GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Optra 🢒 Transmission/Transaxle 🢒 Manual Transmission - D20 🢒 Shift Linkage Adjustment

    Caution: Refer to Battery Disconnect Caution in the Preface section.


    Object Number: 1248163 Size: SH
  1. Disconnect the negative battery cable.

    2. Important: All the gears must be easy to engage when the vehicle is stationary, the engine is running, and the clutch is disengaged.

  2. Position the gearshift lever into NEUTRAL.
  3. Loosen the rod clamp bolt.

    4. Important: The speed gears and the synchronizer parts on this vehicle receive lubrication through specific passages in the mainshaft.


    Object Number: 1248166 Size: SH
  4. Remove the adjustment hole plug from the shift lever cover.
  5. Turn the gearshift rod and fully insert a 5 mm (0.2 in) gage pin into the adjustment hole.

    6. Object Number: 1248167 Size: SH
  6. Remove the boot from the console.
  7. Pull the boot upward to expose the shift control lever mechanism.
  8. Position the gearshift lever close to the left side of the NEUTRAL position.
  9. Insert a 5 mm (0.2 in) gage pin into the holes to align the gearshift lever with the gearshift lever housing.

    10. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1248163 Size: SH
  10. Tighten the rod clamp bolt.

    11. Tighten
    Tighten the rod clamp bolt to 14 N·m (124 lb in).


    Object Number: 1248169 Size: SH
  11. Remove the 5 mm (0.2 in) gage pin from the adjustment hole.
  12. Install the adjustment hole plug.
  13. Remove the 5 mm (0.2 in) gage pin from the gearshift lever.
  14. Install the boot to the console.

    15. Object Number: 1248170 Size: SH
  15. Connect the negative battery cable.