Automatic Transmission Servicing Chevrolet Cavalier III

APPLICATION

TRANSAXLE APPLICATION

Identifying Oil Pan Gasket (Hydra-Matic 3T40). Scheme 148

Identifying Oil Pan Gasket (Hydra-Matic 4T40-E). Scheme 149

LUBRICATION

Note. The 4T40-E is not equipped with a dipstick.

3T40

Check transmission fluid level at every engine oil change. Transmission fluid should be changed under normal operating conditions at 100,000 miles. Under continuous extreme operating conditions (trailer towing, heavy city traffic with ambient temperature more than 90°F (32°C) or delivery service), fluid and filter should be changed every 50,000 miles.

4T40-E

This transaxle is not equipped with transaxle fluid dipstick. Check transmission fluid level only when leaks have occurred. Under continuous extreme operating conditions (trailer towing, heavy city traffic with ambient temperature more than 90°F (32°C) or delivery service), fluid and filter should be changed every 50,000 miles.

CHECKING FLUID LEVELS

1. Start engine. Operate vehicle for at least 15 minutes or until operating temperature is reached. With engine at idle and vehicle on level ground, move gear selector lever through all ranges, ending in Park.
2. Remove transaxle dipstick, wipe clean and fully reinsert into filler tube. Remove dipstick again, and inspect fluid level. Fluid level should be between ADD 1 PT. mark and FULL HOT mark, between COLD and HOT mark, or within cross-hatched area on dipstick, depending on dipstick.

Note. The 4T40-E is not equipped with a dipstick.

1. Fluid level must be checked with transaxle temperature of at least 104°F (40°C). To obtain proper temperature, run engine at idle for 3-5 minutes. Shift through each gear range, holding in each range for 3 seconds.
2. Place gear selector in Park. Leave engine running. Raise and support vehicle. Place oil drain pan below oil check plug. Oil check plug is located in center of transaxle above pan rail, on torque converter side. (Scheme 150) Remove oil check plug.
3. Oil level should be even with bottom of oil check plug hole. If fluid does not drain from hole, add fluid until fluid starts to pour from hole. Tighten oil check plug to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).

Scheme 150

RECOMMENDED FLUIDS

On all models, manufacturer recommends Dexron-III ATF. Fill transaxle with appropriate quantity. See FLUID CAPACITIES .

FLUID CAPACITIES

TRANSAXLE FLUID CAPACITIES (1)

DRAINING & REFILLING

Note. Some transaxles are equipped with a reusable-type oil pan gasket. Reusable oil pan gasket is constructed of rubber with metal or plastic backing. On transaxles equipped with reusable-type gasket, sealing surface of oil pan is flat. Transaxles not equipped with reusable-type gasket have a ridge on sealing surface of oil pan. Clean reusable gasket with solvent. Inspect reusable gasket for damage and replace as necessary. Using any other type of gasket in place of reusable-type gasket may result in fluid leaks.

Note. If oil pan bolts are equipped with conical washers, DO NOT reuse bolts if washers have become reversed. (Scheme 151)

Scheme 151

1. Raise and support vehicle. Place drain pan under transaxle oil pan. Remove transaxle oil pan front and side bolts only. Loosen rear bolts about 4 turns each.
2. Using a screwdriver, carefully pry pan loose. Allow fluid to drain. Remove remaining bolts, and remove oil pan. Remove and discard old pan gasket, if reusable-type gasket is not used. Remove filter and "O" ring or sleeve-type seal. Remove any remaining gasket material on transaxle case.
3. Thoroughly clean pan, magnet and screen (if metal) with solvent, and then dry using compressed air. Replace paper filter, if equipped. Install NEW "O" ring on pick-up tube or NEW sleeve into transaxle case. (Scheme 152) Lubricate with clean fluid before installation.
4. Install filter assembly into filter pick-up tube recess. Install oil pan and gasket. Use NEW pan gasket if transaxle is not equipped with reusable-type gasket. Tighten pan bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Add required amount of fluid to transaxle through filler tube. See «FLUID CAPACITIES»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__fluid-capacities).
5. With gear selector lever in Park and parking brake applied, start engine and check fluid level. See «CHECKING FLUID LEVELS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__checking-fluid-levels). Add fluid if necessary. DO NOT overfill.

