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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 261 (Manual Transmission - GETRAG (M86) - Overhaul) >> Repair Instructions >> Transaxle Case Assembly

Transaxle Case Assembly

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Tools Required

  1. Install the shift rod and bushing.
    Fig 1: View Of Shift Rod & Bushing
    GM658859Courtesy of GENERAL MOTORS CORP.
    2. Fig 2: Installing Intermediate Shaft Needle Bearing
    GM762370Courtesy of GENERAL MOTORS CORP.
  2. Install the intermediate shaft needle bearing to the transmission housing using the J 44383  (1) and the J 8092  (2).
    3. Fig 3: Installing New Shifter Shaft Bearing Using J 44381 & J 8092
    GM658858Courtesy of GENERAL MOTORS CORP.
  3. Install a new shifter shaft bearing flush with the casting in the transmission housing, using the J 44381  (1) and the J 8092  (2).
    4. IMPORTANT: Do not over apply the threadlocker to the bolt threads.
  4. Apply GM P/N United States 12345382, GM P/N Canada 10953489 to the reverse lockout lever bolt threads.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: The spring (2) fingers must be positioned on either side of the lever (3).
    Fig 4: View Of Transmission Housing Bolt, Spring & Reverse Lockout Lever
    GM658860Courtesy of GENERAL MOTORS CORP.
  5. Install the reverse lockout lever (3), spring (2), and the bolt (1) to the transmission housing, if equipped.

    Tighten:  Tighten the bolt to 6 N.m (53 lb in).

    6. Fig 5: Installing Differential Race
    GM658871Courtesy of GENERAL MOTORS CORP.
  6. Install a new differential bearing race to the transmission housing using the J 44385  (2) and the J 7079-2  (1).
    7. Fig 6: Installing Differential Bearing Race Seal
    GM660201Courtesy of GENERAL MOTORS CORP.
  7. Install a new differential side bearing race seal to the transmission housing using the J 44385  (2) and the J 7079-2  (1).
    8. Fig 7: Installing Countershaft Bearing To Clutch Housing
    GM658878Courtesy of GENERAL MOTORS CORP.
  8. Install the countershaft bearing to the clutch housing using the J 44381  (1) and the J 7079-2  (2).
  9. Install a new snap ring.
    10. Fig 8: Installing Input Shaft Bearing
    GM747502Courtesy of GENERAL MOTORS CORP.
  10. Install the input shaft bearing to the clutch housing using the J 44381  (2) and the J 7079-2  (1).
    11. Fig 9: Installing Output Shaft Bearing Race
    GM658868Courtesy of GENERAL MOTORS CORP.
  11. Install the output shaft bearing race and bolts using the J 44387-1 (2), J 44387-2 (3), and the J 7079-2  (1).

    Tighten:  Tighten the output shaft bearing bolts to 10 N.m (89 lb in).

    12. Fig 10: Installing Differential Bearing Race To Clutch Housing
    GM658872Courtesy of GENERAL MOTORS CORP.
  12. Install a new differential bearing race to the clutch housing using the J 44385  (2) and the J 7079-2  (1).
    13. Fig 11: Installing Shifter Detent
    GM1518813Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If either the case or shifter detent is damaged, it may be necessary to install a new shifter detent and/or case.
  13. Install the shifter detent into the case if necessary.
    14. Fig 12: Installing Differential Output Shaft Seal To Clutch Housing
    GM658880Courtesy of GENERAL MOTORS CORP.
  14. Install a new differential output shaft seal to the clutch housing using the J 44385  (2) and the J 8092  (1).
  15. Install the snap rings to the input shaft and output shaft bearings.
  16. Install the input shaft and output shaft bearings into the transmission housing using the J 44385  (2) and the J 7079-2  (1).
    Fig 13: Installing Input & Output Shaft Bearings
    GM658882Courtesy of GENERAL MOTORS CORP.
    17. Fig 14: View Of Gear Assemblies & Shift Forks
    GM634461Courtesy of GENERAL MOTORS CORP.
  17. Install the shift forks and the input shaft and output shaft onto the J 44375  .
    18. Fig 15: View Of Countershaft, Input Shaft, Intermediate Shaft & Shift Fork
    GM634460Courtesy of GENERAL MOTORS CORP.
  18. Install the countershaft and the shift fork onto the J 44375  .
  19. Rotate the shaft to verify all gears are properly meshing.
    20. Fig 16: Installing Housing & Shafts
    GM634463Courtesy of GENERAL MOTORS CORP.
  20. Install the housing onto the shift forks and the shafts on to the J 44375  . Line up the shift forks and the shafts with the housing.
    21. IMPORTANT: Install the transaxle case to the shafts evenly using the J 44376  .
    Fig 17: Installing Transaxle Case Using The J 44376
    GM658883Courtesy of GENERAL MOTORS CORP.
  21. Install the transaxle case to the shafts using the J 44376  .
    22. Fig 18: Shifting Transmission Into 4th And 5th Gear Using A Screwdriver
    GM513921Courtesy of GENERAL MOTORS CORP.
  22. Shift the transmission into 4th and 5th gear using a screwdriver in an upward direction.
  23. Apply GM P/N United States 12345493, GM P/N Canada 10953488 to the input and output shaft bolts.
  24. Install NEW input and output shaft bolts while holding the transmission into 4th and 5th gear in an upward direction.

