GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Geo 🢒 1996 🢒 Tracker - 2WD 🢒 Transmission/Transaxle 🢒 Automatic Transmission - 4 Speed-M41 🢒 Transmission Assembly Installation

    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.

  1. Install the rear transmission mount and install the bolts.

    2. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  2. Install the PNP switch and adjust as necessary. Install the PNP switch bolt.

    3. Tighten
    Tighten the bolt to 10 N·m (7.5 lb ft).

  3. Install the manual shaft nut seal, the lock plate and the nut.

    4. Tighten
    Tighten the nut to 5 N·m (44 lb in).

  4. Stake the lock plate.
  5. Install the 2 bell housing studs.

    6. Object Number: 480279 Size: SH
  6. Install transmission.
  7. Install upper bell housing bolts.

    8. Tighten
    Tighten the bolts to 85 N·m (62 lb ft).

  8. With the aide of an assistant, install the transfer case and the bolts (1) (If 4WD equipped).

    9. Tighten
    Tighten the bolts to 31 N·m (23 lb ft).


    Object Number: 480323 Size: SH
  9. Install the transmission wire harness, the retainer, and the bolt.
  10. Connect the electrical connectors and the vent tubes to the transmission and the transfer case (If 4WD equipped).
  11. Install the crossmember (7) and the crossmember bolts (3,5,6).

    12. Tighten
    Tighten the crossmember bolts to 60 N·m (44 lb ft).

  12. Install the ground wire and the ground wire bolt to the transfer case mount.

    13. Tighten
    Tighten the ground wire bolt to 7 N·m (62 lb in).


    Object Number: 480289 Size: SH
  13. Install speedometer cable (2), the speedometer cable bracket, and the bolt (1) to the transfer case (If 4WD equipped).
  14. Install the transfer case skid plate (2) and the bolts (1,4) (If 4WD equipped).
  15. Remove the jack from the transmission.

    16. Object Number: 480359 Size: SH
  16. Install the cooler hoses (1,2) and the clamps (5,6) to the transmission cooler pipes (3,4).

    17. Object Number: 480304 Size: SH
  17. Install the lower bellhousing nuts.

    18. Tighten
    Tighten the lower bellhousing nuts to 85 N·m (62 lb ft).

  18. Install the torque converter bolts.

    19. Tighten
    Tighten the torque converter bolts to 50 N·m (37 lb ft).

  19. Install the flywheel inspection cover plate (1) and the bolts (2).

    20. Tighten
    Tighten the flywheel inspection cover plate bolts to 10 N·m (89 lb ft).


    Object Number: 480296 Size: SH
  20. Install the engine brace (1) and the bolts (2) to the left side of the transmission.

    21. Tighten
    Tighten the engine brace bolts to 60 N·m (44 lb ft).


    Object Number: 480274 Size: SH
  21. Install the starter and the lower bolt.

    22. Tighten
    Tighten the starter lower bolt to 30 N·m (22 lb ft).

  22. Connect the starter electrical connections.
  23. Install the following components:
    24. • The catalytic converter seal
    • The gasket
    • The converter assembly
    • The springs (2)
    • The flange bolts

    Tighten
    Tighten the flange bolts to 50 N·m (37 lb ft).

  24. Install the exhaust front hanger (1).
  25. Install the nuts which secure the converter to the exhaust pipe.

    26. Object Number: 480329 Size: SH
  26. Install the oxygen sensor to the exhaust.

    27. Tighten
    Tighten the oxygen sensor to 9 N·m (80 lb ft).

  27. Install the exhaust hanger and the O2 sensor harness to the crossmember.

    28. Object Number: 480337 Size: SH
  28. Install the fluid indicator tube (1), the bolt (2), and the O-ring seal.

    29. Object Number: 480367 Size: SH
  29. Install the shift cable bracket and the bolts.

    30. Tighten
    Tighten the shift cable bolts to 7 N·m (62 lb ft).

  30. Install the shift cable to manual lever (2).
  31. Install the shift cable and retainer (4) to the cable (3) bracket (1).

    32. Object Number: 166185 Size: SH
  32. Install the rear propeller shaft, the bolts, and the nuts to the flange (1).

    33. Tighten
    Tighten the rear propeller shaft bolts and nuts to 50 N·m (37 lb ft).

  33. Install the front propeller shaft, the bolts, and the nuts to the flange (1) (If 4WD equipped).

    34. Tighten
    Tighten the front propeller shaft bolts and nuts to 50 N·m (37 lb ft).

  34. Fill the transfer case (If 4WD equipped).
  35. Lower the vehicle.
  36. Install the upper starter bolt, the nut, and the ground wire.
  37. Install the fluid indicator.

    38. Object Number: 166145 Size: SH
  38. Route the TV. cable (2) to the upper engine.
  39. Install the throttle body cover and screws. Adjust the TV. cable as necessary.

    40. Object Number: 167065 Size: SH
  40. If the vehicle is equipped with 4WD, perform the following steps:
    41. 40.1. Install the transfer case shifter boot clamp, the #1 boot and the transfer case shifter assembly.
    40.2. Install the transfer case boot cover and the #2 boot.
    40.3. Install the transfer case boot cover screws.
    40.4. Install the gear shift control lever knob (1) and the screw to the gearshift control lever.

    Object Number: 480250 Size: SH
  41. Install the center front console while connecting the electrical connectors. Install the screws and the clips.
  42. Install the center rear console and connect the electrical connectors. Install the screws and the clips.
  43. Adjust the shift cable as necessary.

    44. Object Number: 1557102 Size: SH
  44. Connect the negative battery cable.
  45. Refill the transmission fluid and inspect for leaks. Refer to Transmission Fluid Check .
  46. Test the transmission for proper installation.