How to remove Manual Transaxle on 2006 Chevrolet Cobalt ?

Manual Transaxle Removal & Installation

Getrag Transaxle

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Remove the positive battery post from the underhood junction block.
4. Disconnect the positive cables from the underhood junction block.
5. Disconnect the surge tank inlet hose from the surge tank.
6. Remove the underhood junction block bracket nuts.
7. Loosen the underhood junction block bracket bolt.
8. Disconnect the front wiring harness from the underhood junction block bracket.
9. Reposition the underhood junction block bracket aside.
10. Disconnect the hydraulic clutch hose from the clutch actuator cylinder.
11. Remove the front wheel and tire assemblies.
12. Remove the both front fender liners.
13. Remove the steering gear mounting bolts and secure the steering gear with mechanic-s wire.
14. Disconnect the wheel speed sensor wires from the both front wheels and unclip from the frame.
15. Separate the ball joints from the steering knuckles.
16. With the wheels in the straight ahead position, remove the key from the ignition switch.
17. Secure the cooling module to the upper body structure.
18. Remove the left and right splash shields.
19. Remove the front transaxle mount to cradle through bolt.
20. Remove the rear transaxle mount to frame bolts.
21. Remove both stabilizer link to Stabilizer bar nuts.
22. Remove both tie rod to steering knuckle nuts.
23. Separate the outer tie rods from the steering knuckles.
24. Remove the intermediate steering shaft to steering gear pinch bolt and discard.
    
    WARNING

    DO NOT rotate the intermediate shaft once separated from the gear. Possible damage or a malfunction could occur.
25. Disconnect the intermediate steering shaft from the steering gear.
26. Remove both lower control arm ball stud to steering knuckle pinch bolts.
    
    WARNING

    Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result.
27. Lower the lower control arms in order to disengage the steering knuckle.
28. Mark the frame to body position with a paint pen or permanent marker.
29. Lower the vehicle to about 3 feet off the ground in order to place a hydraulic lift table under the frame.
30. Use two 2 x 4's between the lift table and the frame and lift the table to the frame.
31. Slowly remove the frame bolts using the following sequence:
    1. Remove the front frame bolts.
    2. Partially unscrew the rear frame bolts exposing 1 ¹ / ₂ inches (25mm) of bolt shank.
32. Slowly lower the lift table to the floor. Secure the cooling module to the upper body structure.
33. Remove the upper transaxle to mount bolts.
34. Remove the upper transaxle to engine bolt.
35. Drain the transaxle.
36. Disconnect the drive axles from the transaxle and secure out of the way.
37. Remove the starter.
38. Disconnect the shift cables from the transaxle.
39. Disconnect the backup lamp switch harness connector.
40. Disconnect the vehicle speed sensor.
41. Lower the vehicle.
42. Use the engine support fixture rear hook to lower the powertrain enough to allow clearance between the side rail and powertrain.
43. Raise the vehicle.
44. Use a transaxle jack to secure the transaxle, and remove the transaxle to engine bolts.
45. Remove the transaxle from the vehicle.
46. Remove the front transaxle mount from the transaxle.
47. Remove the rear transaxle mount and bracket from the transaxle.

To install:

1. Install the rear transaxle mount to the transaxle.
2. Install the front transaxle mount to the transaxle.
3. Tighten the transaxle mount through bolts in the following order: Tighten the rear bolt to 74 ft. lbs. (100 Nm). Tighten the front bolt to 74 ft. lbs. (100 Nm).
4. Use a transaxle jack to position the transaxle to the vehicle.
   
   NOTE

   The number 3 position does not require a bolt.
   
   
   
   
   

   

   Fig. Engine-to-transmission bolts-Getrag transmission
5. Secure the transaxle to the engine. Tighten the bolts to 55 ft. lbs. (75 Nm).
6. Connect the vehicle speed sensor.
7. Connect the backup lamp switch harness connector.
8. Connect the shift cable to the transaxle.
9. Install the starter.
10. Connect the drive axles to the transaxle.
11. Lower the vehicle.
12. Use the engine support fixture in order to raise the powertrain assembly.
13. Install the transaxle mount to the mid-rail.
14. Hand start the transaxle mount to mid-rail bolts. Tighten the bolts to 25 ft. lbs. (34 Nm).
15. Using a floor jack, raise the transaxle until it contacts the transaxle mount.
    
    NOTE

    The transaxle mount to transaxle bolts must be hand started. Do not pry the transaxle or mount to align the holes.
16. Hand start the transaxle mount to transaxle bolts using the following sequence:
    1. Rear bolt
    2. Middle bolt
    3. Front bolt
17. Using the previous sequence, tighten the transaxle mount bolts. Tighten the bolts to 33 ft. lbs. (45 Nm).
18. Reposition the underhood electrical center.
19. Connect the wiring harness to the tray bracket.
20. Install the electrical center nuts and bolt. Tighten the nuts to 89 inch lbs. (10 Nm). Tighten the bolt to 18 ft. lbs. (25 Nm).
21. Position the underhood junction block to the original position.
22. Install the surge tank inlet hose to the surge tank.
23. Install the front wiring harness to the junction block bracket.
24. Connect the positive battery cables to the junction block bracket.
25. Install the positive battery post to the junction block bracket.
26. Install the junction block bracket, bolt and nuts. Tighten the nuts to 89 inch lbs. (10 Nm). Tighten the bolt to 18 ft. lbs. (25 Nm).
27. With the frame on the lift table, raise the frame to the vehicle.
28. Hand-start all the frame bolts while aligning the frame to the paint marks.
29. Tighten the frame bolts. Tighten the bolts to 74 ft. lbs. (100 Nm) plus 180°.
30. Lower and remove the hydraulic table.
31. Connect the lower control arm to the steering knuckle.
    
    NOTE

    The torque sequence must be followed in the order that is listed.
32. Install the ball joint pinch bolt and nut.
    
    NOTE

    The front and rear transaxle mounts must be allowed to settle with the through bolts loosened.
    
    
    
    
    First Pass: Tighten the nut to 37 ft. lbs. (50 Nm). Reverse nut ³ / ₄ turn

    Second Pass: Tighten the nut to 37 ft. lbs. (50 Nm) plus 30°.
33. Hand-start the front transaxle mount through bolt.
34. Loosen the rear transaxle mount through bolt.
35. Tighten the rear transaxle mount to frame bolts. Tighten the rear bolts to 37 ft. lbs. (50 Nm).
36. Tighten the front and rear transaxle mount through bolts in the following order. Tighten the rear bolt to 74 ft. lbs. (100 Nm). Tighten the front bolt to 74 ft. lbs. (100 Nm).
37. Install the outer tie rods to the steering knuckles.
38. Install the new outer tie rod to the knuckle nuts. Tighten the nuts to 15 ft. lbs. (20 Nm) plus 180°.
39. Connect the control links to the Stabilizer bar.
40. Connect the intermediate shaft to the steering gear.
41. Install a new intermediate shaft pinch bolt. Tighten the bolt to 25 ft. lbs. (34 Nm).
42. Install the left and right splash shields.
43. Remove the engine support fixture.
44. Install the top engine to transaxle bolt. Tighten the bolt to 55 ft. lbs. (75 Nm).
45. Connect the hydraulic clutch hose to the clutch actuator cylinder.
46. Bleed the clutch hydraulic system.
47. Release the cooling module from the upper body structure.
48. Connect the negative battery cable.
49. Fill the transaxle to the proper level.