Scheme 152

1. Raise and support vehicle. Place drain pan under transaxle oil pan. Remove oil pan bolts from front and side. Loosen rear transaxle oil pan bolts about 4 turns each.
2. Using a screwdriver, carefully pry pan loose. Allow fluid to drain. Remove bolts, and remove oil pan. Remove and discard old pan gasket, if reusable-type gasket is not used. Remove filter and "O" ring or sleeve-type seal. (Scheme 153) Remove any remaining gasket material on transaxle case.
3. Thoroughly clean pan, magnet and screen (if metal) with solvent, and then dry using compressed air. Replace filter and seal. Lubricate with clean fluid before installation.
4. Install filter assembly into filter pick-up tube recess. (Scheme 154) Install oil pan and gasket. Use NEW pan gasket if transaxle is not equipped with reusable-type gasket. Tighten pan bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
5. Fill transaxle to proper level. See «FLUID CAPACITIES»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__fluid-capacities). Lower vehicle and start engine. Allow engine to idle until transmission fluid reaches 104°F (20°C). Depress brake pedal and shift gear selector through all gear ranges, pausing a few seconds in each range. Place gear selector lever in Park.
6. With engine running, raise vehicle and remove transaxle oil check plug. Add fluid in increments of one pint (.5L) until fluid drains from oil check hole. Install oil check plug and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).

Scheme 153

Scheme 154

OIL COOLER FLUSHING

Note. DO NOT use solutions that contain alcohol or glycol. Use of solutions that contain alcohol or glycol may damage flushing equipment, oil cooler components and/or transaxle components.

Preparation

1. After the repair or replacement transaxle is installed in the vehicle, do not reconnect the oil cooler pipes.
2. Remove the fill cap (9) on the Transmission Oil Cooler and Line Flusher (J-35944-A) and fill the flusher tank (4) with 20-21 oz. (0.6L) of flushing solution using the measuring cup (6). DO NOT overfill. Install the fill cap (9) on the flusher and pressurize the flusher tank (4) to 80-100 psi (550-700 kPa), using the shop air supply at the tank air valve (9). (Scheme 155)
3. Connect the flusher discharge hose (5) to the oil cooler return pipe (top connector). This may require (J-35944-600). Clip the discharge hose (5) onto the oil drain container. Attach the flusher to the undercarriage of the vehicle with the hook provided, and connect the flushing system feed supply hose (3) from the flusher to the oil cooler feed pipe (bottom connector). This may require (J-35944-600). (Scheme 156)
4. With the water supply valve (1) on the flusher in the OFF position, connect the water supply hose (7) from the flusher to the water supply at the faucet. (Scheme 155)and (Scheme 156). Turn ON the water supply at the faucet.

Scheme 155

Scheme 156

Initial Flush

1. Turn the flusher water supply valve (1) to the ON position and allow water to flow through the oil cooler and pipes for 10 seconds to remove any remaining transmission fluid. (Scheme 157) If water does not flow through the oil cooler and pipes, the cause of the blockage must be diagnosed and the plugged component must be repaired or replaced. Continue with the cooler flushing and flow check procedure once the blockage is corrected.
2. Turn the flusher water supply valve (1) to the OFF position and clip the discharge hose (5) onto an appropriate container with a lid, to avoid splashback. (Scheme 158) Turn the flusher water supply valve (1) to the ON position and depress the trigger (8) to mix cooler flushing solution into the water flow. (Scheme 155) Use the clip provided on the handle to hold the trigger (8) down. The discharge will foam vigorously when the solution is introduced into the water stream.
3. Flush the oil cooler and pipes with water and solution for 2 minutes. During this flush, attach the shop air supply of 120 psi (825 kPa) to the flushing system feed air valve (2) located on the flusher for 3-5 seconds at the end of every 15-20 second interval to create a surging action.
4. Release the trigger (8) and turn the flusher water supply valve (1) to the OFF position.

Scheme 157

Scheme 158

Back Flush

1. Disconnect both hoses from the oil cooler pipes and then connect them to the opposite oil cooler pipe. This will allow the oil cooler and pipes to be back flushed. Repeat steps 2 and 3 of the INITIAL FLUSH procedure. Release the trigger (8) of the flusher and allow water only to rinse the oil cooler and pipes for one minute.
2. Turn the flusher water supply valve (1) to the OFF position and turn OFF the water supply at the faucet. Attach the shop air supply to the flushing system feed air valve (2) on the flusher, and blow out the water from the oil cooler and pipes. Continue until no water comes out of the discharge hose (5).

