Transmission Replacement. Chevrolet Joy 2008

For 1990-2009 cars

#### Tools Required

EN46567 (DW110-020-A) Engine Support Fixture

### Removal Procedure

1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 0.8L engine or Air Cleaner Assembly Replacement for the 1.0L engine.

Caution: Refer to Batteries Produce Explosive Gases Caution in the Preface section.

2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 0.8L engine or Air Cleaner Assembly Replacement for the 1.0L engine.
3. Remove the battery and battery tray. Refer to Battery Replacement .
4. Remove the select and shift cable pins (1) and remove the washers (2).
5. Disconnect the select and shift cable (3).
6. Remove the cable E-rings (4).
7. Disconnect the cables from the cable bracket.
8. Remove the bending strap from the engine wiring harness. Disconnect the ground wire and the backup lamp switch connector.
9. Remove the ground wire bolt (2).
10. Disconnect the ground wire (1).
11. Disconnect the backup lamp switch connector (3).
12. Remove the bolts (1) and disconnect the radiator lower hose (2).
13. Remove the bolt (3) and remove the crankshaft position (CKP) sensor.
14. Disconnect the vehicle speed sensor (VSS) connector.
15. Remove the VSS.
16. Remove the starter motor. Refer to Starter Motor Replacement .

Caution: Refer to Hot Exhaust System Caution in the Preface section.

17. Remove the weatherstrip from the air inlet grille panel.
18. Position EN46567 (1) on the air inlet grille panel and the front upper panel.
19. Remove the exhaust manifold bolt. Tighten the engine fixture joint with a bolt.
20. Remove the side bolt (1) from the transaxle exhaust manifold and the side bolt (2) from the thermostat housing.
21. Remove the transaxle under cover (2).
22. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
23. Remove the drain plug. Drain the fluid.
24. Remove the clutch cable adjust nut (1).
25. Disconnect the clutch cable from the transaxle mount hole (2).
26. Remove the front under longitudinal frames and stabilizer. Refer to Stabilizer Shaft Replacement .
27. Remove the drive axle from the transaxle side. Refer to Front Drive Axle Inner Shaft Replacement .
28. Remove the bolts (1) from the clutch housing lower plate. Remove the lower plate (2).

Caution: Refer to Hot Exhaust System Caution in the Preface section.

29. Remove the front exhaust pipe nuts.
30. Remove the gasket and separate the exhaust manifold pipe.
31. Support the transaxle with a transaxle support jack.
32. Remove the transaxle lower bolt (1) and nut (2).
33. Remove the transaxle mount bolts (1).
34. Remove the transaxle.
35. Slide the transaxle sideways, away from the engine block.
36. Lower the transaxle.

### Installation Procedure

1. Properly support the transaxle onto the transaxle support jack.
2. Raise the transaxle into position.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the transaxle mounting bolts (1).

Tighten
Tighten the bolts on the body side to 45-55 N·m (33-41 lb ft).

4. Install the transaxle lower bolt (1) and nut (2).

Tighten
Tighten the bolt and nut to 55-65 N·m (41-48 lb ft).

5. Install the front exhaust pipe.

Tighten
Tighten the nuts on the exhaust manifold side to 25-35 N·m (18-25 lb ft).

6. Install the clutch housing lower plate (2).
7. Install the drive axle. Refer to Front Drive Axle Inner Shaft Replacement .
8. Install the front under longitudinal frames and stabilizer. Refer to Stabilizer Shaft Replacement .
9. Connect the clutch cable (2).
10. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
11. Install the transaxle under cover (1).

Tighten
Tighten the bolts to 35-55 N·m (25-41 lb ft).

12. Install the transaxle upper bolts (1).

Tighten
Tighten the bolts to 55-65 N·m (41-48 lb ft).

13. Remove the engine fixture joint bolt (1) from the exhaust manifold and replace the bolt.
14. Remove the engine support fixture.
15. Install the air inlet grille panel weatherstrip.
16. Install the starter motor. Refer to Starter Motor Replacement .
17. Install the VSS, if equipped.
18. Connect the speedometer cable.
19. Install and connect the CKP sensor (3).

Tighten
Tighten the bolt to 5-8 N·m (44-70 lb in).

20. Connect the radiator lower hose (2).

Tighten
Tighten the bolt to 8-15 N·m (70-132 lb in).

21. Connect the backup lamp switch connector (3).
22. Connect the ground wire (1) and install the bolt (2).
23. Connect the select and the shift cable (4).
24. Install the battery and the battery tray. Refer to Battery Replacement .
25. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 0.8L engine or Air Cleaner Assembly Replacement for the 1.0L engine.
26. Install the transaxle drain plug (2).

Tighten
Tighten the drain plug to 25-30 N·m (18-22 lb ft).

27. Install the oil level plug (1).
28. Refill with the recommended transaxle fluid to the proper level.

Specifications

• | The Classification is 75W-85 (GL-4).

• | The Capacity is 2.1L (2.21 qt).

29. Install the oil level plug.

Tighten
Tighten the plug to 25-30 N·m (18-22 lb ft).