Automatic Transaxle Overhaul & Testing - 3t40 Chevrolet Cavalier III

APPLICATION

AUTOMATIC TRANSAXLE APPLICATIONS

IDENTIFICATION

Note. For vehicle body code identification, see GENERAL MOTORS BODY CODE & SERIES IDENTIFICATION article in GENERAL INFORMATION.

Transaxle identification plate is attached to transaxle case. (Scheme 1) Transaxle model is printed on the service parts identification label located on spare tire wheel well cover inside vehicle trunk. Transaxle RPO code is MD9.

Scheme 1

GEAR RATIOS

TRANSAXLE GEAR RATIOS

DESCRIPTION & OPERATION

The 3T40 3-speed automatic transaxle consists of a torque converter, final drive gear, differential, 3 multiple clutch disc packs, roller clutch, intermediate band, valve body and oil pump. The 4-element torque converter couples engine crankshaft to planetary gear set through a sprocket and drive link assembly. (Scheme 2)and (Scheme 3).

Scheme 2

Scheme 3

RECOMMENDED FLUID

On all models, transaxle uses Dexron-III transmission fluid. Fill transaxle with appropriate quantity. See FLUID CAPACITIES .

FLUID CAPACITIES

TRANSAXLE FLUID CAPACITIES (1) (2)

CONTROL VALVE ASSEMBLY

See CONTROL VALVE & OIL PUMP ASSEMBLY under TRANSAXLE DISASSEMBLY.

DRIVE AXLE SHAFTS

See appropriate article in DRIVE AXLES.

OIL COOLER FLUSHING

1. If available, fill Transmission Oil Cooler and Line Flusher (J-35944-A) with solution, and connect to transaxle cooler lines on transaxle. Follow equipment manufacturer's instructions to flush oil cooler and cooler lines.
2. If line flusher is not available, flush cooler and cooler lines with a mixture of clean solvent and water. Flush cooler in both directions until all old fluid and debris is removed. If necessary, replace plugged or damaged cooler and/or lines.

TRANSAXLE & OIL COOLER FLOW CHECK

1. Disconnect oil cooler discharge hose from oil cooler and place in collection pan. While monitoring fluid flow from cooler line, start engine and let idle with transaxle in Park. If fluid flow is greater than 2.0 qts. (1.9L) in 30 seconds, go to step 3 . If fluid flow is less than 2.0 qts. (1.9L) in 30 seconds, go to next step.
2. Disconnect oil cooler feed line at radiator. Connect a discharge hose to cooler feed line and place in collection pan. Start engine with transaxle in Park and run for 30 seconds. A minimum of 2.0 qts. (1.9L) of fluid must discharge from transaxle in 30 seconds. If flow is insufficient, inspect transaxle. If flow is okay, inspect oil cooler and oil cooler return pipe.
3. Transaxle and oil cooler flow are okay. Remove discharge hose and reconnect oil cooler hose and pipes. Refill transaxle with appropriate fluid to proper level. See «LUBRICATION»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40) .

TROUBLE SHOOTING

Note. For illustration of hydraulic circuit operation, see HYDRA-MATIC 3T40 article in OIL CIRCUIT DIAGRAMS.

PRELIMINARY INSPECTION

Transaxle malfunctions may be caused by poor engine performance, improper adjustments or failure of hydraulic, mechanical or electronic components. Always begin by checking fluid level, fluid condition and shift cable adjustment. Perform road test to determine if problem has been corrected. See ROAD TEST under PERFORMANCE TESTS. If problem still exists, diagnose by symptom. See SYMPTOM DIAGNOSIS .

Chatters Or Slips In 1st Gear

Check oil level, Throttle Valve (T.V.) cable, oil pressure, forward clutch, driven sprocket support and case cover gasket.

Inoperative Or Slips In 1st Gear

Check for a leaking forward clutch piston seal.

Slips In Reverse Or No Reverse

Check for low line pressure. Check direct clutch, restricted low-reverse clutch housing cup plug, low-reverse pipe "O" ring, low-reverse clutch plates, case-to-cover gasket and direct clutch plates. Check speed sensor.

Delayed Or No Upshifts

Check manual linkage, T.V. cable, oil level, governor, intermediate servo and band, control valve assembly, valve body spacer, case cover and case.

Slipping Or Harsh 1-2 Shift

Check oil level, T.V. cable, oil pressure, intermediate servo and band, T.V. link, control valve assembly, 1-2 accumulator piston and seal, spacer plate, case and case cover.

Delayed Or Rough 2-3 Shift

Check oil level, T.V. cable, manual linkage, oil pressure, direct clutch, direct clutch exhaust No. 1 check ball and control valve assembly.

Slipping, Soft Or Early 2-3 Shift

Check oil level, T.V. cable, manual linkage, oil pressure, intermediate servo, accumulator exhaust check valve, spacer plate, check ball No. 5, case cover and direct clutch.

Delayed Or No 2-3 Shift

Check oil level, T.V. cable or manual linkage, governor, speed sensor, intermediate servo, accumulator exhaust check valve, direct clutch accumulator cup plug, case-to-governor shaft sleeve, center gasket, case cover, throttle lever and bracket assembly, control valve assembly, spacer plate, case-to-governor shaft sleeve and direct clutch.

Delayed Neutral-To-Drive Shift

Check for lack of oil feed to forward clutch.

Delay Engagement In Drive & Reverse

Check oil level, oil pressure, converter-driven sprocket support bushings and turbine shaft. Some vehicles may have a delayed reverse-to-drive shift during cold weather operation. This condition may be caused by the manual valve and thermal element. Revised manual valve and thermal element use larger cross-drilled holes through the manual valve, and a second cold window has been added to the thermal element.

No 2nd Gear In "D"

Check low roller clutch for galled or missing rollers and missing springs.

All Gear Ranges Inoperative

Check oil level and pressure, drive link, manual linkage, input shaft, reaction carrier, differential and torque converter. This condition may also be caused by the thermal element moving forward, because a retaining clip has fallen out. The clip may be located in the bottom oil pan.

Inoperative In "D" Range

Check oil level and pressure. Check forward clutch and case cover for leaks or incorrect gaskets between case cover and driven sprocket support passages.

Forward Gears Inoperative

Check oil pressure, manual linkage, driven sprocket support for turned sleeve, case cover, forward clutch and control valve assembly.

Starts In 2nd Gear

Check governor and control valve assembly for stuck 1-2 shift valve. Check for sticking throttle valve.

Skips 2nd Gear

Check intermediate servo and band, accumulator exhaust valve and control valve assembly. Check spacer plate gaskets, case cover and case, governor feed to 1-2 shift valve, intermediate band apply feed orifice and spacer plate.

A no 2nd gear condition may be the result of fluid leaking past intermediate servo piston. This may be caused by a worn inner servo piston lip seal. Check lip seal, intermediate band and direct clutch assembly for wear. Replace components as necessary.

Shifts From 3rd To 1st At High Speeds

Check governor or speed sensor, intermediate servo, direct clutch orifice No. 2 check ball and 1-2 accumulator.

No Full Throttle Detent Downshift

Check T.V. cable, throttle cable assembly, control valve assembly and spacer plate.

No Overrun Braking In "1" Range, Reverse Okay

Check manual linkage, low-reverse clutch and control valve assembly.

Binds In 3rd Gear

Check for damaged direct clutch center seal.

Inoperative In "2" Range

Check intermediate servo and band. Check 1-2 accumulator.