TRANSAXLE & OIL COOLER FLOW CHECK

1. Disconnect both hoses from the oil cooler pipes. Connect the oil cooler feed pipe (bottom connector) to the transaxle and the return pipe (top connector) to the discharge hose (5). This may require J-35944-600. Clip the discharge hose (5) onto the empty oil drain container. (Scheme 158)
2. Confirm the transaxle is filled with ATF. See «CHECKING FLUID LEVELS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__checking-fluid-levels). Start the engine with the transaxle in PARK range and run for 30 seconds. A minimum of 2 qts. (1.9L) must be discharged during this 30-second run time. If fluid flow is greater than 2 qts. (1.9L) in 30 seconds, go to next step. If fluid flow is less than 2 qts. (1.9L) in 30 seconds, go to step 4.
3. Remove the discharge hose (5), reconnect the cooler feed and return pipes to the transaxle and refill the unit to the proper fluid level. Inspect the transaxle oil cooler pipe connections at the radiator, the auxiliary cooler (if equipped) and the transaxle for leaks.
4. Disconnect the oil cooler feed line at the radiator. Connect the discharge hose (5) to the cooler feed line. Clip the discharge hose (5) to the empty oil drain container. (Scheme 158) Start the engine with the transaxle in PARK range and run for 30 seconds. A minimum of 2 qts. (1.9L) must be discharged during this 30-second run time. Perform the following according to the flow rate: Insufficient feed flow: Inspect the transaxle. Sufficient feed flow: Inspect the oil cooler return pipe and the oil cooler (and auxiliary cooler, if equipped).

ON-VEHICLE REPAIRS

Various components may be serviced without transaxle removal, depending on application. For servicing of these components, see appropriate component under ADJUSTMENTS and/or REMOVAL & INSTALLATION . For additional information on testing electrical components, see appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS.

ADJUSTMENTS

PARK/NEUTRAL POSITION SWITCH

Note. Adjustment procedure is included with component removal and installation procedure. See PARK/NEUTRAL POSITION SWITCH under REMOVAL & INSTALLATION.

SHIFT CABLE

Note. Most FWD vehicles are equipped with a self-adjusting shift cable.

1. Set the parking brake. Remove the console. See REMOVAL & INSTALLATION in appropriate SHIFT INTERLOCK SYSTEMS article in AUTOMATIC TRANSMISSIONS.
2. Lift and unlock the shift cable retainers. Push the shifter neutral lock clip.
3. Move the shifter slightly in order to center the lock clip. Ensure that the transaxle is in neutral. Press and lock the shift cable retainers.
4. Pull the shifter neutral lock clip to its original position. Install the console. See REMOVAL & INSTALLATION in appropriate SHIFT INTERLOCK SYSTEMS article in AUTOMATIC TRANSMISSIONS.

THROTTLE VALVE CABLE (3T40)

Note. Throttle Valve (T.V.) cable is not used on 4T40-E

1. Depress and hold the readjustment tab. Pull the cable conduit out until the slider mechanism hits the stop. Release the button.
2. Position a 17-mm socket and torque wrench onto the throttle body pulley cam assembly.
3. Rotate the torque wrench to the full wide open throttle position and apply 62-69 INCH lbs. (7-10 N.m) torque. Release the applied pressure on the torque wrench. Remove the torque wrench and socket
4. Check that the cable moves freely. The cable may appear to function properly with the engine stopped and cold. Inspect the engine after the engine is hot. Road test the vehicle.

Removal

Note. Tools required: Slide Hammer (J-6125-1B), Axle Seal Remover (J-23129), Bushing Installer/Remover (J-28537), Left Side Axle Seal Installer (J-29130) and Driver Handle (J-8092).

1. Remove the front fender liner. Remove the drive axle. See appropriate article in DRIVE AXLES.
2. Remove the seals (117). Use the (J-23129) and the (J-6125-1B). (Scheme 160)

Installation

1. Install the new oil seals using the (J-29130). Lubricate the seal lip with a light wipe of transmission oil.
2. Install the drive axle into the transaxle case. (Scheme 159)
3. Install the front fender liner. Lower the vehicle.
4. Fill the transaxle to the proper level with appropriate fluid. See «LUBRICATION»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__lubrication). Inspect the oil seal for leaks.

