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Home >> Pontiac >> 2002 >> Firebird Base, 2D Convertible, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transmission - M49 >> Repair Instructions >> Transmission Replacement >> Installation Procedure

Installation Procedure

  1. Remove the transmission from the J 3289-20, if necessary.
  2. Mount the transmission to the jack stand.
  3. Remove the J 36842 from the transmission, if necessary.
  4. Install the bellhousing (1) to the transmission (2).
    NOTE: 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.
  5. Install the transmission bolts (3).

    Tighten 

    Tighten the transmission bolts (3) to 75 N.m (55 lb ft).

    Fig 1: Installing Transmission Bolts
    G01766616Courtesy of GENERAL MOTORS CORP.
  6. Install the clutch actuator cylinder (2).
  7. Install the clutch actuator cylinder bolts (1).

    Tighten 

    Tighten the clutch actuator cylinder bolts (1) to 8 N.m (71 lb in).

  8. Install the clutch line to the actuating cylinder.
  9. Install the clutch bleeder to the actuating cylinder.
    Fig 2: Installing Clutch Actuator Cylinder
    G01766617Courtesy of GENERAL MOTORS CORP.
  10. Slowly raise the manual transmission (4) to the vehicle.
  11. Install the flywheel housing bolts (1, 2) and nuts (3).

    Tighten 

    Tighten the flywheel housing bolts (1,2) and nuts (3) to 95 N.m (70 lb ft).

  12. Install the transmission support and mount. Refer to Transmission Support and Mount Assembly .
  13. Remove the transmission jack.
  14. Remove the J 42055 from the transmission jack.
  15. Remove the engine safety stand.
    Fig 3: Installing Flywheel Housing Bolts
    G01766618Courtesy of GENERAL MOTORS CORP.

    Important:  DO NOT rely on an audible click or a visual verification of the clutch hydraulic hose quick connect fitting connection.

  16. Connect the clutch actuator cylinder hose to the clutch master cylinder hose.
  17. Push together the clutch hydraulic hose quick connect fittings, then pull back on the fittings to verify engagement.
  18. Check the clutch hydraulic hoses for twists or kinks.
    Fig 4: Connecting Clutch Actuator Cylinder Hose
    G01766619Courtesy of GENERAL MOTORS CORP.
  19. Install the flywheel housing cover (3) to the transmission (1).
  20. Install the flywheel housing cover bolts (2).

    Tighten 

    Tighten the flywheel housing cover bolts (2) to 9 N.m (80 lb in).

    Fig 5: Installing Flywheel Housing Cover To Transmission
    G01766620Courtesy of GENERAL MOTORS CORP.
  21. Install the right transmission brace (1).
  22. Install the right transmission brace bolts (2, 3, 4).

    Tighten 

    Tighten the right transmission brace bolts (2, 3, 4) to 50 N.m (37 lb ft).

    Fig 6: Installing Right Transmission Brace And Bolts
    G01766621Courtesy of GENERAL MOTORS CORP.
  23. Install the left transmission brace (1).
  24. Install the left transmission brace bolts (2, 3).

    Tighten 

    • Tighten the left transmission brace bolts (2) (to transmission) to 50 N.m (37 lb ft).
    • Tighten the left transmission brace bolts (3) (to engine) to 28 N.m (21 lb ft).
      Fig 7: Installing Left Transmission Brace And Bolts
      G01766622Courtesy of GENERAL MOTORS CORP.
    • Install the wiring harness clip bolt (1) to the right side of the transmission.

      Tighten 

      Tighten the wiring harness clip bolt (1) to 11 N.m (97 lb in).

      Fig 8: Installing Wiring Harness Clip Bolt
      G01766623Courtesy of GENERAL MOTORS CORP.
    • Install the wiring harness clip bolt (2) to the left side of the transmission.

      Tighten 

      Tighten the wiring harness clip bolt (2) to 11 N.m (97 lb in).

    • Connect the speed sensor (1) and backup lamp switch (3) electrical connectors.
    • Install the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (3.8L ENGINE) .
    • Install the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - ONE PIECE .
    • Install the torque arm.
      Fig 9: Installing Wiring Harness Clip Bolt
      G01766624Courtesy of GENERAL MOTORS CORP.
    • Fill transmission with fluid.
    • Lower the vehicle.
    • Install the control assembly. Refer to Shift Control Assembly Replacement .
    • Bleed the clutch hydraulic system. Refer to BLEEDING .
      Fig 10: Filling Transmission
      G01766625Courtesy of GENERAL MOTORS CORP.
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