Expert: Tim's Auto Repair replied 4 years ago.

hi
this isn't too bad,,,just take your time and have patients
thanks
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ALL THE BONUS MONEY THAT I RECEIVE DURING THE MONTH OF JUNE WILL BE DONATED TO
THE AMERICAN RED CROSS FOR TORNADO RELEIF IN THE MID WEST,NORTHEAST AND DEEP
SOUTH,,THANKS FOR YOUR SUPPORT
GM Cavalier/Sunfire 1995-2000

Manual Transaxle Assembly

REMOVAL & INSTALLATION

REMOVAL & INSTALLATION

See Figures 1, 2 and 3
FIG : Fig. 1: Support the engine using the proper device

FIG : Fig. 2: Remove the flywheel cover

FIG : Fig. 3: The transaxle-to-engine bolt locations

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Disconnect the negative battery cable.

Install a suitable engine support device, and raise the engine enough to take the pressure off the
transaxle mounts.
Remove the left side hush panel.
Disconnect the clutch master cylinder pushrod from the clutch pedal.
Remove the air cleaner and duct assembly from the throttle body.
Remove the wiring harness from the mount bracket.
Remove the upper transaxle mount-to-transaxle bolts.
Remove the clutch master cylinder from the clutch actuator.
Disconnect the ground cables from the transaxle mounting studs.
Detach the back-up light switch connector.
Disconnect the transaxle vent tube.
Remove the rear transaxle-to-engine bolts.
Lower the engine support fixture enough to ease removal and installation of the transaxle.

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
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14.
15.
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18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

Raise and safely support the vehicle.

Drain the transaxle fluid into a suitable container.
Remove the tire and wheel assemblies.
Remove the left side splash shield.
Disconnect both front ABS wheel speed sensor harness and move out of the way.
Remove the flywheel cover.
Disconnect the vehicle speed sensor at the transaxle.
Remove the left and right ball joint nuts and separate them from the steering knuckle.
Remove the left stabilizer link pin.
Remove the left side U-bolt from the stabilizer bar.
Remove the left side suspension support attaching bolts.
Remove the drive axles from the transaxle.
Remove the front lower transaxle mount.
Position a suitable jack under the transaxle.
Remove the transaxle-to-engine mounting bolts (noting their location).
Remove the transaxle away from the engine by carefully lowering the jack.
To install:
Position the transaxle on the jack and move it into place.
Install the transaxle-to-engine mounting bolts and tighten them to 55 ft. lbs. (75 Nm).
Install the front transaxle mount.
Install the flywheel cover.
Install the drive axles into the transaxle assembly.
Install the left side suspension support and attaching bolts.
Install the left side U-bolt to the stabilizer bar.
Connect the ball joints to the steering knuckle and install the nuts, tighten to 41 ft. lbs. (55 Nm).
Install the left side stabilizer link pin assembly.
Route the left side ABS wheel speed sensor wiring harness and connect both front wheel speed
sensor connectors.
Install the inner splash shield.
Connect the vehicle speed sensor to the transaxle.
Install both tire and wheel assemblies.
Lower the vehicle.
Install the ground cables to the transaxle mounting studs.
Install the vent tube to the transaxle.
Attach the back-up light switch connector.
Install the upper transaxle mounting bolts and tighten to 55 ft. lbs. (75 Nm).
Install the clutch master cylinder to clutch actuator cylinder.
Install the rear transaxle mount. Tighten the bolts to 55 ft. lbs. (75 Nm).
Clip the wiring harness to the mount bracket.
Remove the engine support fixture.
Connect the shift cables clamp and nut. Tighten the nut to 89 inch lbs. (10 Nm).
Install the air cleaner and duct assembly to the throttle body.
Connect the pushrod to the clutch pedal.
Install the left side hush panel.
Connect the negative battery cable.
Fill the transaxle with Synchromesh Transaxle Fluid.
Road test the vehicle and verify proper operation.

Driven Disc and Pressure Plate

REMOVAL & INSTALLATION

ADJUSTMENTS

REMOVAL & INSTALLATION

See Figures 1 through 15
FIG : Fig. 1: Exploded view of the clutch disc and cover assembly

1.
2.
3.
4.
5.
6.
7.

8.