Engine Stalls In "R" Or "D" Range

Check for missing or clogged Torque Converter Clutch (TCC) auxiliary valve body filter. Also check for TCC engaging too soon. Fault may result from TCC wiring harness contacting valve body cover of transaxle. To correct this condition, repair any damaged wiring, and tape TCC wiring harness to larger main wire conduit.

Noise In All Gear Ranges

Check torque converter.

High Pitched Whine Or Popping

Check oil pump system for pump cavitation or out-of-position filter.

Buzzing Or High Pitched Rattle

Check for binding, pinching or touching cooler lines (near radiator). Some vehicles may exhibit buzzing noise during slight throttle in forward gears. This noise may be caused by vibration of the 1-2 accumulator valve.

Whine Or Growl Under Light Acceleration

Check drive link assembly, sprockets, chain and related bearings.

Noise In 1st Or Reverse Gear

Check input gear, input internal gear, input carrier or input sun gear for damage.

Noise In 2nd Gear

Check for worn or pitted reaction gear set, reaction internal gear, reaction carrier, reaction sun gear, or related bearings and thrust washers.

Hum During Light Acceleration (All Gear Ranges)

Check differential or final drive gear and related parts for wear or damage.

Light Rattle In 2nd Or 3rd Gear At 25-40 MPH

Check for warped steel plates, excess clutch pack clearance or parallel-grooved fiber plates in low-reverse clutch pack. Check case for excess case-to-plate spline clearance.

CLUTCH & BAND APPLICATIONS

CLUTCH & BAND APPLICATIONS (1)

PERFORMANCE TESTS

Note. Ensure engine is at normal operating temperature. Engine coolant temperature must be greater than 130°F (54°C) before Torque Converter Clutch (TCC) will apply. If temperature is not as specified, check and repair cooling system as necessary. If TCC will not apply, see HYDRA-MATIC 3T40 ELECTRONIC CONTROLS article.

ROAD TEST

If transaxle shift speeds are not as specified during road test, check for DTCs. See HYDRA-MATIC 3T40 ELECTRONIC CONTROLS article. If slippage occurs, determine which components are applied in each gear to aid in diagnosis. See CLUTCH & BAND APPLICATIONS under TROUBLE SHOOTING. Perform hydraulic pressure test to check transaxle internal components. See HYDRAULIC PRESSURE TESTS .

Note. Perform the following tests in the sequence given. Ensure engine is operating properly, and transmission fluid level and tire pressure are correct.

Electrical Function Check

1. Connect scan tool. Ensure gearshift lever is in "P" position and parking brake is set. Start engine. Using scan tool, ensure the following data can be displayed and is functioning properly: Engine Speed Transmission Output Speed Vehicle Speed Transmission Range Brake Switch Engine Coolant Temperature Throttle Angle Ignition Voltage TCC Enable Solenoid TCC Slip Speed If all data is displayed and appears accurate, go to next step. If any data is in question, diagnose and repair as necessary. See HYDRA-MATIC 3T40 ELECTRONIC CONTROLS article or appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
2. Using scan tool, monitor brake switch signal while depressing and releasing brake pedal. Ensure scan tool displays CLOSED with brake pedal released and OPEN with brake pedal depressed.
3. Apply brake pedal and set parking brake. Shift transmission from Park to Reverse, Reverse to Neutral, and then from Neutral to Drive. Pause 2-3 seconds in each range. Ensure engagements are immediate and not harsh.
4. Using scan tool, monitor transmission range. Move gearshift lever through all ranges. Pause in each range for 2-3 seconds and return gearshift lever to "P" position. Ensure all gearshift lever positions match scan tool display.
5. Using scan tool, monitor throttle angle while increasing and decreasing engine speed with accelerator pedal. Ensure actual engine speed matches engine speed displayed on scan tool.
6. Record test results inn question for reference and continue with road test.

Upshift Control & Torque Converter Clutch Apply

Note. To include normal driving ranges in the following test, check shift speeds at 10, 25 and 50 percent throttle angles.

1. Using scan tool, monitor the following parameters: Throttle Angle Vehicle Speed Engine Speed TCC Solenoid State TCC Slip Speed Place gearshift lever in "D" position. Accelerate vehicle to chosen throttle angle (10, 25 or 50 percent) and hold steady. As transmission upshifts, note vehicle speed as shift occurs for each gear change. Compare shift speeds with specification. See «SHIFT SPEED SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40) table. Check for harsh, soft or delayed shifts. Note any noise or vibration. Repeat procedure for each throttle angle.
2. Check for TCC apply in 3rd gear. Note TCC apply point. A noticeable drop in engine RPM should be observed, and slip speed decrease to less than 100 RPM. Ensure TCC apply speed is within specification and TCC disengages with light application of brake pedal. See «TORQUE CONVERTER CLUTCH ENGAGEMENT»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40) table. If TCC apply is not detected, check for DTCs. See HYDRA-MATIC 3T40 ELECTRONIC CONTROLS article. Check TCC operation. See «TORQUE CONVERTER DIAGNOSIS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40__torque-converter-diagnosis) .

SHIFT SPEED SPECIFICATIONS

TORQUE CONVERTER CLUTCH ENGAGEMENT

Part Throttle Detent Downshift

Place gearshift lever in "D" position. Accelerate vehicle to 25-55 MPH in 3rd gear. Quickly increase throttle angle to 100 percent. Ensure TCC releases, and transaxle immediately downshifts to 2nd gear.

Manual Downshifts

1. Place gearshift lever in "D" position. Accelerate vehicle to 25-45 MPH. Release throttle while moving gearshift lever to "2" position. Ensure TCC releases, transaxle immediately downshifts to 2nd gear, and engine slows vehicle (engine braking).
2. Place gearshift lever in "D" position. Accelerate vehicle to 25 MPH. Release throttle while moving gearshift lever to "1" position. Ensure TCC releases, transaxle immediately downshifts to 1st gear, and engine slows vehicle (engine braking).

Coasting Downshifts

Place gearshift lever in "D" position. Accelerate vehicle to 3rd gear and ensure TCC is applied. Release throttle and lightly apply brake pedal. Ensure TCC releases, and downshift occur at specified vehicle speeds. See SHIFT SPEED SPECIFICATIONS table.

Manual Gear Range Selection

Note. Shift solenoids control upshifts in manual gear ranges. Perform the following tests during 10-15 percent throttle angle.

1. With vehicle stopped, place gearshift lever in "R" position. Slowly accelerate vehicle. Ensure there is no noticeable slip, noise or vibration.
2. With vehicle stopped, place gearshift lever in "1" position. Accelerate vehicle to 15 MPH. Ensure no upshifts occur, TCC does not apply and there is no noticeable slip, noise or vibration.
3. With vehicle stopped, place gearshift lever in "2" position. Accelerate vehicle to 25 MPH. Ensure 1-2 upshift occurs, and there is no noticeable slip, noise or vibration.

TORQUE CONVERTER DIAGNOSIS

Note. Torque converter is a sealed unit and can not be disassembled. Manufacturer does not recommend testing torque converter stall speed.

Stator Check

1. Torque converter stator roller clutch may fail and can either remain locked up at all times or freewheel in both directions. If stator is freewheeling at all times, vehicle tends to have poor acceleration from a standstill. Vehicle may operate normally at speeds greater than 30-35 MPH.
2. If poor acceleration is noted, ensure exhaust system is not blocked, engine timing is correct and transaxle is in 1st gear when starting from a standstill. If stator is locked up at all times, performance from a standstill will appear normal. Engine RPM and acceleration is limited at high speeds. Engine may overheat from this condition. A visual inspection of torque converter may reveal converter is Blue in color indicating an overheat condition.

