Mike's Workshop Manuals: Service manuals for every vehicle
Home >> Chevrolet >> 2005 >> Optra5 Base, Standard >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission - ZF 4HP 16 - Introduction And Mechanical Repair >> Repair Instructions >> Transmission Replacement >> Installation Procedure

Installation Procedure

    Fig 1: Identifying DW 260-010
    GM1255936Courtesy of GENERAL MOTORS CORP.
  1. Install the transaxle assembly into the vehicle.
  2. Use the DW 260-010  (1) to support the transaxle assembly. See Special Tools .
    3. Fig 2: Identifying Lower Engine Retaining Bolts
    GM1255937Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the bolts (1, 2, 3) that retain the lower engine to the transaxle.

    Tighten: 

    • Tighten bolt (1) to 75 N.m (55 lb ft)  .
    • Tighten bolt (2) to 21 N.m (15 lb ft)  .
    • Tighten bolt (3) to 31 N.m (23 lb ft)  .

    4. Fig 3: View Of Rear Mounting Bracket And Bolts
    GM1290871Courtesy of GENERAL MOTORS CORP.
  4. Install the bolts (1) to the rear transaxle mounting bracket.

    Tighten:  Tighten bolt to 62 N.m (45 lb ft)  .

  5. Install the bolt and nut (2) to the damping block connection.

    Tighten:  Tighten bolt to 68 N.m (50 lb ft)  .

    6. Fig 4: View Of Transaxle With Rubber Access Cover Removed
    GM1255972Courtesy of GENERAL MOTORS CORP.
  6. Install the flywheel to torque converter bolts.

    Tighten:  Tighten the converter to flywheel bolts to 45 N.m (33 lb ft)  .

  7. Install the starter motor. Refer to Starter Motor Replacement (1.4L/1.6L) or Starter Motor Replacement (1.8L/2.0L) in Engine Electrical.
  8. Install the drive axle. Refer to Inner Axle Shaft Replacement - Front Drive Axle (Manual) or Inner Axle Shaft Replacement - Front Drive Axle (Automatic) in Front Drive Axle.
    9. Fig 5: Identifying Inlet Pipes
    GM1290944Courtesy of GENERAL MOTORS CORP.
  9. Install the oil cooler pipes to the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe Replacement .
  10. Lower the vehicle.
    11. Fig 6: View Of Left Transaxle Mounting Bracket And Bolts
    GM1290961Courtesy of GENERAL MOTORS CORP.
  11. Install the left transaxle mounting bracket. Refer to Transmission Mount Bracket Replacement .
    12. Fig 7: View Of Upper Transaxle To Engine Bolts
    GM1255970Courtesy of GENERAL MOTORS CORP.
  12. Install the bolts that secure the upper transaxle to the engine.

    Tighten:  Tighten the bolts to 75 N.m (55 lb ft)  .

    13. Fig 8: Identifying Shift Control Cable And Clip
    GM1255921Courtesy of GENERAL MOTORS CORP.
  13. Install the clips to the shift control cable. Connect the cable.
    14. Fig 9: Identifying Shift Control Cable And Retaining Clip
    GM1290880Courtesy of GENERAL MOTORS CORP.
  14. Install the PNP switch electrical connector.
  15. Connect the transaxle wiring harness to the transaxle.
    16. Fig 10: View Of J 28467-B
    GM1289833Courtesy of GENERAL MOTORS CORP.
  16. Remove J 28467-B  (1).
  17. Install the battery. Refer to Battery and Battery Tray Replacement in Engine Electrical.
  18. Add transaxle fluid. Refer to Transmission Fluid Level Inspection .
  19. Connect the negative battery cable.
scientia non olet · About Mike's Workshop Manuals