CAUTION The clutch driven disc may contain asbestos, which has been determined to be a
cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust
from any clutch surface! When cleaning clutch surfaces, use a commercially available brake
cleaning fluid.
Prior to any vehicle service that requires the removal of the actuator cylinder, the master
cylinder pushrod must be disconnected from the clutch pedal. If not disconnected, permanent
damage to the actuator cylinder will occur if the clutch pedal is depressed while the actuator
cylinder is disconnected.
Disconnect the negative battery cable.
Remove the clutch master cylinder pushrod from the clutch pedal.
Remove the transaxle.
If any of the parts are to be reused, mark the pressure plate assembly and the flywheel so they can
be assembled in the same position. They were balanced as an assembly at the factory.
Loosen the attaching bolts one turn at a time until spring tension is relieved.
Support the pressure plate and remove the bolts. Remove the pressure plate and clutch disc. Do not
disassemble the pressure plate assembly. Replace it if defective.
Inspect the flywheel, clutch disc, pressure plate, throwout bearing and the clutch fork and pivot
shaft assembly for wear. Replace the parts as required. If the flywheel shows any signs of
overheating or if it is badly grooved or scored, it should be resurfaced or replaced.
Clean the pressure plate and flywheel mating surfaces thoroughly.

5.

To install:
Clean all parts well. Apply a small amount of high temperature grease to the pilot bearing inside the
end of the crankshaft.
Position the clutch disc and pressure plate into the installed position, and support with clutch
aligning tool J-29074 or equivalent. The clutch plate is assembled with the damper springs offset
toward the transaxle. One side of the factory supplied clutch disc should be stamped Flywheel Side.
Install the pressure plate-to-flywheel bolts. Tighten them gradually in a cross pattern as follows:
Install lightly seat all bolts.
Tighten bolts 1, 2, 3, then 4, 5, and 6 to 12 ft. lbs. (16 Nm).
Final torque bolts 1, 2, 3, then 4, 5, 6 to 15 ft. lbs. (20 Nm).
Lubricate the outside groove and the inside recess of the release bearing with high temperature
grease. Wipe off any excess. Install the release bearing.
Pack the inside recess of the release bearing completely full of chassis grease.

1.
2.
3.

Be sure the bearing pads are located on the fork ends and both spring ends are in the fork holes
with the spring completely seated in bearing groove.
Install the transaxle.
Install clutch master cylinder pushrod to the clutch pedal and install the retaining clip.
If equipped with cruise control, check switch adjustment at clutch pedal bracket.

1.
2.

When adjusting the cruise control switch, do not exert an upward force on the clutch pedal pad
of more than 20 ft. lbs. (27 Nm) or damage to the master cylinder pushrod retaining ring can
result.
Connect the negative battery cable.
Bleed clutch system as necessary and road test vehicle.

1.
2.

3.
1.
2.
3.
4.

Fig. Fig. 2: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...

Fig. Fig. 3: ... then carefully removing the clutch and pressure plate assembly from the flywheel

Fig. Fig. 4: Check across the flywheel surface, it should be flat

Fig. Fig. 5: If necessary, lock the flywheel in place and remove the retaining bolts ...

Fig. Fig. 6: ... then remove the flywheel from the crankshaft in order replace it or have it
machined

Fig. Fig. 7: Upon installation, it is usually a good idea to apply a threadlocking compound to the
flywheel bolts

Fig. Fig. 8: Check the pressure plate for excessive wear

Fig. Fig. 9: Be sure that the flywheel surface is clean, before installing the clutch

Fig. Fig. 10: Typical clutch alignment tool, note how the splines match the Transaxle's input
shaft

Fig. Fig. 11: Use the clutch alignment tool to align the clutch disc during assembly

Fig. Fig. 12: Pressure plate-to-flywheel bolt holes should align

Fig. Fig. 13: You may want to use a threadlocking compound on the clutch assembly bolts
FIG : Fig. 14: Clutch cover bolt tightening sequence

Fig. Fig. 15: Be sure to use a torque wrench to tighten all bolts

ADJUSTMENTS
The clutch system in the General Motors J-Body vehicles is a hydraulic system and requires no
adjustments. If the system is malfunctioning, use normal clutch diagnosis to determine the
problem.
Please ACCEPT my answer so I can get credit for my work.i don't receive commission unless you
do ..I'm not always going to be giving you good news,so please don't let this stand in the way of
you accepting my answer.it does not cost you more money.we will still be able to communicate..
Bonuses and positive feedback are appreciated!if you are not satisfied with my answer,please do
not leave bad feed back,i will gladly opt out and let another expert handle the question.if i have
sent any diagrams,please print them.they will only stay on here for an hour or so.PLEASE ASK IF
YOU NEED MORE HELP

ALL THE BONUS MONEY THAT I RECEIVE DURING THE MONTH OF JUNE WILL BE DONATED TO
THE AMERICAN RED CROSS FOR TORNADO RELEIF IN THE MID WEST,NORTHEAST AND DEEP
SOUTH,,THANKS FOR YOUR SUPPORT
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