Noise Test

1. Torque converter whine is usually noticed when vehicle is stopped and transaxle is in Reverse or Drive. Whine will increase when engine RPM is increased and will stop when vehicle is moving or when torque converter clutch is applied. Ensure whine originates from torque converter.
2. Start engine, and allow it to reach normal operating temperature. Apply parking and service brakes. Place transaxle in Drive. Depress accelerator pedal to increase engine speed to about 1200 RPM for less than 6 seconds. DO NOT depress accelerator for more than 6 seconds or transaxle damage may occur. Torque converter noise will increase under this load.

Note. Torque converter whine should not be confused with pump whine, which is usually noticeable in Park, Neutral and all other gear ranges. Pump whine will vary with pressure.

HYDRAULIC PRESSURE TESTS

1. Check ATF level, Throttle Valve (T.V.) cable adjustment and manual control linkages. See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING. Ensure engine is tuned properly.
2. Connect tachometer to engine. Connect pressure gauge to pressure test port on transaxle case. Pressure test port is located on bellhousing side, above valve body cover, next to vent pipe.
3. Set parking brake. Start engine and increase engine speed to 1000 RPM. Check line pressure with transaxle in indicated gear ranges and with minimum T.V. cable travel. Ensure line pressure is as specified. See «LINE PRESSURE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40) table.
4. Check line pressure with transaxle in indicated gear ranges and with T.V. cable at full extent of travel. Ensure line pressure is as specified. See «LINE PRESSURE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40) table.

LINE PRESSURE SPECIFICATIONS

Insufficient Line Pressure

1. Check fluid level. Check oil strainer "O" ring seal for leakage or damage. Check for plugged oil strainer. If pressure is low in "N" and "D" positions, and low to normal in "2" and "R" positions, Throttle Valve (T.V.) cable may be binding or out of adjustment.
2. Inspect control valve and pump assembly for loose bolts or internal leaks. Check throttle valve and plunger, shift T.V. valve, pressure regulator valve, T.V. boost valve and pressure relief valve for sticking or damage. Check for missing or misplaced No. 5 or No. 6 check ball. (Scheme 13)
3. Check 1-2 accumulator piston and/or seal. If pressure is low in "1" position only, check for damaged low blow-off valve and missing or misplaced No. 4 check ball. If pressure is low in "R" position only, inspect low-reverse clutch housing-to-case cup plug for leaks.
4. Inspect oil pump for loose bolts and damaged or missing pump valve seals. Check intermediate oil passages to pressure regulator for blockage. Check driven sprocket support-to-case cover for leaks.

Excessive Line Pressure

1. With pressure high in "N" and "D" positions, and normal to high in "2" and "R" positions, check for broken, sticking or misadjusted Throttle Valve (T.V.) cable.
2. Inspect T.V. linkage for binding or incorrect cable adjustment. Check throttle valve or shift T.V. valve for sticking. Inspect T.V. lifter for bend or damage. Check if lifter length is too short.
3. Inspect components of control valve and pump assembly for sticking or damaged T.V. valve and plunger, shift T.V. valve, pressure regulator valve, T.V. boost valve and/or pump slide.
4. Check for worn or missing pressure regulator valve retaining pin. If line pressure is too high in "1" position only, check for sticking low blow-off valve. Inspect internal pump case or case cover for leaks.

TORQUE CONVERTER

1. With torque converter removed from vehicle, insert fingers into splined inner race of roller clutch, and ensure stator turns freely clockwise, but does not turn or is very difficult to turn counterclockwise. DO NOT use driven sprocket support or shafts to turn race, as test result may not be correct.
2. Using Torque Converter End Play Checker (J-35138), measure torque converter end play. (Scheme 4) End play should be.020" (.5 mm) or less. Torque converter must be replaced if it leaks, is unbalanced or is contaminated with antifreeze.

Scheme 4

Note. See appropriate AUTOMATIC TRANSMISSION REMOVAL article in TRANSMISSION SERVICING.

TRANSAXLE DISASSEMBLY

Clean exterior of transaxle case with solvent and dry with compressed air. Remove torque converter by pulling straight out. Place transaxle in Support Fixture (J-28664-B) and Support Fixture Base (J-3289-20) so right-side axle end faces downward to drain fluid.

VEHICLE SPEED SENSOR & GOVERNOR ASSEMBLY

Remove speed sensor housing bolts, speed sensor housing and "O" ring. Remove thrust bearing, speed sensor rotor and governor assembly. (Scheme 3)and (Scheme 37).

INTERMEDIATE SERVO ASSEMBLY

1. Remove all oil pan bolts except for 2. Leave these 2 bolts finger tight. Tap oil pan loose with rubber mallet. Remove bolts, oil pan and oil strainer. Discard oil strainer "O" ring.
2. Remove reverse oil pipe retaining bracket-to-servo cover bolt. Remove remaining servo cover bolts. Lift off intermediate servo cover and gasket. Remove intermediate servo assembly. (Scheme 5)
3. If necessary, detach snap ring, and remove intermediate band apply pin from intermediate servo piston. Discard oil seals. Remove 3rd accumulator exhaust valve and spring. Inspect spring and exhaust valve for wear or damage. (Scheme 6)

Scheme 5

Scheme 6

Note. Perform BAND APPLY PIN SELECTION CHECK to determine correct pin to be used during reassembly.

Band Apply Pin Selection Check

1. Install Band Apply Pin Gauge (J-28535) over intermediate servo bore, and retain with 2 servo cover bolts. (Scheme 7) Remove band apply pin from intermediate servo assembly.
2. Install Band Apply Pin Gauge Extension (J-28535-4) onto servo piston end of band apply pin. Install band apply pin and gauge extension into gauge on servo bore.
3. Using INCH-lb. torque wrench, apply 100 INCH lbs. (11.3 N.m) of torque to hex nut on gauge tool. If pin is correct size, White line on gauge extension will appear in window.
4. If White line does not appear in window, use longer or shorter pin as necessary. See «INTERMEDIATE BAND APPLY PIN IDENTIFICATION»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40) table. Repeat step 3 to ensure pin size is correct. Set selected pin aside until transaxle is reassembled.

INTERMEDIATE BAND APPLY PIN IDENTIFICATION

Scheme 7

LOW-REVERSE PIPE, OIL WEIR & RETAINERS

Remove bolt from governor oil pipe retainer and remove pipe retainer, oil weir retainer and oil weir. Remove bolt, retainer and low-reverse oil pipe. Remove oil seal and oil seal back-up washer. Remove bolt, oil dipstick stop and oil filter bracket. Remove bolt and parking lock bracket.

LOW-REVERSE SEAL & OUTPUT SHAFT

1. Grind about 3/4" from end of a No. 4 screw extractor. Insert modified screw extractor into low-reverse cup plug. (Scheme 8) DO NOT hammer or force screw extractor into cup plug. Carefully twist screw extractor to remove cup plug.
2. Rotate differential carrier until end of output shaft is visible. While holding differential carrier, rotate output shaft until open ends of output shaft retaining ring are visible. Using Snap Ring Remover/Installer (J-34757), push both ends of retaining ring downward to partially dislodge from output shaft. Rotate output shaft and remove retaining ring with needle-nose pliers. Gently remove output shaft from transaxle.

