Connect the backup light switch.

    28. Object Number: 414940 Size: SH
  28. Install the shift control assembly.

    29. Tighten
    Tighten the shift control assembly to 24 N·m (18 lb ft).

  29. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 2.4L.

    30. Object Number: 414943 Size: SH
  30. Connect the transaxle vent tube.

    31. Object Number: 414953 Size: SH
  31. Install the negative battery cable to the transaxle case.
  32. Install the upper radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
  33. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 2.2L or Air Cleaner Assembly Replacement in Engine Controls - 2.4L.
  34. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  35. Fill the transaxle with Syncromesh Transaxle Fluid GM P/N 12345349 or equivalent.
  36. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding .