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Home >> Pontiac >> 2005 >> Sunfire Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transmission - GETRAG 5 Speed >> Repair Instructions >> Transmission Replacement >> Installation Procedure

Installation Procedure

  1. Install the transaxle to the engine block.
    2. Fig 1: Locating Transaxle-To-Engine Mount Bolts
    GM414961Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the transaxle-to-engine lower mounting bolts.

    Tighten:  Tighten the transaxle-to-engine lower mounting bolts to 75 N.m (55 lb ft).

    3. Fig 2: Identifying Transaxle Case & Support Stand
    GM414959Courtesy of GENERAL MOTORS CORP.
  3. Remove the following components
    • The safety strap
    • The transaxle jack
  4. Install the front transaxle mount-through bolt.

    Tighten:  Tighten the front transaxle mount-through bolt to 60 N.m (44 lb ft).

  5. Install the flywheel inspection cover.
  6. Install the washer solvent container. Refer to Washer Solvent Container Replacement in Wipers/Washer Systems.
    7. Fig 3: View Of Transaxle Support Components
    GM414963Courtesy of GENERAL MOTORS CORP.
  7. Remove the jackstand supporting the engine.
  8. Install the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
  9. Install the drive axles. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shaft.
  10. Install the front suspension crossmember. Refer to iCrossmember Replacement in Frame and Underbody.
    11. Fig 4: View Of Engine Strut-To-Strut Bracket
    GM414910Courtesy of GENERAL MOTORS CORP.
  11. Install the engine strut-to-strut bracket.
    12. Fig 5: Locating Rack & Pinion Mounting Bolts
    GM414934Courtesy of GENERAL MOTORS CORP.
  12. Install the rack and pinion mounting bolts.

    Tighten:  Tighten the rack and pinion mounting bolts to 120 N.m (89 lb ft).

  13. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  14. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
  15. Lower the vehicle.
    16. Fig 6: Identifying Upper Transaxle Mounting Bolts
    GM414938Courtesy of GENERAL MOTORS CORP.
  16. Install the upper transaxle mounting bolts

    Tighten:  Tighten the upper transaxle mounting bolts to 96 N.m (71 lb ft).

    17. Fig 7: Identifying Clutch Actuator Cylinder Pressure Line
    GM621603Courtesy of GENERAL MOTORS CORP.
  17. Connect the clutch master cylinder line.
    18. Fig 8: Locating Vehicle Speed Sensor (VSS)
    GM623138Courtesy of GENERAL MOTORS CORP.
  18. Connect the vehicle speed sensor.
    19. Fig 9: Locating Backup Light Switch Connector
    GM621567Courtesy of GENERAL MOTORS CORP.
  19. Connect the backup light switch.
  20. Remove the engine support fixture.
    21. Fig 10: View Of Negative Battery Cable To Engine Block
    GM439868Courtesy of GENERAL MOTORS CORP.
  21. Install the negative battery cable to the engine block.
  22. Install the air inlet duct.
  23. Fill the transaxle with Dexron III Transaxle Fluid GM P/N 12346143 (Canadian P/N 10952622) or equivalent.
  24. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding in Clutch.
  25. Install the battery.
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