Scheme 8

CONTROL VALVE & OIL PUMP ASSEMBLY

Note. During oil pump assembly removal, do not remove bolts marked "A" and "C" from auxiliary valve body unless auxiliary valve body removal is necessary. (Scheme 9)

1. Remove all control valve assembly cover bolts except for 2. Leave these 2 bolts finger tight. Tap cover edge with rubber mallet to loosen control valve cover and gasket. DO NOT pry on cover during removal.
2. Remove 2 bolts securing throttle lever and bracket assembly to control valve. Lift off throttle lever and bracket assembly with throttle valve cable link. Use care not to bend link.
3. Disconnect electrical connectors. Remove TCC solenoid and wiring harness. (Scheme 10) Remove all auxiliary valve body bolts except one bolt marked "A" and 4 bolts marked "C". (Scheme 9) Remove remaining control valve assembly and oil pump bolts. (Scheme 11) Carefully lift off control valve, auxiliary valve body and pump assembly. Place assembly on bench with machined surface up.
4. Remove check ball No. 1 from direct clutch passage on spacer plate. (Scheme 12) Lift out oil pump drive shaft. Remove spacer plate and spacer plate gaskets. Remove 5 check balls from case cover. (Scheme 13)

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Input Shaft-To-Case Cover End Play

1. Install Output Shaft Loader Adapter Plug (J-26958-10) into right-side axle end of case. (Scheme 14) Mount Output Shaft Aligner/Loader (J-26958) to right-side axle end of case. Adjust loader by turning handle until knob bottoms.
2. Install Input Shaft Lifter (J-28544) into input shaft bore and tighten. Install dial indicator with Extension Post (J-25025-7A). Place dial indicator plunger on end of lifter. Press down on lifter, zero dial indicator, and lift up tool. End play should be.004-.033" (.10-.84 mm). End play snap ring is located on input shaft, beneath driven sprocket. If end play is not as specified, replace snap ring. See «INPUT SHAFT END PLAY SELECTIVE SNAP RING IDENTIFICATION»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40) table.

INPUT SHAFT END PLAY SELECTIVE SNAP RING IDENTIFICATION

Scheme 14

TRANSAXLE CASE COVER & INPUT UNIT

1. Disconnect manual valve rod from manual valve. Remove transaxle case cover bolts (includes 2 No. 4 Torx bolts). (Scheme 15) Use rubber mallet to loosen case cover. DO NOT pry cover from case. Remove case cover, and position aside with 1-2 accumulator up, as accumulator pin may drop out of cover.
2. Remove 1-2 accumulator spring, piston, pin and center case-to-cover gasket. Remove case cover-to-drive sprocket thrust washer and driven sprocket thrust bearing assembly. Case cover-to-drive sprocket thrust washer may come off with case cover. Remove and discard turbine shaft "O" ring.
3. Inspect drive link. Ensure driven sprocket support surfaces are flush with case. Midway between sprockets, push bottom section of drive link toward top section until all slack has been removed. Mark case at right angle to bottom side of link. Push link in opposite direction until slack is removed. Mark case from same point on link. Distance between marks should not exceed.875" (22.2 mm). Replace link if measurement exceeds specification.
4. Note direction of Black guide link prior to removal. Link must be installed in same direction or noise may occur. Remove drive sprocket, driven sprocket and chain as an assembly. (Scheme 3) Remove drive and driven sprocket-to-support thrust washers. These washers may come off with sprockets.
5. Using 3/16" drift, remove detent lever-to-manual shaft pin. Remove manual shaft-to-case nail. (Scheme 16) Withdraw manual shaft from case, and lift out manual valve rod and detent lever assembly. Remove park lock actuator rod.
6. Remove driven sprocket support and thrust washer on direct clutch side. (Scheme 16) Thrust washer may come out with driven sprocket support. Remove intermediate band anchor hole plug and intermediate band assembly.
7. While lifting input shaft, remove and separate direct and forward clutch assemblies. (Scheme 39) Remove input internal gear-to-input shaft thrust washer, and remove input internal gear.
8. Remove input carrier assembly, input carrier-to-input internal gear thrust washer and input carrier-to-input sun gear thrust washer. Remove input sun gear and input drum.

Scheme 15

Scheme 16

REACTION UNIT

Note. Before disassembling reaction unit, measure reaction sun gear-to-input drum snap ring and low-reverse clutch housing-to-low race end play. This determines appropriate snap ring and thrust washer to be used during transaxle reassembly procedure. See REACTION SUN GEAR-TO-INPUT DRUM END PLAY and LOW-REVERSE CLUTCH HOUSING-TO-LOW ROLLER CLUTCH RACE THRUST WASHER END PLAY .

Reaction Sun Gear-To-Input Drum End Play

1. Install Output Shaft Aligner/Loader (J-26958) in fully loaded position. (Scheme 14) Using 2 case cover bolts, install Reaction Sun Gear Snap Ring Gauge (J-28588) to case. (Scheme 17) Position Extension Post (J-25025-7A) between open ends of selective snap ring on reaction sun gear.
2. Press reaction sun gear down to seat. Install dial indicator onto extension post. Position feeler gauge (part of gauge set J-28588) beneath extension post, and zero dial indicator.
3. Rotate selective snap ring under extension post while removing feeler gauge. Dial indicator should indicate between.013" and -.005". (.33 and -.13 mm) end play. If end play is not as specified, replace snap ring to adjust end play. Snap ring is located on reaction sun gear shaft. Measure thickness of snap ring for proper identification. See «REACTION SUN GEAR-TO-INPUT DRUM SNAP RING IDENTIFICATION»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40) table.

REACTION SUN GEAR-TO-INPUT DRUM SNAP RING IDENTIFICATION

Scheme 17

Low-Reverse Clutch Housing-To-Low Roller Clutch Race Thrust Washer End Play

1. With dial indicator, gauge and output shaft aligner/loader still installed from previous procedure ( «REACTION SUN GEAR-TO-INPUT DRUM END PLAY»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40__reaction-sun-gear-to-input-drum-end-play) ), press down reaction sun gear to seat and zero dial indicator.
2. Insert screwdriver through parking pawl case opening. (Scheme 18) Lift reaction internal gear, and read low-reverse clutch selective end play. DO NOT rest screwdriver on spacer in parking pawl case opening, as spacer damage will result.
3. End play should be.003-.046" (.08-1.17 mm). Select appropriate washer to correct end play if necessary. See «LOW-REVERSE CLUTCH HOUSING-TO-LOW ROLLER WASHER IDENTIFICATION»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40) table. Washer controlling end play is located between low-reverse clutch housing and low roller clutch assembly.

Scheme 18

LOW-REVERSE CLUTCH HOUSING-TO-LOW ROLLER WASHER IDENTIFICATION

Reaction Unit Disassembly

1. Remove dial indicator, gauge and output shaft aligner/loader. Leave output shaft loader adapter in place. Remove reaction sun gear. Remove low-reverse clutch housing-to-case snap ring. Snap ring is.092" (2.34 mm) thick. Using Low-Reverse Clutch Housing Remover/Installer (J-34008), remove low-reverse clutch housing. (Scheme 19)
2. Remove low-reverse clutch housing-to-case spacer ring from groove in case. Lift out final drive sun gear shaft and reaction gear set as an assembly. Remove roller clutch and reaction carrier assembly from final drive sun gear shaft.

