Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET1994CAVALIER Z24, 2D COUPE, STANDARDREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONMANUAL TRANSOVERHAUL - MUNCIE 76 MM 5-SPEEDCOMPONENT DISASSEMBLY & REASSEMBLYTRANSAXLE CASEREASSEMBLY

1994 Chevrolet Cavalier Z24, 2D Coupe, Standard

Transaxle Case: Reassembly

1994 Chevrolet Cavalier Z24, 2D Coupe, StandardSECTION Reassembly

Using Shift Shaft Bearing Installer (J-36189) and driver handle, install shift shaft bearing. Using Shift Shaft Seal Installer (J-35823), install shift shaft seal. See VIEW "C" in Fig 1 . Using shift rail bushing remover/installer and driver handle, install 3 shift rail bushings. Using Reverse Shift Rail Bushing Installer (J-36030) and driver handle, install reverse rail bushing.
Using seal/race differential installer, install differential carrier support outer bearing race. Using seal/race differential installer and driver handle, install axle seal. See VIEW "C" in Fig 1 . Fill lip of axle seal with chassis grease. Apply sealant to edges of 3 shift rail plugs, and install plugs even with bore surface.
Using Shift Detent Lever Bushing Remover/Installer (J-36039) and driver handle, install detent lever bushing. Install detent lever. Using Sliding Sleeve Bushing Remover/Installer (J-36034) and driver handle, install sliding sleeve bushing.
Install sleeve, spring and plug. Apply sealant to edge of plug prior to installation. Install stud so chamfered end faces out. Tighten stud to specification. See TORQUE SPECIFICATIONS .

Fig 1: Removing & Installing Transaxle Case Components Using Special Tools

Courtesy of GENERAL MOTORS CORP.

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.