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2003 Cavalier: 2.2 Ecotech Engine and automatic transmission

Customer Question
how do I change the...
how do I change the transmission and motor mounts on a 2003 Cavalier with 2.2 Ecotech Engine and automatic transmission?
Submitted: 6 years ago.Category: Chevy
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Answered in 24 minutes by:
6/4/2011
Chevy Mechanic: John, Master A.S.E Automotive technician replied 6 years ago
John
John, Master A.S.E Automotive technician
Category: Chevy
Satisfied Customers: 9,176
Experience: A.S.E MasterTechnician A1-A8 w/L1,38 years experience General Motors Master Technician
Verified

Hello & Welcome to JA,

 

Here is information to help you. This is part of your question.

 

Transmission Replacement

Tools Required

Flywheel Holding Tool

  1. Disconnect the negative battery cable. Disconnect the air duct hose from the intake plenum.
  2. Install the engine support fixture. Object Number: 414408  Size: SH
    Click here for detailed picture of above image.
  3. Disconnect the transaxle wiring harness from the transaxle and the PNP switch.
    Object Number: 104580  Size: SH
    Click here for detailed picture of above image.
  4. Remove the upper transmission to engine bolts and stud.
  5. Raise and support the vehicle. Remove the front wheel and tire assemblies.
  6. Remove the left front fender liner. Disconnect the engine strut from the lower engine mount strut bracket.
  7. Remove the wiring harness from the retaining clips.
  8. Remove the steering gear mounting bolts and secure the steering gear with mechanics wire.
  9. Disconnect the wheel speed sensor wires from the both front wheels and unclip from the frame.
  10. Separate the ball joints from the steering knuckles. Remove the lower suspension support. .
    Object Number: 510437  Size: SH
    Click here for detailed picture of above image.
  11. Remove the 2 bolts from the transmission brace.
    Object Number: 494775  Size: SH
    Click here for detailed picture of above image.
  12. Disconnect the shift cable from the shift linkage.
  13. Disconnect the cable from the bracket.
    Object Number: 510441  Size: SH
    Click here for detailed picture of above image.
  14. Remove the flywheel inspection cover.
  15. Remove the starter.
  16. Mark the relationship of the flywheel to the torque converter for reassembly.
  17. Use the special tool to prevent the crankshaft from rotating.
    Object Number: 475919  Size: SH
    Click here for detailed picture of above image.
  18. Remove the torque converter to flywheel bolts.
  19. Remove the transmission cooler lines by removing the nut holding the bracket to the transaxle case.
    Object Number: 414901  Size: SH
    Click here for detailed picture of above image.
  20. Disconnect the VSS wiring harness from the sensor.
  21. Disconnect the wheel drive shafts from the transaxle. Lower the vehicle.
  22. Remove the body to transmission mount bolts.
  23. Lower the transmission and engine with the engine support fixture enough to remove the transmission.
  24. Raise the vehicle.
  25. Remove the oil pan to drain the transmission. .
  26. Install the oil pan. Support the transmission with a suitable jack.
    Object Number: 104581  Size: SH
    Click here for detailed picture of above image.
  27. Remove the transaxle to engine nut.
  28. Separate the engine and the transaxle.
  29. Remove the transaxle from the vehicle.
  30. Remove the PNP switch.
  31. Remove the shifter cable bracket.
  32. Remove the lower transmission to engine stud.
  33. Remove the transmission mount.
  34. Flush the transmission cooler and the lines.
  1. Install the PNP switch.
  2. Install the shifter cable bracket.
  3. Install the lower transmission to engine stud.
  4. Install the transmission mount.
    Object Number: 104581  Size: SH
    Click here for detailed picture of above image.
  5. Position the transaxle in the vehicle. Object Number: 104580  Size: SH
    Click here for detailed picture of above image.
  6. Install the lower transmission to engine bolts and nuts.

    Tighten
    Tighten the bolts and nuts to 90 N·m (66 lb ft).

  7. flush the oil cooler. Lubricate the transaxle cooler pipes before inserting into seals.
  8. Connect the transaxle cooler pipes to the transaxle.

    Tighten
    Tighten the cooler pipes to 8 N·m (71 lb in).

  9. Use the special tool to prevent the crankshaft from rotating.
    Object Number: 475919  Size: SH
    Click here for detailed picture of above image.
  10. Install the torque converter to flywheel bolts.

    Tighten
    Tighten the torque converter bolts to 62 N·m (46 lb ft).

  11. Install the wheel drive shafts to the transaxle. Object Number: 414901  Size: SH
    Click here for detailed picture of above image.
  12. Connect the wiring harness to the VSS.
    Object Number: 510441  Size: SH
    Click here for detailed picture of above image.
  13. Install the starter.
  14. Install the flywheel inspection cover bolts.

    Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  15. Lower the vehicle.
  16. Use the engine support fixture to raise the engine and transmission assembly.
  17. Install the transaxle mount to body bolts.

    Tighten
    Tighten the bolts to 90 N·m (66 lb ft).