Scheme 19

FINAL DRIVE UNIT

Note. Before disassembling unit, check final drive-to-case end play. This determines appropriate final drive differential-to-case thrust washer to be used during transaxle reassembly procedure. See FINAL DRIVE-TO-CASE END PLAY .

Final Drive-To-Case End Play

1. Position transaxle so right-side axle seal is up. Using Output Shaft Aligner/Loader Adapter Plug (J-26958-10), press down adapter to seat final drive onto final drive internal gear-to-case snap ring.
2. Install dial indicator onto post, and install post in motor mount bolt hole. (Scheme 20) Ensure indicator plunger rests on top of adapter. Zero dial indicator while pressing down on adapter.
3. Insert large screwdriver into transaxle governor bore, and lift final drive by prying up on governor drive gear. Dial indicator should indicate.005-.032" (.12-.82 mm) end play.
4. Select appropriate thrust washer to correct end play if necessary. See «FINAL DRIVE-TO-CASE THRUST WASHER IDENTIFICATION»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40) table. Thrust washer controlling end play is located between differential carrier and differential carrier case thrust bearing assembly.

FINAL DRIVE-TO-CASE THRUST WASHER IDENTIFICATION

Final Drive Unit Disassembly

1. Remove dial indicator, indicator post and loader/aligner adapter. Remove final drive internal gear spacer-to-case snap ring. Snap ring is .092" (2.34 mm) thick. Remove final drive internal gear spacer. Use care not to deform or bend spacer.
2. Using Final Drive Unit Remover/Installer (J-33381), lift final drive unit from case. Remove final drive differential-to-case selective thrust washer. Remove differential carrier-to-case thrust roller bearing assembly from final drive assembly. If thrust washer and thrust bearing did not come out with final drive assembly, remove from case.

Scheme 20

COMPONENT DISASSEMBLY & REASSEMBLY

Note. Some procedures in COMPONENT DISASSEMBLY & REASSEMBLY may provide instructions for installing component(s) in transaxle case.

TRANSAXLE CASE

Note. Disassembly procedures provide instructions for removing drive sprocket roller bearing, drive sprocket support, 3rd oil cup plug, parking pawl and governor oil pipe. Do not remove components unless necessary.

Disassembly

1. Using slide hammer and Adapter (J-26941), remove driven sprocket support bearing. (Scheme 3)or (Scheme 39). Inspect bearing bore and roller bearing race on driven sprocket for wear or damage and replace if necessary.
2. To remove drive sprocket support, remove torque converter oil seal. Remove Torx screws, and remove drive sprocket support. Using screw extractor, remove parking pawl shaft cup plug from oil pan side of case. Remove parking pawl components as necessary.
3. To remove governor pipe, remove governor oil pipe clamp screw and clamp. (Scheme 3) Remove right-side axle end first. Use a piece of wood to protect machined case surface if pipe must be pried out. Grind 1/2" from end of No. 4 screw extractor. Install No. 4 screw extractor into 3rd oil cup plug. Remove cup plug. (Scheme 3)
4. With final drive assembly and right-side axle shaft removed from case, inspect final drive case bushing for wear or scoring. Use Bushing Remover (J-28537-6) and Driver Handle (J-8092) to remove bushing.

Inspection

1. Inspect case assembly for damage, cracks, porosity and interconnected oil passages. Ensure exhaust vent holes are open. Inspect for stripped bolt holes.
2. Check case lugs, intermediate servo bore and snap ring grooves. Inspect case bushings for wear or scoring. Inspect drive and driven sprocket support bearing assemblies for pitting and scoring to carrier and rollers. Check rollers for excessive clearance.
3. Inspect drive and driven sprocket supports for damage to journal splines. Check for heat discoloration and cracks on support assembly. Inspect governor pipe for damage, cracks and leakage. Check parking pawl shaft cup plug, parking pawl shaft and parking pawl for damage and excessive wear. Inspect 3rd oil cup plug for tightness in bore or damage. Check all sealing and mating surfaces for straightness.

Reassembly

1. Install NEW final drive case bushing using Bushing Installer (J-28537-2) and Driver Handle (J-8092). Drive in bushing until tool bottoms. Using Seal Driver (J-29130) and driver handle, install NEW right-side axle seal. DO NOT damage seal guard during installation. Using a 13-mm socket, install manual shaft oil seal with lip up.
2. Using a 1/4" drift, install NEW cup plug. (Scheme 3) Cup plug should seat fully in bore. Before installing, coat ends of governor oil pipe with Loctite sealer. Install governor pipe and retaining clamp.
3. Install parking pawl and spring, parking pawl shaft and retainer. Ensure large loop of pawl spring is positioned on right side of pawl. Coat parking pawl shaft cup plug with sealant, and install plug using a 3/8" drift.
4. Install driven sprocket support roller bearing assembly with bearing identification facing up. Lightly tap driven sprocket support bearing into position using Bearing Installer (J-28677). Install NEW converter oil seal using Driver (J-28540-A).

Scheme 21

1. Remove final drive internal gear and final drive internal gear thrust bearing. Lift out final drive sun gear and thrust bearing. (Scheme 21) Inspect final drive internal gear and sun gear for cracks, damage, heat discoloration and worn or missing teeth.
2. Inspect differential side gears and pinions for wear or damage. Using a 3/16" pin punch, drive out differential pinion shaft retaining pin. Remove pinion shaft, differential pinion gears and thrust washers. Push pinion gears from differential carrier. Ensure dished pinion thrust washers are removed with pinion gears. (Scheme 21)
3. Slide differential side gears toward center of carrier and remove. Remove side gear thrust washers. Keep thrust washers with gears for reassembly reference. Ensure end play between carrier and final drive pinion is.009-.025" (.23-.64 mm).
4. Inspect final drive pinions for damage. If pinions must be removed, detach spiral retaining ring, and withdraw pinion pins. Carefully remove pinion gears and thrust washers together to prevent dropping needle roller bearings. Remove needle bearings from each pinion gear and check for damage. Remove governor drive gear only if replacement is necessary. Using Puller (J-8433) and a thick, flat washer, pull governor drive gear from differential.

1. If governor drive gear is removed, lightly tap it into place with plastic mallet. Install needle bearings. Install steel pinion thrust washer onto end of pin (side opposite first thrust washer). Install one bronze pinion thrust washer to each end of pin. Slide pinion pin from assembly, keeping bearings intact in gear.
2. Install pinion gear assembly into differential carrier. Install pinion pin (stepped end last) into carrier through pinion gear assembly. Install other final drive pinion gears using same procedure. Install spiral retaining ring.
3. Install pinion pin so step is outside. Ensure bronze thrust washer is present on each end of final drive pinion, between carrier and steel thrust washer.
4. Install internal gear thrust bearing, sun gear (with stepped side facing upward), thrust bearing (with outside race to internal gear), and internal gear into final drive internal carrier. Install differential side gear thrust washers and side gears. Hold them in place with petroleum jelly. Coat side gear pinion dished thrust washers with petroleum jelly, and install them onto side gear pinions. Install pinion gears in differential carrier windows.
5. Install differential carrier case selective thrust washer into differential carrier case. Install thrust bearing into carrier assembly. Use petroleum jelly to hold bearing in place. Using Final Drive Unit Remover/Installer (J-33381-A), install differential carrier assembly into final drive internal case.
6. Install final drive internal gear spacer into case. Ensure parking pawl moves freely after spacer installation. Install snap ring into groove. Ensure final drive-to-case end play is.005-.032" (.12-.82 mm). See «FINAL DRIVE UNIT»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40__final-drive-unit) under TRANSAXLE DISASSEMBLY. (Scheme 20)

Check final drive sun gear shaft, reaction internal gear and reaction sun/internal gear thrust bearing for excessive wear or damage. (Scheme 22) Check rear portion of center spline. If spline has a step (due to wear), replace reaction internal gear and shaft.

