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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 23 (DRIVE AXLES)REMOVAL & INSTALLATIONDRIVELINE SUPPORT ASSEMBLYREMOVAL (MANUAL)
2001 Chevrolet Cavalier LS, 2.4 T

Removal (Manual)

2001 Chevrolet Cavalier LS, 2.4 TSECTION Removal (Manual)
WARNING: This page is about a different car, the 2003 Chevrolet Corvette and 2002 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. On convertible models, open the folding top stowage compartment lid. Remove the screws attaching the lower sides of the extension panel. Remove the screws attaching the top of the extension panel. Remove the panel upward from the bracket.
  2. On all models, open the console door. Pull up on the rear of the electronic traction control/ride control switch in order to release the retaining clips. If the electronic traction control/ride control switch does not release from the trim plate, carefully insert a screwdriver into the recess located at the rear of the switch and gently pull up the rear of the switch. Disconnect the electrical connector from the switch.
  3. Disconnect the LED connector from the wiring harness connector. Remove the electronic traction control/ride control switch. Using a small flat bladed screwdriver, carefully remove the console retaining nut covers. Remove the nuts retaining the rear of the console. Remove the nuts retaining the front of the console and the instrument panel accessory trim plate.
  4. Lift the rear of the console slightly and pull rearward to release the front of the console from under the instrument panel accessory trim plate. Disconnect the electrical connector from the electrical accessory plug. Unscrew the console electrical accessory plug retainer from the console electrical accessory plug housing. Remove the electrical accessory plug retainer and housing from the console.
  5. Disconnect the electrical connector from the fuel door release/rear lift window release switch and remove switch from console (if equipped). Remove the console from the vehicle.
  6. Carefully pry off the shift control knob button. See Figure. Pry the shift control knob retainer out of the slots and remove the retainer. Unscrew the shift control knob.
  7. Grasp the sides of the shift control boot and apply light pressure in toward the shift control lever to begin to release the shift boot retaining tabs from the instrument panel accessory trim plate. Using light pressure, continue to release the remaining boot retaining tabs. Lift the boot away from the trim plate and remove the boot.
  8. Open the cigar lighter door and remove the ashtray. Pry gently at the side edge of the instrument panel accessory trim plate grille with a flat-bladed screwdriver to release the tab. Remove the instrument panel accessory trim plate grille. Remove the accessory trim plate retaining screws next to the cigar lighter and behind the ashtray. Remove the accessory trim plate retaining screw in the grille opening.
  9. Grasp the sides of the accessory trim plate near the curve at the base. Pull the trim plate rearward to release the locking tabs. Lift the rear of the trim plate to clear the driveline tunnel studs. Disconnect the electrical connector from the cigar lighter. Rotate the shift control boot and reposition one end down into the shifter opening in the trim plate. Lift the accessory trim plate over the shifter and shift control boot, and remove the trim plate.
  10. Remove the shift control closeout boot retaining nuts. Remove the shift control closeout boot. Place shifter in Neutral. Engage shift control neutral lock-pin by pressing down. See Figure.
  11. Remove transmission shift rod clamp bolt. See Figure. Remove shift control mounting bolts. Raise the shift control to release the locator from the shifter bracket on the side of the driveline support assembly. Release the shift control from the transmission shift rod clamp and remove the shift control assembly.
  12. Using a flat bladed tool, carefully pry the instrument panel courtesy lamp assembly from the left lower closeout panel, located under the left side of the instrument panel. Remove the push-on retaining nut from the steering column bracket stud.
  13. Release the left lower closeout panel push-in retainers from the instrument panel lower support beam. Insert the instrument panel courtesy lamp assembly up through the opening in the closeout panel. Lower and remove the closeout panel. Release the notch in the right forward edge of the closeout panel from the tab on the accelerator pedal bracket.
  14. Remove the clutch master cylinder pushrod retainer, located on the clutch pedal arm.
  15. Disconnect the clutch master cylinder pushrod from the clutch pedal arm.
  16. Raise and suitably support the vehicle.
  17. Remove the clutch actuator cylinder hose from the hose retaining clip (at the rear of the engine).
  18. Using the Hydraulic Clutch Line Separator (J-36221), depress the White circular release ring on the actuator cylinder hose and simultaneously pull lightly on the master cylinder hose to disconnect.
  19. Protect both hose coupling ends from dirt and damage.
  20. Remove the rear tire and wheel assemblies.
  21. Remove the catalytic converter assembly. See CATALYTIC CONVERTERS .
  22. Tie off the left muffler assembly to the underbody to support the muffler out of the way. See Figure. Tie off the right muffler assembly to the underbody in the same manner.
  23. Remove the driveline tunnel closeout panel bolts. See Figure. Remove the driveline tunnel closeout panel.
    24. NOTE: Use care not to scratch the rear transverse spring.
  24. Measure the transverse spring stud height. See Figure. This measurement will be used in the installation to set-up the vehicle trim height. Using the Transverse Spring Compressor (J-33432-A), compress the rear transverse spring. See Figure. Remove the retainers, nuts, bolts and insulators retaining the transverse spring to the lower control arms. See Figure. Remove the rear transverse spring mounting bolts, spring spacers and insulators from the crossmember. Remove the rear transverse spring.