Scheme 159

Scheme 160

1. Raise and support the vehicle. Remove the vehicle speed sensor assembly. See «VEHICLE SPEED SENSOR»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing).
2. Remove the governor. (Scheme 161) Remove the governor compression ring. (Scheme 161)
3. Remove the governor shaft seal. Remove the governor shaft bushing and the screen.

1. Install the governor shaft bushing and the screen. (Scheme 161) Install the governor shaft seal.
2. Install the governor compression ring. (Scheme 161) Install the governor.
3. Install the vehicle speed sensor assembly. See «VEHICLE SPEED SENSOR»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing). Lower the vehicle. Adjust the transaxle oil level. See «CHECKING FLUID LEVELS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__checking-fluid-levels) under LUBRICATION.

Scheme 161

Raise and support the vehicle. Remove the oil pan and filter. See DRAINING & REFILLING under LUBRICATION. Remove the oil feed pipes. See OIL FEED PIPES. Remove the 2 intermediate-4th servo cover bolts, the servo and the spring. (Scheme 162)

Install the intermediate-4th band servo piston spring, the servo and the servo cover bolts. Tighten the bolts to specification. See TORQUE SPECIFICATIONS . Install the oil feed pipes. See OIL FEED PIPES . Install the filter and the pan. See DRAINING & REFILLING under LUBRICATION. Lower the vehicle. Connect the negative battery cable. Fill transaxle to proper level with appropriate fluid. See LUBRICATION. See FLUID CAPACITIES . Check fluid level. See CHECKING FLUID LEVELS .

Scheme 162

1. Raise and support the vehicle. Remove the oil pan, filter, and the seal. See «DRAINING & REFILLING»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION. Remove the reverse oil pipe. (Scheme 163)
2. Remove the back-up ring seal. Remove the reverse pipe to case O-ring.
3. Remove the low and reverse cup plug. Use the screw extractor. (Scheme 164)

1. Use a drift pin and a mallet in order to install the low and reverse cup plug seal (120) into the case. Seat the seal (120) fully against the low and reverse clutch piston housing. (Scheme 165)
2. Install the reverse pipe to case O-ring. Install the new back up ring seal. Install the reverse oil pipe. (Scheme 163) Install the oil pan, the filter and the seal. See «DRAINING & REFILLING»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION.
3. Fill the transaxle to proper level with appropriate fluid. See «LUBRICATION»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__lubrication). Inspect the oil pan gasket for leaks.

Scheme 163

Scheme 164

Scheme 165

Raise and support the vehicle. Remove the oil pan and filter. See DRAINING & REFILLING under LUBRICATION. Remove the oil feed pipes. See OIL FEED PIPES. Remove the 3 low-reverse band servo cover bolts, the servo and the spring. (Scheme 166)

Install the low-reverse band servo and cover. (Scheme 166) Install and tighten the bolts to specification. See TORQUE SPECIFICATIONS. Install the oil feed pipe. See OIL FEED PIPES. Install oil filter and oil pan. See DRAINING & REFILLING under LUBRICATION.

Scheme 166

1. Raise and support the vehicle. Position the drain pan.
2. Remove the transaxle oil cooler hoses from the pipes. Remove the transaxle oil cooler pipe fittings at the radiator. (Scheme 167)
3. Remove the transaxle oil cooler pipe clip bolt. Remove the transaxle oil cooler pipes.

1. Install the transaxle oil cooler pipes. (Scheme 167) Install the transaxle oil cooler pipe clip bolt. Tighten the transaxle oil cooler pipe clip bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
2. Install the transaxle oil cooler pipe fittings at the radiator. Tighten the transaxle oil cooler pipe fittings to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Install the transaxle oil cooler hoses to the pipes.
3. Lower the vehicle. Fill the transaxle to proper level with appropriate fluid. See «LUBRICATION»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__lubrication). Inspect for proper completion of the repairs. Inspect for fluid leaks.

Scheme 167

OIL COOLER PIPES & SEALS (4T40-E)

Note. Tools required: Cooler Line Seal Remover (J-41239-10) and Cooler Line Seal Installer (J-41239-1).

Note. Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss.

1. Raise and support the vehicle. Position the oil drain pan. Remove the transaxle oil cooler pipe at the transaxle. (Scheme 168) Remove the cooler pipe bracket stud. (Scheme 169) Remove the oil cooler pipe seals. (Scheme 170)
2. Remove the transaxle oil cooler pipe fittings at the radiator. (Scheme 167) Remove the transaxle oil cooler pipe clip bolt. Remove the transaxle oil cooler pipes.