    Tighten:  Tighten the shaft bolts to 110 N.m (81 lb ft).

    25. Fig 19: Installing Sealant To Rear Cover
    GM514887Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If shimming is required, refer to Shimming Procedures  before installing the cover.
  25. Install sealant GM P/N United States 12346286, GM P/N Canada 10953472 to the rear cover.
    26. IMPORTANT: The oil guide only installs in one direction. Ensure the oil guide is completely seated in the gear shafts.
  26. Install the oil guide.
  27. Install the rear cover.
    Fig 20: View Of Rear Cover
    GM513914Courtesy of GENERAL MOTORS CORP.
  28. Install the rear cover bolt.

    Tighten:  Tighten the rear cover bolt to 25 N.m (18 lb ft).

    29. Fig 21: View Of Backup Lamp Switch
    GM514888Courtesy of GENERAL MOTORS CORP.
  29. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480 to the backup lamp switch.
  30. Install the backup lamp switch into the transaxle case.

    Tighten:  Tighten the backup lamp switch to 18 N.m (13 lb ft).

    31. Fig 22: Identifying J 44375
    GM634458Courtesy of GENERAL MOTORS CORP.
  31. Turn the transaxle case and the J 44375  over on the table.
  32. Remove the J 44375  from the gear shafts and the shift forks.
    33. Fig 23: View Of Oil Tube
    GM513926Courtesy of GENERAL MOTORS CORP.
  33. Install the oil tube into the transaxle case.
    34. Fig 24: View Of Shift Fork
    GM679562Courtesy of GENERAL MOTORS CORP.
  34. Install the shift rod to the shift fork.
    35. Fig 25: Applying Sealer To Transaxle Case-To-Shifter Cover Mating Surface
    GM514892Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Use only the approved sealer for the transaxle case to shifter cover mating surface.
  35. Apply sealer GM P/N United States 12378516, GM P/N Canada 88900757 to the transaxle case to shifter cover mating surface.
    36. Fig 26: View Of Shifter And Retaining Bolts
    GM513882Courtesy of GENERAL MOTORS CORP.
  36. Install the shifter and the shifter retaining bolts.

    Tighten:  Tighten the shifter retaining bolts to 25 N.m (18 lb ft).

    Install all possible shifter bolts with the shifter in the neutral position. Install the last shifter bolt in gear and then shift the transmission back into neutral.

  37. Shift the transmission into neutral.
  38. Apply GM P/N United States 12346004, GM P/N Canada 10953480 to the shifter guide bolt.
    Fig 27: View Of Shifter Guide Bolt
    GM513880Courtesy of GENERAL MOTORS CORP.
    39. NOTE: Hand start and tighten the shifter guide bolt to avoid damaging the shift lever.
  39. Install the shifter guide bolt.

    Tighten:  Tighten the shifter guide bolt to 25 N.m (18 lb ft).