  18. Raise the vehicle.
  19. Reposition the wiring harness into its clips on the body rail.
    Object Number: 104578  Size: SH
    Click here for detailed picture of above image.
  20. Install the front suspension support assembly. Connect the ball joints to the steering knuckles. Route and clip the wheel speed sensor wiring into the proper position on both sides.
  21. Install the steering gear to the front suspension crossmember.
  22. Install the steering gear bolts to the front suspension crossmember.

    Tighten
    Tighten the bolts to 110 N·m (81 lb ft).


    Object Number: 510437  Size: SH
    Click here for detailed picture of above image.
  23. Install the transmission brace bolts.

    Tighten
    Tighten the bolts to 72 N·m (53 lb ft).

  24. Install the left front fender liner. Install the front wheel and tire assemblies. Lower the vehicle.
    Object Number: 104580  Size: SH
    Click here for detailed picture of above image.
  25. Install the upper transmission to engine bolts and stud.

    Tighten
    Tighten all of the bolts to 90 N·m (66 lb ft).

  26. Install the engine wiring harness grounds to the transaxle to engine mount stud and nut.

    Tighten
    Tighten the nut to 8 N·m (71 lb in).

  27. Remove the engine support fixture.
    Object Number: 494775  Size: SH
    Click here for detailed picture of above image.
  28. Install the shift linkage to the transmission.
    Object Number: 414408  Size: SH
    Click here for detailed picture of above image.
  29. Connect the electrical connectors to the PNP switch and transaxle.
  30. Connect the air duct hose to the intake plenum.
  31. Connect the negative battery cable. Inspect the transmission fluid level. Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
  32. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned.

     

     

  33. Reset the TAP values.
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Customer reply replied 6 years ago
Are you saying that I MUST remove the entire transmission to replace the transmission mount? Isn't there any way of supporting it and pulling out the four bolts that hold it in place, remove it and then install the new one?
Chevy Mechanic: John, Master A.S.E Automotive technician replied 6 years ago

No, i just did not read your question properly, sorry.

 

Transmission Mount Replacement

Important: In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support.

  1. Use a jack or a utility stand to raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the mount.
  2. Inspect the transmission/transaxle mount. Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions:
    The rubber surface is covered with cracks.
    The rubber is separated from the metal plate of the mount.
    The rubber is split through the center.
  3. If there is movement between the metal plate of the transmission/transaxle mount and the transmission, tighten the transmission mount fasteners to the correct tightening specification.

 

  1. Raise and support the vehicle. Remove the left front wheel and tire assembly. Remove the left front fender liner.

  2. Install a jackstand and a block of wood to support the transaxle.


  3. Remove the expansion bolt from the transmission mount.


  4. Remove the transmission mount bolts.
  5. Remove the mount.

  1. Transfer the mount bracket to the new mount.


  2. Position the mount and start the bolts into the threads.

    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.

  3. Tighten the mount bolts.

    Tighten
    Tighten the bolts to 66 N·m (41 lb ft).




  4. Install the mount expansion bolt.

    Tighten
    Tighten the bolt to 55 N·m (41 lb ft).




  5. Remove the jackstand and the wood block.
  6. Install the left fender liner. Install the left tire and wheel assembly. Lower the vehicle.
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Customer reply replied 6 years ago
Okay, this answers the first part for the transmission mount, what about the motor mounts (the upper front - passenger side; and the dog bone)? I believe there are only these two and they look to be fairly simple...
Chevy Mechanic: John, Master A.S.E Automotive technician replied 6 years ago
Engine Mount Replacement

Important: Torque axis mounting systems allow more engine movement than other mounting systems. The engine movement is the design intent of the mounting system. Do not replace the torque axis mounts unless the mount or the rubber is damaged.

  1. Remove the cruise control module mounting nuts.

  2. Remove the A/C low pressure line retaining bracket (1) nut.

  3. Using a block of wood between the floor jack and the oil pan , support the engine.


  4. Remove the engine mount (2) to bracket bolts (1).


  5. Remove the engine mount to body nuts (1).
  6. Remove the engine mount.
  1. Install the engine mount to the vehicle.


  2. Align the engine mount (2) to the mount bracket using a dowel (1).


  3. Hand tighten the engine mount to body nuts (1).

  4. Install the engine mount (2) to bracket bolts (1).

    Tighten

    Tighten the engine mount to body nuts to 66 N·m (49 lb ft).
    Tighten the engine mount to bracket bolts to 130 N·m (96 lb ft) plus 45 degrees.


  5. Install the A/C low pressure line retaining bracket (1) nut.

    Tighten
    Tighten the nut to 10 N·m (89 lb in).

  6. Install the cruise control module. Remove the floor jack
  7. Engine Mount Strut Replacement
    1. Raise and support the vehicle. Remove the right engine splash shield.

    2. Remove the engine mount strut bolts.
    3. Remove the engine mount strut.



    1. Install the engine mount strut.

      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 engine mount strut bolts.

      Tighten
      Tighten the engine mount strut bolts to 100 N·m (74 lb ft) + 90 degrees.

    3. Install the right engine splash shield. Lower the vehicle.
  8. .
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Category: Chevy
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