1. Install the (J-41239-1) on the transaxle case using cooler pipe bracket stud hole. (Scheme 171) Press the new seals in. Tighten the (J-41239-1) until the seal bottoms out in the case bore.
2. Install the cooler pipe bracket stud. Install the transaxle oil cooler pipes. Install the transaxle oil cooler pipe clip bolt. Tighten the transaxle oil cooler pipe clip bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
3. Install the transaxle oil cooler pipe fittings at the radiator. Tighten the transaxle oil cooler pipe fittings to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Install the transaxle oil cooler hoses to the pipes.
4. Lower the vehicle. Inspect the transaxle fluid level. See «CHECKING FLUID LEVELS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__checking-fluid-levels). Operate the engine for 2-3 minutes. Re-inspect the transaxle fluid level. Inspect for fluid leaks.

Scheme 168

Scheme 169

Scheme 170

Scheme 171

1. Disconnect the negative battery cable. Raise and support the vehicle. Remove the transaxle oil filter assembly. See «DRAINING & REFILLING»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION. Remove the oil feed pipe bolts. (Scheme 172) Inspect the 8 oil feed pipe seal rings. Replace the seal rings only if the seal rings are cut, swollen or damaged. Remove the low and the reverse band oil pipe assembly.
2. Remove the 8 low-reverse band oil pipe assembly seals. Inspect the oil feed pipes for plugged passages, bent pipes, or cracks. Inspect the oil feed pipe seal rings. Verify the proper location of the seal rings. Replace the seal rings if these are cut, swelled or damaged.

1. Install the 8 low-reverse band oil pipe assembly seals. Install the low-reverse band oil feed pipe assembly onto the transaxle. (Scheme 172) Hand start the bolts that attach the oil feed pipe assembly to the transaxle. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Install the transaxle oil filter assembly.
2. Install the transaxle oil pan and gasket. See «DRAINING & REFILLING»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION. Lower the vehicle. Fill transaxle to proper level with appropriate fluid. See «LUBRICATION»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__lubrication).

Scheme 172

1. Apply parking brake and block wheels. Place transaxle in NEUTRAL. Remove the shift linkage. Disconnect the electrical connector. (Scheme 173)
2. Remove the PNP switch mounting bolts. Remove the PNP switch assembly.

1. Align the flats of the shift shaft with the switch. (Scheme 173) Install the PNP switch mounting bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
2. Ensure that the engine will only start in PARK or NEUTRAL position. Readjust the switch if the engine will start in any other position.

Scheme 173

Note. Observe the Throttle Valve (T.V.) cable routing when you remove the cable. Duplicate the cable routing when installing the cable. (Scheme 174)

1. Remove the T.V. cable end from the accelerator control lever assembly slot. Remove the T.V. cable conduit end from the bracket by compressing the locking tangs. (Scheme 175)
2. Remove the T.V. cable routing clips or straps. Remove the bolt that is securing the T.V. cable to the transaxle.
3. Pull up on the cable cover at the transaxle until the cable is visible. Remove the cable from the transaxle link. Remove the transaxle case seal.

1. Install a new seal into the transaxle case hole. Install the transaxle end of the cable to the T.V. link. Install the T.V. cable bolt and washer assembly to the transaxle. (Scheme 175) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
2. Install the T.V. cable routing clips or straps. Install the T.V. cable conduit end to the bracket.
3. Install the T.V. cable into the accelerator control lever assembly slot. Pull on the upper end of the cable. The cable should travel a short distance with light resistance caused by the small return spring on the T.V. lever.
4. When releasing the upper end of the T.V. cable, the cable should return to the zero T.V. position. Adjust the T.V. cable. See «THROTTLE VALVE CABLE (3T40)»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__throttle-valve-cable-3t40) under ADJUSTMENTS.

Scheme 174

Scheme 175

TRANSAXLE MOUNT ASSEMBLY (3T40)

Note. Tools required: Universal Engine Support Fixture (J-28467-B).