Scheme 22

Remove selective bearing and low roller clutch race. Pull low roller clutch from reaction carrier assembly. Remove reaction carrier-to-low roller clutch thrust washer from carrier. Pull final drive sun gear shaft from reaction internal gear. (Scheme 22)

1. Inspect low roller clutch race and roller clutch bearings for damage. Inspect 4-tanged thrust washer for scoring, excessive wear and distorted tangs. Inspect reaction carrier, roller clutch cam ramps and bushing for damage or scoring.
2. Inspect reaction carrier pinions for damage, rough bearings or excessive wear. Ensure pinion pins DO NOT rotate. Using feeler gauge, check pinion end play. Pinion end play should be .009-.025" (.23-.64 mm).

1. Install thrust washer into reaction carrier. Ensure all rollers are installed in cage, and install roller clutch into carrier. Install clutch race with groove of race facing up. Install 4-tanged thrust washer. (Scheme 22) Use petroleum jelly to hold washer in position. Hold carrier assembly and ensure low roller clutch race rotates clockwise only. (Scheme 23)
2. Install reaction carrier and clutch assembly into reaction internal gear. Install selective bearing and reaction gear assembly. Ensure gear does not contact final drive internal gear spacer.
3. Install low-reverse clutch backing plate into case with stepped side down. Install low-reverse clutch waved plate. Lubricate composition plates with ATF. Install composition plates first, and then install steel plate. (Scheme 22) Install low-reverse clutch waved plate and snap ring. Snap ring is.042" (1.07 mm) thick.

Scheme 23

Compress low-reverse clutch spring retainer, and remove snap ring. Remove clutch release spring and clutch piston from housing. Remove inner and outer piston seals. (Scheme 24)and (Scheme 25).

Inspect clutch housing for damage or plugged feed hole. Check bushing for cracks, damage or warpage. Inspect clutch splines and snap ring groove for damage or burrs. Remove any burrs on splines or snap ring groove. Inspect clutch piston and apply ring for distortion, cracks or damage. Inspect piston seals for nicks, cuts or hardening.

1. Install NEW seals onto piston. Using Inner/Outer Seal Installer (J-26744-A), install clutch piston. (Scheme 25) Install clutch release spring. Compress spring, and install snap ring. Using Handle (J-34008), install low-reverse clutch housing. (Scheme 19)
2. Ensure oil feed hole in housing lines up with feed hole in case. If housing does not go past snap ring groove, remove tool and install sun gear. Rotate sun gear back and forth until housing is in place. Install.092" (2.36 mm) thick snap ring. Apply maximum air pressure of 50 psi (3.5 kg/cm 2 ) to feed hole to check for proper operation. (Scheme 26)

Scheme 24

Scheme 25

Scheme 26

1. Check reaction sun gear for cracks, splits, spline damage, gear-to-journal wear and plugged lubrication passages. Inspect input drum for distortion, damaged splines and pins. To check and adjust reaction sun gear-to-input drum end play, see «REACTION UNIT»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40__reaction-unit) under TRANSAXLE DISASSEMBLY.
2. Install correct thickness low-reverse housing/low race selective washer as previously determined. See «LOW-REVERSE CLUTCH HOUSING-TO-LOW ROLLER CLUTCH RACE THRUST WASHER END PLAY»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40__low-reverse-clutch-housing-to-low-roller-clutch-race) under REACTION UNIT in TRANSAXLE DISASSEMBLY. (Scheme 18)and (Scheme 22).

Check all parts for pitting, scoring, damaged gear teeth and cracks. Ensure lubrication holes are open. Check input carrier thrust washers for wear and distortion of tangs. (Scheme 27) Check carrier pinion pins for tightness. Ensure pins DO NOT rotate. Ensure input carrier pinion end play is.009-.027" (.23-.69 mm).

Scheme 27

1. Place forward clutch housing in holding fixture with clutch pack facing up. Remove snap ring, backing plate, steel and composition clutch plates from housing. (Scheme 28) Remove Belleville plate.
2. Using Clutch Pack Compressor (J-23456) and Adapter (J-23327-1), compress retainer and spring assembly in order to remove snap ring. Remove tools, retainer and spring assembly from clutch housing. Remove piston and insert from housing, and remove seals from piston.

Inspect input shaft oil seal rings for damage. DO NOT remove seal rings unless replacement is necessary. Inspect clutch plates and all components for excessive wear or damage and replace if necessary.

1. If necessary, install inner and outer seals on piston with lips facing housing. Lubricate seals, and install piston into clutch housing using Inner/Outer Seal Installer (J-26744-A).
2. Position spring guide, retainer and spring assembly into clutch housing. Compress retainer and spring assembly using compressor tool, and install snap ring. Remove compressor tool.
3. Install Belleville plate. Lubricate and alternately install composition and steel plates. Install backing plate with identification side facing upward. (Scheme 28) Install snap ring.
4. If removed, install NEW input shaft seal rings. Ensure cut ends are assembled as shown, and rings are seated in groove. (Scheme 29) Hold rings in place with petroleum jelly.

Scheme 28

Scheme 29

1. Remove clutch pack snap ring. Remove backing plate, composition and steel clutch plates from clutch housing. (Scheme 30) If forward clutch is disassembled, keep direct clutch plates separate from forward clutch plates.
2. Remove snap ring holding apply ring and release spring assembly. Remove apply ring and release spring assembly from housing. Remove direct clutch piston from clutch housing. Remove inner and outer seals from piston. Remove center seal from clutch housing.

1. Inspect direct clutch housing bushings for damage, cracking or scoring. Inspect composition plates, steel plates and backing plate for wear, burning or scoring. Inspect apply ring, retainer and release spring assembly for damage.
2. Inspect direct clutch piston for distortion, cracks or damage. Inspect clutch housing for excessive wear. If there is intermediate band failure, inspect outer surface of direct clutch. (Scheme 31)
3. If removal is necessary, drive check ball capsule (toward direct clutch side of housing) from housing using a 1/4" drift. Install NEW capsule from direct clutch side of housing, and seat with a 3/8" drift.
4. If intermediate band/direct clutch is burned, remove intermediate servo cover and gasket. Remove 3rd accumulator exhaust valve and spring. (Scheme 6) Inspect 3rd accumulator exhaust valve bore and valve seat condition.
5. Plug feed and release holes in bore with petroleum jelly. Install a dual-land 3rd accumulator exhaust valve. Ensure valve is centered in seat. Pour solvent into valve bore, and check for leakage on inside of case. Small amount of seepage is okay.
6. If valve leaks, replace transaxle case. If valve does not leak, remove check valve, and install NEW conical spring onto valve (small end first). Install valve with spring into bore. Replace servo gasket and cover.

