LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2004 >> Optra LS, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission - ZF 4HP 16 - Repair Instructions >> Repair Instructions >> Transmission Replacement >> Removal Procedure

Removal Procedure

    Fig 1: View Of J 28467-B
    GM1289833Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  1. Disconnect the negative battery cable.
  2. Move the gear select lever to the Park position.
  3. Remove the battery. Refer to Battery and Battery Tray Replacement in Engine Electrical.
  4. Install J 28467-B  (1).
    5. Fig 2: Identifying Shift Control Cable And Retaining Clip
    GM1290880Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the transaxle wiring harness from the transaxle.
  6. Disconnect the electrical connector from the park/neutral position (PNP) switch.
    7. Fig 3: Identifying Shift Control Cable And Clip
    GM1255921Courtesy of GENERAL MOTORS CORP.
  7. Remove the clips from the shift control cable and disconnect the cable from the transaxle.
    8. Fig 4: View Of Upper Transaxle To Engine Bolts
    GM1255970Courtesy of GENERAL MOTORS CORP.
  8. Remove the bolts that secure the upper transaxle to the engine.
    9. Fig 5: View Of Left Transaxle Mounting Bracket And Bolts
    GM1290961Courtesy of GENERAL MOTORS CORP.
  9. Remove the left transaxle mounting bracket. Refer to Transmission Mount Bracket Replacement .
    10. Fig 6: Identifying Inlet Pipes
    GM1290944Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Vehicle Lifting and Jacking Notice in Cautions and Notices.
  10. Raise and suitable support the vehicle.
  11. Drain the transaxle fluid.
  12. Remove the oil cooler pipes from the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe Replacement .
    13. Fig 7: View Of Transaxle With Rubber Access Cover Removed
    GM1255972Courtesy of GENERAL MOTORS CORP.
  13. Remove the drive axle. Refer to Front Drive Axle Inner Shaft Replacement (Manual) or Front Drive Axle Inner Shaft Replacement (Automatic) in Front Drive Axle.
  14. Remove the starter motor. Refer to Starter Replacement (1.4L/1.6L) or Starter Replacement (1.8L/2.0L) in Engine Electrical.
  15. Remove the rubber access cover from the transaxle, then remove the flywheel to torque converter bolts.
    16. Fig 8: View Of Rear Mounting Bracket And Bolts
    GM1290871Courtesy of GENERAL MOTORS CORP.
  16. Support the transaxle.
  17. Remove the bolts (1) from the rear transaxle mounting bracket.
  18. Remove the bolt and nut (2) from the damping block connection.
    19. Fig 9: Identifying DW 260-010
    GM1255936Courtesy of GENERAL MOTORS CORP.
  19. Use DW 260-010  (1) to support the transaxle assembly. See Special Tools .
    20. Fig 10: View Of Lower Engine Retaining Bolts
    GM1255935Courtesy of GENERAL MOTORS CORP.
  20. Remove the bolts that retain the lower engine to the transaxle.
    21. Fig 11: Identifying DW 260-010
    GM1255936Courtesy of GENERAL MOTORS CORP.
  21. Using the DW 260-010  (1), remove the transaxle assembly. See Special Tools .
scientia non olet · About LEMON Manuals