1. Remove the air intake duct. Disconnect the T.V. cable, if equipped. See «THROTTLE VALVE CABLE (3T40)»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing).
2. Remove the power brake booster check valve and hose. Install the engine support fixture. (Scheme 176)
3. Raise and support the vehicle. Remove the engine mount strut. Remove the left front tire and the wheel assembly. Remove the left front fender liner.
4. Remove the crossmember. See appropriate article in ENGINES.
5. Remove the left front ABS wheel speed sensor connector. (Scheme 177) Remove the harness from the suspension support. (Scheme 178) Remove the left front ball joint.
6. Remove the stabilizer shaft from the left lower control arm. (Scheme 179) Remove the front suspension support. (Scheme 180)
7. Remove the left side drive axle from the transaxle. Remove the transaxle cooler pipes. See «OIL COOLER PIPES (3T40)»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing). Plug in order to prevent leakage.
8. Remove the power steering pressure line from the power steering gear. Plug in order to prevent leakage. Remove the power steering return line from the power steering gear. Plug in order to prevent leakage. See appropriate POWER RACK & PINION article in STEERING.
9. Remove the transaxle mount to body bolts. (Scheme 181) Remove the pipe expansion bolt from the transaxle support assembly. (Scheme 182)
10. Lower the engine and the transaxle assembly just enough to be able to remove the transaxle support assembly and the mount assembly. (Scheme 183)
11. Remove the transaxle mount from the transaxle support assembly. (Scheme 184) Remove the transaxle support assembly bolts. (Scheme 183) Remove the transaxle support assembly.

1. Position the transaxle support assembly into the vehicle. (Scheme 183) Install the transaxle support assembly bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
2. Install the transaxle mount to the transaxle support assembly. (Scheme 183) Raise the engine and the transaxle assembly. (Scheme 181) Install the transaxle mount to body bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
3. Install the transaxle pipe expansion bolt to the transaxle support assembly and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
4. Install the power steering pressure line to the power steering gear. Install the power steering return line to the power steering gear. See appropriate POWER RACK & PINION article in STEERING.
5. Install the transaxle cooler lines. See «OIL COOLER PIPES (3T40)»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing). Install the left drive axle to the transaxle.
6. Install the front suspension support. (Scheme 184) Install the stabilizer shaft to the left lower control arm. Install the left front ball joint. See appropriate POWER RACK & PINION article in STEERING.
7. Route the left front ABS wheel speed sensor. Connect the left front ABS wheel speed sensor. (Scheme 177)
8. Install the crossmember and the engine mount strut. See appropriate article in ENGINES. Install the left front fender liner. Install the left front tire and the wheel assembly.
9. Lower the vehicle. Remove the engine support fixture. (Scheme 176)
10. Install the power brake booster check valve and hose.
11. Install the T.V. cable. See «THROTTLE VALVE CABLE (3T40)»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing).
12. Install the air intake duct. Adjust the power steering oil level.
13. Inspect the transaxle oil level. Inspect the transaxle for oil leaks.

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

1. Raise and support the vehicle. Remove the left front wheel and tire assembly.
2. Remove the left front fender liner. Install a jackstand and a block of wood to support the transaxle.
3. Remove the expansion bolt from the transaxle mount. (Scheme 185) Remove the 4 transaxle mount bolts. (Scheme 186) Remove the mount.

1. Transfer the mount bracket to the new mount. Position the mount and start the 4 bolts into the threads. (Scheme 186) Tighten the mount bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
2. Install the mount expansion bolt. (Scheme 185) Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Remove the jackstand and the wood block.
3. Install the left fender liner. Install the left tire and wheel assembly. Lower the vehicle.

Scheme 185

Scheme 186

Disconnect the negative battery cable. Raise and support the vehicle. Remove the electrical connector at the vehicle speed sensor. Remove the retaining stud and the sensor. (Scheme 187) Pull straight out in order to avoid damage to the case.

Clean and dry the vehicle speed sensor. Install the vehicle speed sensor and the retaining stud. (Scheme 187) Tighten the stud to specification. See TORQUE SPECIFICATIONS. Install the electrical connector at the sensor. Lower the vehicle. Connect the negative battery cable. Check transaxle fluid level. See CHECKING FLUID LEVELS under LUBRICATION.

Scheme 187

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS
• FLUID CAPACITIES
• CHECKING FLUID LEVELS
• ADJUSTMENTS
• REMOVAL & INSTALLATION
• LUBRICATION
• DRAINING & REFILLING
• THROTTLE VALVE CABLE (3T40)