Scheme 30

Scheme 31

1. Install inner and outer seals onto pistons with lips facing drum. Install center seal on housing with lip facing away from drum. Lubricate all seals, and then install piston into clutch housing.
2. Install apply ring, retainer and release spring assembly, and snap ring. Lubricate direct clutch plates with ATF and install into housing, starting with a flat steel plate, and then alternating between composition and flat steel plates (4 of each). Ensure smooth fiber composition plates are used. (Scheme 30)
3. Install backing plate into housing with chamfered or polished side against composition plate. Install snap ring. Ensure composition plates turn freely.

Inspect intermediate band for burns, flaking or damage. Install intermediate band, aligning lugged end with apply pin bore. Install band anchor hole plug.

1. Inspect driven sprocket support and sleeve for damage. Ensure sleeve is tight in bore and aligns with holes in support. Inspect driven sprocket support bushing and bearing assembly for damage and wear. (Scheme 16)
2. Pull out bearing assembly using slide hammer and Bearing Remover (J-26941). Using Bearing Installers (J-28677 and J-8092), install bearing with identification facing up.
3. Check bearing race on driven sprocket. If race needs replacement, replace driven sprocket support. Inspect seal rings for nicks or cuts. Replace worn or damaged components as needed.

1. Inspect manual valve rod, rod retainer and detent lever for damage. (Scheme 16) Check threads of manual shaft, and file any raised edges.
2. Inspect parking lock actuator rod for damage or broken retainer lugs. If removed, install parking lock actuator rod into manual shaft lever. Use a 3/16" drift and install roll pin into detent lever. Tap nail into place.

1. Inspect drive chain for damage. Replace chain if necessary. Inspect driven sprocket support bearing. (Scheme 39) If damaged, replace driven sprocket support bearing assembly. Inspect drive and driven sprocket teeth for nicks, burrs, scoring and wear. Replace as necessary.
2. Check internal splines for nicks, burrs and excessive wear. Inspect turbine shaft for excessive wear or damage. Inspect turbine shaft seal ring grooves and seal rings for damage.
3. DO NOT remove seal rings unless they are being replaced. If turbine shaft seal ring removal is necessary, carefully cut old seals from turbine shaft. Install NEW seals.
4. Use Sizer (J-29569-2) on 2 seal rings on valve body side of sprocket. Use seal installer on seal ring on case side of sprocket. Push sizer down over seal and turn. Remove sizer, and inspect seal to ensure it is seated in groove.

CASE COVER

Note. Do not disassemble case cover unless repair or replacement of cover or components is necessary.

Remove detent spring/roller assembly retaining screw, and remove spring/roller assembly. Remove 2 thermostatic roll pin retainers. Remove thermostatic element and plate. Remove axle oil seal and guard if necessary. Using a drift, drive out manual valve cup plug. Carefully withdraw manual valve. DO NOT use manual valve to drive out cup plug.

1. Inspect case cover and threads for damage. Inspect vent assembly for damage and clogging. Check manual valve movement. Check manual valve electrical connector and replace if necessary. Inspect manual detent spring and roller assembly. Check case cover sleeve. Ensure hole in sleeve aligns with case cover passages intersecting case cover (pump shaft) bore.
2. Inspect 1-2 accumulator piston seals for damage and free fit in grooves. Inspect thermostatic element for damage or distortion. Inspect vent assembly and cooler line connectors for damage. Replace components if necessary.

1. Install NEW axle oil seal and seal guard. Install detent spring and roller assembly. If 1-2 accumulator piston seal was removed, install NEW seal ring. Install 1-2 accumulator piston (flat side down).
2. Install 1-2 accumulator piston pin. Install manual valve assembly with small diameter first. Using a 3/8" drift, replace manual valve cup plug. Coat cup plug with sealant before installation. With NEW "O" ring on electrical connector, install connector with tab located at case slot.
3. If removed, install thermostatic element roll pins into case. Using Roll Pin Height Checker (J-29023), adjust installed height of center roll pin to.24" (6.0 mm). (Scheme 32) Recheck thermostatic element roll pin installed height. Install thermostatic element plate.
4. Install thermostatic element onto roll pins. Place Roll Pin Height Checker (J-29023) against roll pin, between case surface and thermostatic element. Install roll pin retainers, and tap down onto roll pins until element contacts touch. Set roll pin washer height after installing and setting center roll pin height.
5. Set roll pin retainer height to.21" (5.3 mm). (Scheme 33) Adjustment is important for thermostatic element operation. Thermostatic element controls fluid level in control valve cover oil sump.

Scheme 32

Scheme 33

CONTROL VALVE & OIL PUMP ASSEMBLIES

Note. As valve assembly components are removed from valve body bore, place individual parts in correct order in relative position to valve body. Valves, bushings and springs are not interchangeable. (Scheme 34)

1. Position control valve assembly face up with line boost valve at top. Remove valve retaining pins. Drill out all blind retainer pins from valve body. If valve body is cleaned in solvent, low blow-off assembly must be replaced.
2. Remove remaining auxiliary valve body cover bolts, auxiliary valve body, gasket and cover. (Scheme 9) Remove pump slide, rotor, vanes and vane rings.

1. Clean all components. DO NOT clean pump seals in solvent. Check all parts for wear or damage. Replace pump shaft bearing assembly using Bearing Remover/Installers (J-35914 and J-7092-2). Drive bearing out toward case cover side. Using bearing installers, press bearing and seal assembly flush to pump pocket surface or up to .012" (.3 mm) below pump pocket.
2. Measure pump rotor and/or slide thickness. Measure on flat, undamaged surface. Use original measurement when obtaining replacement parts. Pump rotor thicknesses range from .7052-.7071" (17.912-17.960 mm) in .0004" (.010 mm) increments. Hone both sides of replacement rotor and/or slide to remove burrs.

1. Install pump slide into pump pocket. Install pump slide seal and seal support. Use petroleum jelly to retain slide parts. Align slide with pump slide pivot hole, and install pump slide pivot pin. Install vane ring and pump rotor into pump pocket. Install pump vanes into pump rotor.
2. Ensure pump vane wear pattern is against centering ring, and each pump vane is seated flush with rotor. Install top vane ring and slide "O" ring seal in pump slide.
3. Install pump slide-to-auxiliary valve body oil seal ring. Check auxiliary valve body sleeve for damage. Install auxiliary valve body, gasket and cover. Align pump rotor step with auxiliary valve body sleeve. To complete reassembly, reverse disassembly procedure. (Scheme 34)

Scheme 34

Scheme 35

Remove auxiliary valve body components. (Scheme 34)or (Scheme 35). Keep parts in order for reassembly reference.

Clean all parts, except solenoid and switches, in solvent. Inspect all parts for wear or damage.

1. To reassemble, reverse disassembly procedure. Ensure auxiliary valve body sleeve is aligned with step in pump rotor. Before installing solenoid, locate metal clip attached to valve body and discard. Install solenoid with NEW "O" ring and plastic wire routing clip. Install cover gasket.
2. Ensure valve body bolt sizes are correct. Coat threads of bolt "F" with sealant before installation. (Scheme 11) Tighten bolts to specifications. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40__torque-specifications).

Disassembly & Reassembly

Remove snap ring from apply pin (if not previously done). Separate intermediate servo piston, spring retainer and apply pin. Remove and discard oil seals. (Scheme 36) Check all parts for wear or damage. Intermediate servo is assembled during transaxle assembly. See TRANSAXLE REASSEMBLY.

