GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Optra 🢒 Transmission/Transaxle 🢒 Manual Transmission - D20 🢒 Transmission Case Assemble

Assembly Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1248215 Size: SH
  1. Install the speedometer-driven gear bolt and the speedometer-driven gear into the transaxle housing.

    2. Tighten
    Tighten the speedometer-driven gear bolt to 5 N·m (44 lb in).


    Object Number: 1251744 Size: SH
  2. Install the clutch-release bearing guide and the clutch-release bearing. Refer to Clutch Concentric Actuator Cylinder Replacement in Clutch.
  3. Install the backup lamp switch into the transaxle housing.

    4. Tighten
    Tighten the backup lamp switch to 20 N·m (15 lb ft).


    Object Number: 1248221 Size: SH
  4. Install the differential into the transaxle housing. Refer to Differential Case Assemble .
  5. Install the bearing plate, with the shafts attached.
  6. Install the bearing plate bolts.

    7. Tighten
    Tighten the bearing plate bolts to 22 N·m (16 lb ft).


    Object Number: 1248219 Size: SH
  7. Install the transaxle cover and the transaxle cover bolts.

    8. Tighten

        • Tighten the bigger transaxle cover bolts to 20 N·m (15 lb ft).
        • Tighten the smaller transaxle cover bolts to 15 N·m (11 lb ft).

    Object Number: 1248207 Size: SH
  8. Install the gearshift lever cover and the gearshift lever cover bolts.

    9. Tighten
    Tighten the gearshift lever cover bolts to 22 N·m (16 lb ft).

  9. Install the transaxle into the vehicle. Refer to Transmission Replacement .