  25. Support one of the 2 lower control arms with a straight jack.
  26. Disconnect the outer tie rod end from the suspension knuckle.
  27. Remove the shock absorber lower mounting bolt.
  28. Disconnect the lower ball joint from the suspension knuckle.
  29. Remove the straight jack from the control arm.
  30. Repeat steps  25- 29 for the other side of the vehicle.
  31. Assemble the Transmission Support Fixture (J-42055).
  32. Install the Transmission Support Fixture to a transmission jack.
  33. Position and firmly secure the Transmission Support Fixture with the transmission jack to the transmission.
  34. Disconnect the wiring harness and brake pipe clip retainers from the rear suspension crossmember.
  35. Remove the transaxle mount-to-rear crossmember nuts.
  36. Position a transmission jack under the rear suspension crossmember and firmly secure the crossmember to the jack.
  37. Using only hand tools, remove the rear suspension crossmember retaining nuts.
  38. With the aid of an assistant, slowly lower the rear suspension crossmember away from the vehicle frame rails and remove the crossmember.
  39. Remove the transaxle mount bracket-to-differential bolts.
  40. Remove the transaxle mount with bracket. See Figure. Removing the transaxle mount will allow for greater stability on a workbench after the driveline is removed.
  41. Using a pry bar, carefully release the axle shafts from the differential.
  42. Tie off the axle shafts to the underbody to support out of the way. The muffler assembly pipes toward the rear provide a good location to help support the axle shafts.
  43. Release the retainer securing the wiring harness to the L-shaped brackets along the driveline support assembly. See Figure. Slide the harness up out of the brackets and position aside.
  44. Slowly lower the driveline approximately 2.0" (51 mm), while simultaneously adjusting the angle of tilt, in order to access the electrical connectors. See Figure.
  45. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. See Figure.
  46. Disconnect the wiring harness retainer from the stud at the differential rear cover.
  47. Disconnect the wiring harness retainer clip from the top of the differential. See Figure.
  48. Disconnect the backup lamp switch electrical connector. See Figure.
  49. Disconnect the reverse lockout solenoid electrical connector.
  50. Disconnect the gear select (skip shift) solenoid electrical connector.
  51. Disconnect the transmission fluid temperature sensor electrical connector, if equipped.
  52. Insert a putty knife or similar tool between the edge of the shifter bracket on the side of the driveline support assembly and the brake pipe retainer on the driveline tunnel wall to prevent damage.
  53. Slowly lower the driveline, while simultaneously adjusting the angle of tilt, and observe the relationship between the top rear of the differential and the lowest part of the rear compartment panel floor (the center storage compartment between the frame rails). The differential should not be lowered more than approximately even with the specified body point of reference. (The PCV pipes which route along the rear of the engine intake manifold will likely contact the dash panel). See Figure.
  54. Release the wiring harness from the harness retainer along the top of the transmission.
  55. Check to be sure that the wiring harness is free from the driveline being removed.
  56. Using a block of wood to protect the engine oil pan, place a jack under the rear of the engine oil pan to support the engine and prevent contact with the composite dash panel.
  57. Remove the driveline support assembly-to-engine flywheel housing bolts.
  58. Carefully bend the wiring harness bracket away from the driveline toward the driveline tunnel wall in order to make a clear removal path for the driveline.
    59. NOTE: The aid of an assistant will be necessary for the remaining steps.
  59. Have an assistant insert a flat-bladed screwdriver, or similar tool, between the edge of the driveline support assembly and the engine flywheel housing, then begin to pry the driveline loose from the engine.
  60. Have an assistant guide the front of the driveline during the removal of the driveline from the vehicle.
  61. Slowly lower the driveline, while simultaneously adjusting the angle of tilt and pulling the driveline away from the engine until the propeller input shaft at the front of the driveline support assembly just clears the engine flywheel housing.
  62. Slowly lower the driveline completely out of the vehicle.
  63. Position the chainfall, or equivalent lifting device, in a way which will protect the rear exhaust hangers located on the driveline support assembly.
  64. Using the lifting device, raise the driveline to relieve the weight from the transmission jack.
  65. Disconnect the Transmission Support Fixture from the transmission jack only. The Transmission Support Fixture will provide stability to the driveline components while working on a bench.
  66. Position the driveline on a workbench with the lift device still attached.
  67. Support the driveline support assembly and the differential for additional balance.
  68. Remove the lifting device from the driveline.
  69. Remove the clutch actuator cylinder mounting bolts.
  70. Remove the clutch actuator cylinder from the driveline support assembly.
  71. Remove the rear exhaust hanger mounting bolts.
  72. Remove the rear exhaust hangers from the driveline support assembly.
  73. Remove the transmission-to-driveline support assembly bolts/studs.
  74. Insert a flat-bladed screwdriver, or similar tool, between the edge of the driveline support assembly and the transmission, then begin to pry the driveline support assembly loose from the transmission.
  75. Slowly slide the driveline support assembly away from the transmission while guiding the transmission shift rod through the opening in the driveline support assembly.
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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.