Scheme 36

1. Check governor assembly for wear or damage. Ensure governor weights operate freely and independently of each other. Check for damaged, mispositioned or tilted springs.
2. Install housing components and cover (if removed) with NEW "O" ring. Install NEW "O" ring onto speed sensor housing. Ensure governor assembly is piloted into speed sensor housing before tightening retaining bolts. Install speed sensor housing to transaxle case. (Scheme 37)

Scheme 37

Scheme 38

Scheme 39

Scheme 40

TRANSAXLE REASSEMBLY

Note. Note location of all gear sets, clutch plates, thrust bearings, thrust washers and bushings. (Scheme 38)- (Scheme 40). Recheck snap ring and thrust washer measurements taken during disassembly. See appropriate procedures under TRANSAXLE DISASSEMBLY.

Scheme 41

Scheme 42

Scheme 43

1. Lubricate all bushings, seals, thrust bearings and internal mating surfaces with ATF during reassembly. Use petroleum jelly to hold thrust washers in place.
2. Install selected differential carrier/case thrust washer. (Scheme 21) Install thrust bearing assembly to final drive unit (inner race of bearing against selective washer). Install differential and final drive assembly into case.
3. Install final drive internal gear spacer (cupped side against final drive internal gear). Ensure opening in spacer aligns with parking pawl opening in case. Ensure parking pawl passes through spacer.
4. Install final drive spacer-to-case snap ring with ring gap away from parking pawl opening in case. Install reaction sun gear set into case. (Scheme 22)
5. Install low-reverse clutch backing plate (stepped side down) and clutch plates into case. (Scheme 22) Start with a composition plate, and then alternate between steel and composition plates.
6. Install low-reverse clutch wave plate and housing-to-case thin snap ring. Install low-reverse clutch housing assembly into transaxle case. (Scheme 22) Ensure clutch feed hole in housing lines up with clutch feed hole in case.
7. Install selective snap ring onto reaction sun gear. Install reaction sun gear onto final drive sun gear shaft in transaxle. (Scheme 22)and (Scheme 27). Rotate reaction sun gear while pushing down on low-reverse clutch housing until clutch housing drops below snap ring groove in case.
8. Install low-reverse clutch housing-to-case thick snap ring. (Scheme 22) Install input drum onto reaction sun gear. (Scheme 27) Install input sun gear into input drum. Install input sun gear tanged thrust washer to pinion side of carrier.
9. Install input internal gear tanged thrust washer to internal gear side of carrier (input internal gear tanged thrust washer is larger than input sun gear tanged thrust washer). (Scheme 27) Install input pinion carrier onto input sun gear.
10. Install input internal gear over input carrier. Place forward clutch assembly on bench with input shaft up. Install direct clutch assembly over input shaft, onto forward clutch housing. When clutch housings are fully seated, distance from tang end of direct clutch housing to end of forward clutch housing should be 1.406" (35.71 mm). (Scheme 41)
11. Install input shaft-to-input internal gear thrust washer onto forward and direct clutch assembly. (Scheme 27)and (Scheme 38). Ensure rounded side is against input shaft, and stepped side faces outward, onto forward and direct clutch assembly.
12. Install direct and forward clutch assemblies into case. Rotate clutch assemblies, without pushing down, until they drop into fully seated position in case. When correctly installed, case face-to-direct clutch housing distance should be 1 11/16". (Scheme 42)
13. Install intermediate band. Install band anchor hole plug. Install driven sprocket support-to-direct clutch housing thrust washer. Install driven sprocket support. (Scheme 16)
14. Install manual shaft and parking lock actuator rod into case above driven sprocket support. Install detent lever on manual shaft (hub side away from driven sprocket support), and push manual shaft into place. Install detent lever-to-manual shaft retaining pin. Install manual shaft-to-case retaining nail. (Scheme 16)
15. Assemble drive and driven sprockets with link assembly, and install drive and driven thrust washers to sprockets. Install drive link assembly onto transaxle. (Scheme 3) Black guide link must face in same direction as removed. If NEW assembly is installed, install with Black guide link facing up.
16. Install case cover-to-driven sprocket thrust bearing (outer race against sprocket). Install 1-2 accumulator piston. Install thermostatic element (if removed). See «CASE COVER»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40__case-cover) under COMPONENT DISASSEMBLY & REASSEMBLY.
17. Install 1-2 accumulator spring into case bore. Install inner and outer case-to-cover gaskets and case cover. Install and tighten all case cover bolts. (Scheme 15) The 3 bolts that mate sprocket support-to-case cover must be tightened evenly to avoid cocking sprocket support.
18. Connect manual valve rod to manual valve. Install check balls No. 2-6 into case cover. (Scheme 13) Install check ball No. 1 on direct clutch passage on spacer plate. Install oil pump shaft into bore in case cover. Install 2 guide pins (M6 x 1.0 x 75 mm) in case cover-to-valve body bolt holes. (Scheme 12)
19. Install control valve assembly and bolts. (Scheme 11) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40__torque-specifications). Install valve body wiring harness. Ensure wiring harness is routed properly. (Scheme 10) Connect lever link to T.V. bracket. Install T.V. bracket onto valve body.
20. Remove guide bolts used to install valve body, and install 2 remaining valve body bolts. Thoroughly clean valve body cover. Install cover with NEW gasket. Apply Loctite sealant to indicated cover bolts. (Scheme 43)
21. Turn transaxle so oil pan side is up. Install output shaft into transaxle. (Scheme 3) Rotate final drive so retaining ring groove is visible through access window in case. Install NEW retaining ring onto shaft groove.
22. Install parking lock bracket and dipstick stop. Using a 3/8" drift, install NEW low-reverse oil pipe seal assembly. Install "O" ring backup washer and "O" ring seal onto end of low-reverse pipe. Install pipe and retainer bracket.
23. Install intermediate servo piston assembly. Use NEW inner and outer oil seals on piston and NEW seal on apply pin (apply pin size was determined during transaxle disassembly procedure). Install 3rd accumulator exhaust valve and spring into check valve bore next to servo piston. Install intermediate servo cover and bolts. (Scheme 5)
24. Install reverse oil pipe bracket to oil pipe and servo cover. Install remaining servo cover bolt through bracket and cover. Tighten servo cover bolts. Install NEW oil strainer and "O" ring. Install NEW oil pan gasket and oil pan. Apply Loctite sealant to oil pan bolt threads. (Scheme 43) Rotate transaxle so oil pan side is down.
25. Install governor assembly. Install speed sensor rotor onto governor assembly. Ensure governor shaft is piloted in sensor rotor. Install thrust bearing. Install NEW "O" ring to speed sensor housing, and install housing onto case. Install housing bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-3t40__torque-specifications). Install torque converter.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS

See also:
• FLUID CAPACITIES
• CONTROL VALVE & OIL PUMP ASSEMBLY
• LUBRICATION
• ROAD TEST
• CLUTCH & BAND APPLICATIONS
• HYDRAULIC PRESSURE TESTS
• TORQUE CONVERTER DIAGNOSIS
• BAND APPLY PIN SELECTION CHECK
• REACTION SUN GEAR-TO-INPUT DRUM END PLAY
• LOW-REVERSE CLUTCH HOUSING-TO-LOW ROLLER CLUTCH RACE THRUST WASHER END PLAY
• FINAL DRIVE-TO-CASE END PLAY
• FINAL DRIVE UNIT
• REACTION UNIT
• TORQUE SPECIFICATIONS
• TRANSAXLE REASSEMBLY
• TRANSAXLE DISASSEMBLY
• CASE COVER