GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Geo 🢒 1996 🢒 Tracker - 4WD 🢒 Transmission/Transaxle 🢒 Manual Transmission - 5 Speed-Suzuki 🢒 Transaxle Assembly Removal

    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. Important: After removing the gearshift control lever, remove the bolt directly behind the gearshift lever case. This bolt attaches the gearshift lever case to the transfer case and must be removed before the transfer case removal can be performed.

  2. Remove the gearshift control lever from the gearshift lever case. Refer to Gearshift Control Lever Replacement .

    3. Object Number: 168377 Size: SH
  3. Remove one bolt (2) from the rear of the gearshift lever case (Four-Wheel Drive).
  4. Remove the transfer case gearshift control lever from the transfer case (Four-Wheel Drive Models).
  5. Remove the four bolts from the fan shroud at the radiator.
  6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  7. Remove the two upper transmission-to-engine bolts from the transmission.
  8. Place a drain pan or a suitable container underneath the transmission.

    9. Object Number: 168125 Size: SH
  9. Remove the transmission oil level/filler plug (2) from the transmission.

    10. Object Number: 168118 Size: SH
  10. Remove the transmission oil level/filler plug (3) from the transmission. (Two-Wheel Drive Models)

    11. Object Number: 168125 Size: SH
  11. Remove the transmission drain plug (3) from the transmission and drain the transmission oil.

    12. Object Number: 168118 Size: SH
  12. Remove the transmission drain plug (1) from the transmission and drain the transmission oil. (Two-Wheel Drive Models)

    13. Object Number: 168258 Size: SH
  13. Remove the backup lamp switch electrical connector from the backup lamp switch.
  14. Remove the starter motor electrical connections from the starter motor.
  15. Remove the following items from the transmission:
    16. • The two bolts (4).
    • The one nut.
    • The starter motor.
  16. Remove the transfer case from the vehicle (Four-Wheel Drive Models). Refer to Transfer Case Replacement in Driveline/Axle.
  17. Place index marks on the propeller shaft pinion flange yoke and the differential pinion flange to ensure correct installation (Two-Wheel Drive Models).
  18. Remove the following items from the vehicle (Two-Wheel Drive Models):
    19. • The four bolts.
    • The four nuts.
    • The rear propeller shaft.
  19. Remove the following items from the vehicle (if equipped):
    20. • The four bolts.
    • The front skid plate.
  20. Remove the speedometer cable (3) from the speedometer driven gear case (Two-Wheel Drive Models).
  21. Temporarily install the speedometer driven gear case retaining bolt (2).
  22. Remove the Three-Way Catalytic Converter (TWC) and the muffler/tail pipe assembly from the vehicle.
  23. Remove the drain pan from underneath the transmission.
  24. Support the transmission with a suitable hydraulic jack.

    25. Object Number: 168170 Size: SH
  25. Remove the two bolts (2) from the rear transmission mount (1) (Two-Wheel Drive Models).
  26. Remove the following items from the vehicle:
    27. • The four bolts.
    • The rear transmission crossmember.

    Object Number: 168803 Size: SH

    Important: Observe the alignment marks on the clutch release lever and the clutch release shaft. Make sure the clutch release shaft and the clutch release lever are properly aligned during the installation to ensure correct clutch adjustment.

  27. Remove the following items from the clutch release shaft:
    28. • The bolt (1).
    • The nut (1).
    • The clutch release lever (2).
  28. Remove the two bolts from the flywheel inspection cover.

    29. Object Number: 189859 Size: SH
  29. Place a wood block, H = 200 mm ((8 in), W = 100-150 mm (4-6 in), T = 45 mm (1.8 in), between the distributor gear housing and the bulkhead (2) in order to prevent the distributor and other components from being damaged when the transmission is lowered.
  30. Lower the transmission slowly until the engine contacts its support point on the wood block.
  31. Remove the following items from the gearshift lever case:
    32. • The clamp.
    • The breather hose.

    Object Number: 168821 Size: SH
  32. Remove the following items from the left transmission-to-engine reinforcement brace (1).
    33. • The two bolts (2).
    • The flywheel inspection cover.
  33. Remove the two bolts (2) from the right transmission-to-engine reinforcement brace (1).
  34. Remove the two lower transmission-to-engine nuts from the transmission.
  35. Remove the transmission from the vehicle by carefully moving the transmission away from the engine toward the rear of the vehicle until the input shaft is clear of the clutch pressure plate cover. Then, very slowly lower the transmission jack making sure there are no obstructions.
  36. Inspect the transmission.