Transmission Replacement. Chevrolet Joy 2008

For 1990-2009 cars

#### Tools Required

EN46567 (DW110-020-A) Engine Assembly 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 battery and battery tray. Refer to Battery Replacement .
3. Remove the shift cable pins (1).
4. Remove the washers (2).
5. Disconnect the select and the shift cable (3).
6. Remove the cable E-rings (4).
7. Disconnect the shift cables from the cable bracket.
8. Remove the engine wiring harness retaining strap.
9. Remove the ground wire bolt (2).
10. Disconnect the ground wire (1).
11. Disconnect the backup lamp switch connector (3).
12. Remove the radiator lower hose bolts (2).
13. Disconnect the radiator lower hose (1).
14. Remove the crankshaft position (CKP) sensor bolt (3).
15. Disconnect the CKP sensor connector and remove the CKP sensor.
16. Loosen the speedometer cable nut (1).
17. Disconnect the speedometer cable (2).
18. Remove the vehicle speed sensor (VSS), if equipped.
19. Remove the starter motor (1) by removing the upper 2 bolts (2) that secure the starter motor to the transaxle.

Caution: While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

20. Remove the air inlet grille panel weatherstrip.
21. Position the EN46567 (1) on the air inlet grille panel and the front upper panel.
22. Tighten the engine fixture joint with a bolt after removing the exhaust manifold bolt.
23. Remove the transaxle upper exhaust manifold side bolt (1) and the thermostat housing side bolt (2).
24. Remove the transaxle under cover bolts (1) and the transaxle under cover (2).
25. Remove the front tires and wheels.
26. Drain the transaxle fluid.
27. Remove the cable adjust nut (1).
28. Disconnect the cable from the wire clip (2).
29. Disconnect the clutch cable from the transaxle mount hole (3).
30. Remove the front under longitudinal frames and stabilizer. Refer to Stabilizer Shaft Replacement .
31. Remove the drive axle, only from the transaxle side. Refer to Front Drive Axle Inner Shaft Replacement .
32. Remove the clutch housing lower plate bolts (1) and lower plate (2).

Caution: While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

33. Remove the front exhaust pipe nuts from the exhaust manifold side (1).
34. Remove the gasket and separate the exhaust manifold pipe (3).
35. Remove the front exhaust pipe (2).
36. Support the transaxle with a transmission jack (2) or equivalent.
37. Remove the transaxle lower bolt (1) and nut (2).
38. Remove the transaxle mount bolts (1).
39. To remove the manual transaxle side cover without the interference with the front under longitudinal panel - left, tilt the engine/manual transaxle by loosening the EN46567 (1) joint with the wrench.
40. Lower the transaxle assembly (2) slowly by adjusting the jack (1).
41. Tilt the transaxle assembly by adjusting the jack.
42. Remove the transaxle assembly by pulling and lowering it slowly.

Notice: Support the engine in the normal position when removing the transaxle. Damage to related parts can occur.

Important: If it is impossible to use the special tool, support the engine to normal position with the auto jack.

43. Support the engine to normal position using the EN46567 (1).

### Installation Procedure

Notice: Refer to Fastener Notice in the Preface section.

1. Install the transaxle mounting bolts (1).

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

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

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

3. Install the front exhaust pipe nuts (1).

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

4. Install the transaxle upper exhaust manifold side bolt (1) and the thermostat housing side bolt (2).

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

5. Install the starter motor.

Tighten
Tighten the starter motor bolts (1) to 18-28 N·m (13-21 lb ft).

6. Connect all electric connectors.
7. Install the radiator lower hose bolts (1).

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

8. Install the crank position (CKP) sensor bolt (2).

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

9. Install the drain plug (2).

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

10. Remove the oil level plug (1).
11. Refill recommended fluid to the proper level.

Specification

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

• | The capacity is 2.1L (2.21 qt).

12. Install the oil level plug (1).

Tighten
Tighten the oil level plug to 36-54 N·m (26-40 lb ft).

13. Adjust the clutch cable by the clutch cable adjust nut. Refer to Clutch Assembly Adjustment .
14. Install the transaxle under cover bolts (1).

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

15. Install the battery and battery tray. Refer to Battery Replacement .
16. 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.