GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Geo 🢒 1997 🢒 Metro 🢒 Transmission/Transaxle 🢒 Manual Transmission - 5 Speed-Suzuki 🢒 Transaxle Assembly Installation

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

    Object Number: 180040 Size: SH
  1. Inspect the clutch alignment by inserting J 34860 through the clutch disc and into the crankshaft pilot bearing.

    2. 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 and inspection procedures, refer to Clutch Assembly Replacement in Clutch. Align the clutch disc, if necessary.

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

    4. 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 1 nut to lower right case-to-engine block mounting bolts.

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


    Object Number: 180024 Size: SH
  5. Install the left transaxle mounting bracket (2).
  6. Install the left transaxle mounting bracket bolts (1).

    7. Tighten
    Tighten the 3 left transaxle mounting bracket bolts to 60 N·m (44 lb ft).


    Object Number: 180009 Size: SH
  7. Install the rear transaxle through-bolt (6) and the nut (5) into the rear transaxle mount (2).

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

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

    9. 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. Object Number: 179977 Size: SH
  10. Install the extension rod (1) into the mounting stud at the transaxle.

    11. 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.

    12. Tighten
    Tighten the bolts securing 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):
    13. 12.1. The gearshift control shaft (3)
    12.2. The gearshift control shaft joint (6).
    12.3. The control shaft joint through bolt and nut (4).

    Tighten
    Tighten the control shaft joint through bolt and 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 drive axles. Refer to Wheel Drive Shaft Replacement in Driveline/Axle.
    12.6. Remove the J 28712 from the differential-side and the wheel-side joints of both drive axles.

    Remove the hydraulic jack from the transaxle.


    Object Number: 179979 Size: SH
  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.

    15. 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).

    16. 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.

    18. 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 two upper right case-to-engine block mounting bolts.

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


    Object Number: 429149 Size: SH
  21. Install the speedometer cable (1) into the speedometer driven gear case.
  22. Install the speedometer cable retaining clip.

    23. Object Number: 180022 Size: SH
  23. Install the following components to the gearshift guide case (1):
    24. • The engine wiring harness
    • The gear shift guide bolts 2 

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


    Object Number: 180020 Size: SH
  24. Install the following components to the transaxle:
    25. 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).


    Object Number: 180042 Size: SH
  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).

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


    Object Number: 179980 Size: SH
  26. Connect the backup lamp switch electrical connector (2).
  27. Connect the negative battery cable.