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Home >> Chevrolet >> 2005 >> Optra5 Base, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transmission - D20 >> Repair Instructions >> Transmission Replacement >> Removal Procedure

Removal Procedure

    Fig 1: Transaxle Rear Mounting Bracket
    GM1248179Courtesy of GENERAL MOTORS CORP.
  1. Install the J 28467-B  (DW-117).
  2. Remove the battery and battery tray. Refer to Battery and Battery Tray Replacement in Engine Electrical.
  3. Remove the shift linkage assembly. Refer to Shift Control Linkage Replacement .
  4. Remove the drive axle shaft. Refer to Inner Axle Shaft Replacement - Front Drive Axle (Manual) or Inner Axle Shaft Replacement - Front Drive Axle (Automatic) in Front Drive Axle.
    5. Fig 2: Backup Lamp Switch & Speedometer Speed Sensor Electrical Connector
    GM1248184Courtesy of GENERAL MOTORS CORP.
    NOTE: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly.
  5. Disconnect the backup lamp switch electrical connector.
  6. Disconnect the speedometer speed sensor electrical connector.
    7. Fig 3: View Of Clutch Release Cylinder Pipe And Pin
    GM1290977Courtesy of GENERAL MOTORS CORP.
  7. Remove the pin and the clutch release cylinder pipe.
    8. Fig 4: Removing Rear Mounting Bracket & Bolts
    GM1248186Courtesy of GENERAL MOTORS CORP.
  8. Remove the damping block connection nut and bolt.
  9. Remove the 3 rear mounting bracket bolts.
  10. Remove the rear mounting bracket from the transaxle.
    11. Fig 5: View Of Rear Damping Blocks And Retaining Bolts
    GM1290978Courtesy of GENERAL MOTORS CORP.
  11. Remove the 2 rear damping block retaining bolts.
  12. Remove the rear damping block from the front cross member.
    13. Fig 6: Removing Transaxle Upper Mounting Bracket & Bolts
    GM1248189Courtesy of GENERAL MOTORS CORP.
  13. Remove the 2 cage retaining bolts.
  14. Remove the 3 transaxle upper mounting bracket bolts.
  15. Remove the upper mounting bracket and cage.
    16. Fig 7: Removing Transaxle Upper & Retaining Bolts
    GM1248191Courtesy of GENERAL MOTORS CORP.
  16. Remove the 3 transaxle upper retaining bolts.
    17. Fig 8: Transaxle Support Jack & Transaxle
    GM1248192Courtesy of GENERAL MOTORS CORP.
  17. Support the transaxle with a transaxle support jack.
    18. Fig 9: Removing Transaxle Lower & Retaining Bolts
    GM1248194Courtesy of GENERAL MOTORS CORP.
  18. Remove the 7 transaxle lower retaining bolts.
    19. Fig 10: Transaxle & Engine Block
    GM1248195Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Rest the transaxle only in an upright position.
  19. Remove the transaxle.
  20. Slide the transaxle sideways away from the engine block.
  21. Lower the transaxle.
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