GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Cavalier 🢒 Engine 🢒 Engine Electrical 🢒 Transmission Replacement

Removal Procedure
  1. Disconnect the negative and positive battery cable ends from the battery. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the retaining bolt and the battery.
  3. Remove the washer solvent container. Refer to Windshield Washer Solvent Container Replacement .
  4. Install the engine support fixture. Refer to the instruction manual provided with the tool.
  5. Raise the engine enough to take pressure off of the transaxle mounts.
  6. Remove the air cleaner and duct assembly from the throttle body. Refer to Air Cleaner Assembly Replacement in Engine Controls-2.4L.
  7. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  8. Remove the upper radiator hose. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  9. Remove the wire harness from the upper transaxle mount bracket.

    10. Object Number: 626463 Size: SH
  10. Remove the upper transaxle mount bolts.

    11. Object Number: 439868 Size: SH
  11. Remove the negative battery cable from the transaxle housing.
  12. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.

    13. Object Number: 621603 Size: SH
  13. Disconnect the pressure line from the clutch actuator cylinder.

    14. Object Number: 621567 Size: SH
  14. Disconnect the backup light switch connector.

    15. Object Number: 626463 Size: SH
  15. Remove the rear transaxle mount bolts.

    16. Object Number: 621567 Size: SH
  16. Disconnect the vehicle speed sensor (VSS).

    17. Object Number: 414938 Size: SH
  17. Remove the upper transaxle mounting bolts.

    18. Object Number: 621601 Size: SH
  18. Disconnect the shift cables at the transmission shift control and the bracket.

    19. Object Number: 621599 Size: SH
  19. Remove the cable bracket bolt and the bracket.

    20. Object Number: 414934 Size: SH
  20. Remove the rack and pinion mounting bolts.
  21. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  22. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  23. Remove the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
  24. Remove the front suspension crossmember. Refer to Front Suspension Crossmember Replacement in Front Suspension.

    25. Leave the steering rack in the vehicle.

  25. Remove the flywheel support arm bracket from the flywheel cover to engine lower mount.
  26. Remove the flywheel housing cover bolts.
  27. Remove the flywheel housing cover.
  28. Remove the drive axles from the transmission. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shaft.

    29. Secure the drive axles out of the way.


    Object Number: 414910 Size: SH
  29. Remove the engine strut from the bracket.
  30. Remove the front lower transaxle mount through-bolt.

    31. Object Number: 414959 Size: SH
  31. Attach the transaxle case to the support stand.

    32. Object Number: 414963 Size: SH
  32. Support the engine with a suitable axle jack.

    33. Object Number: 414961 Size: SH
  33. Remove the transaxle-to-engine mount bolts.
  34. Use the following procedure in order to remove the transmission:
    35. 34.1. Slide the transaxle away from the engine.
    34.2. Carefully lower the trans axle jack.
    34.3. Remove the transaxle.

Installation Procedure
  1. Install the transaxle to the engine block.

    2. Object Number: 414961 Size: SH

    Notice: 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.

  2. Install the transaxle-to-engine lower mounting bolts.

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


    Object Number: 414959 Size: SH
  3. Remove the following components
    4. • The safety strap
    • The transaxle jack
  4. Install the front transaxle mount-through bolt.

    5. 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 Windshield Washer Solvent Container Replacement in Wipers/Washer Systems.

    7. Object Number: 414963 Size: SH
  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 Front Suspension Crossmember Replacement in Wipers/Washer Systems.

    11. Object Number: 414910 Size: SH
  11. Install the engine strut-to-strut bracket.

    12. Object Number: 414934 Size: SH
  12. Install the rack and pinion mounting bolts.

    13. 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. Object Number: 414938 Size: SH
  16. Install the upper transaxle mounting bolts

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


    Object Number: 621603 Size: SH
  17. Connect the clutch master cylinder line.

    18. Object Number: 623138 Size: SH
  18. Connect the vehicle speed sensor.

    19. Object Number: 621567 Size: SH
  19. Connect the backup light switch.
  20. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical-2.4L.

    21. Object Number: 439868 Size: SH
  21. Install the negative battery cable to the engine block.
  22. Install the upper radiator hose. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  23. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-2.4L.
  24. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  25. Fill the transaxle with Dexron III Transaxle Fluid GM P/N 12346143 (Canadian P/N 10952622) or equivalent.
  26. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding in Clutch.
  27. Install the battery.