    40. Fig 28: View Of Differential
    GM513904Courtesy of GENERAL MOTORS CORP.
  40. Install the differential into the transaxle case.
    41. IMPORTANT: The step in the roller bearing faces opposite of the pinion gear.
    Fig 29: View Of Roller Bearing
    GM513908Courtesy of GENERAL MOTORS CORP.
  41. Install the roller bearing onto the output shaft.
    42. Fig 30: View Of Transaxle Magnet
    GM514837Courtesy of GENERAL MOTORS CORP.
  42. Install the magnet into the transaxle case.
    43. Fig 31: Applying Sealant To Transaxle Case-To-Clutch Housing Mating Surface
    GM514893Courtesy of GENERAL MOTORS CORP.
  43. Apply sealant GM P/N United States 12378516, GM P/N Canada 88900757 to the transaxle case to clutch housing mating surface.
    44. Fig 32: View Of Clutch Housing & Transaxle Case
    GM513889Courtesy of GENERAL MOTORS CORP.
  44. Install the clutch housing to the transaxle case.
    45. Fig 33: Installing Countershaft Into Clutch Housing Bearing
    GM681423Courtesy of GENERAL MOTORS CORP.
  45. Install the countershaft into the clutch housing bearing using the J 44389  .
    46. Fig 34: View Of Clutch Housing Side Transmission Housing Bolt
    GM513885Courtesy of GENERAL MOTORS CORP.
  46. Install the clutch housing to transaxle case bolts.

    Tighten:  Tighten the housing bolts to 27 N.m (20 lb ft).

  47. Turn the transmission over.
  48. Install the transaxle case to clutch housing bolts.

    Tighten:  Tighten the housing bolts to 27 N.m (20 lb ft).

    Fig 35: View Of Transaxle Case Side Of Housing Bolt
    GM513865Courtesy of GENERAL MOTORS CORP.
    49. Fig 36: Locating Shifter
    GM513877Courtesy of GENERAL MOTORS CORP.
  49. Turn the transmission so the shifter is on top.
  50. Shift the transmission into any gear.
    51. Fig 37: View Of Actuator And Tube
    GM881740Courtesy of GENERAL MOTORS CORP.
  51. Install the actuator and tube.
  52. Install the actuator and tube bolts.

    Tighten:  Tighten the tube bolts to 10 N.m (89 lb in).

    53. Fig 38: View Of Transmission Drain Plug
    GM747503Courtesy of GENERAL MOTORS CORP.
  53. Apply GM P/N United States 12346004, GM P/N Canada 10953480 to the transmission drain plug.
  54. Install the transmission drain plug.

    Tighten:  Tighten the transmission drain plug to 38 N.m (28 lb ft).

    55. Fig 39: View Of Transmission Filler Cap
    GM747504Courtesy of GENERAL MOTORS CORP.
  55. Install the transmission fill cap.
  56. Hold the input shaft with the J 44377  .
  57. Apply GM P/N United States 12345493, GM P/N Canada 10953488 to the intermediate shaft bolt.
  58. Install the bolt in the intermediate shaft.

    Tighten:  Tighten the intermediate shaft bolts to 95 N.m (70 lb ft).

    Fig 40: View Of Intermediate Shaft Bolt
    GM634456Courtesy of GENERAL MOTORS CORP.
    59. Fig 41: Identifying Plastic Oil Guide
    GM513875Courtesy of GENERAL MOTORS CORP.
  59. Install a new plastic oil guide into the intermediate shaft.
    60. IMPORTANT: Ensure not to press the sealing cap past the bottom of the chamfer.
    Fig 42: Identifying Intermediate Shaft Seal
    GM513872Courtesy of GENERAL MOTORS CORP.
  60. Install a new intermediate shaft sealing cap.
  61. Apply GM P/N United States 12345382, GM P/N Canada 10953489 to the vehicle speed sensor bolt.
  62. Install the vehicle speed sensor, seal, and bolt.

    Tighten:  Tighten the bolt to 12 N.m (8 lb ft).

    Fig 43: View Of Vehicle Speed Sensor & Bolt
    GM658863Courtesy of GENERAL MOTORS CORP.
    63. Fig 44: View Of Shift Cable Bracket Assembly
    GM679569Courtesy of GENERAL MOTORS CORP.
  63. Install the shift cable bracket (4), the isolators (3), the spacers (2) and the bolt (1).

    Tighten:  Tighten the shift cable bracket bolt to 20 N.m (15 lb ft).

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