Automatic Transaxle Overhaul - 4t40-e/4t45-e Chevrolet Cobalt I

Fastener Tightening Specifications

Fastener Tightening Specifications

End Play Specifications

End Play Specifications (Selective Washer Table)

Clutch Plate Selection Specifications

Direct Clutch Plate Selection Specifications

Reverse Clutch Backing Plate Specifications

Transmission General Specifications

Transmission General Specifications

Fluid Capacity Specifications

Fluid Capacity Specifications (4T40-E)

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Torque Converter Assembly Removal

1. Remove the torque converter assembly (55).
2. Remove the turbine shaft O-ring (41) from the end of the turbine shaft.

Transmission Holding Fixture Assemble

Tools Required

1. J 41230 Transmission Support Fixture. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. J 41230-TEM Drill Template. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
3. J 3289-20 Support Fixture. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

1. Install the J 41230 transmission support fixture onto the transmission. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. Install the support fixture bolts. Tighten: Tighten the support fixture bolts to 11 N.m (8 lb ft).
3. Install the transmission and the support fixture onto the J 3289-20 fixture base. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
4. Position the transmission with the side cover facing down.
5. Insert the pin into the J 3289-20 fixture base in order to lock the unit into place. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

Stub Shaft Removal

Tools Required

1. J 6125-1B Slide Hammer
2. J 38868 Shaft Remover

1. Remove and discard the snap ring (57) from the end of the stub shaft (58). The stub shaft snap ring is not reusable.
2. Attach the J 6125-1B to the J 38868 . Install the J 38868 into the snap ring groove on the stub shaft (58). Tighten the J 38868 securely to the stub shaft.
3. Pull lightly on the shaft and rotate it until the stub shaft snap ring at the differential seats in the taper on the differential side gear.
4. Pull the stub shaft (58) out with the slide hammer impact.

Output Shaft Speed Sensor Removal

1. Rotate the transmission so that the case side cover is facing upward in order to drain the transmission fluid through the stub shaft end of the transmission.
2. Remove the speed sensor stud (61).
3. Remove the speed sensor assembly (62). Pull the speed sensor assembly straight out from the transmission case in order to prevent damage to the case bore.
4. Remove the O-ring (63).
5. Rotate the transmission with the oil pan facing upward.

Oil Pan and Gasket Removal

1. Remove the twelve oil pan bolts (81).
2. Remove the oil pan (88). The magnet can remain in the oil pan.
3. Remove the oil pan gasket (87). The oil pan gasket is reusable.

Oil Filter/Seal, Oil Level Control Valve Removal

1. Remove the oil level control valve (86). Remove the transmission filter assembly (85).
2. Using a chisel, indent top of seal to relax press fit of seal.
3. Using a small screwdriver remove the filter neck seal (84) from the transmission case. The filter neck seal (84) is not reusable and should be discarded.

Scheme 106

Remove the four oil feed pipe bolts (81) and remove the oil feed pipe assembly (83).

Intermediate/Fourth Servo Removal

1. Remove the three servo cover bolts (25).
2. Remove the servo cover (Intermediate/Fourth) (80) assembly.
3. Remove the servo return spring (75).

Low and Reverse Servo Removal

1. Remove the three servo cover bolts (25).
2. Remove the servo cover assembly (Lo and Reverse) (73).
3. Remove the servo return spring (66).

Case Side Cover Removal

1. Rotate the transmission so that the side cover faces upward.
2. Remove the 11 side cover bolts (3) or studs (4) (model dependent).
3. Remove the transmission side cover (1).
4. Remove the two side cover gaskets (5 and 6) and the side cover to driven support thrust washer (7), if they did not remain with the side cover.

Output Shaft Sleeve Removal

Tools Required

J 41227 Output Shaft Sleeve Puller. See Special Tools .

1. Remove snap ring (57).
2. Insert the legs of J 41227 under the output shaft sleeve (56). See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
3. Tighten the center bolt of the J 41227 down in order to pull the output shaft sleeve (56) off the output shaft (94). See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
4. Remove and discard the output shaft sleeve (56). Use the J 41227 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) . The output shaft sleeve is not reusable.

Oil Pump and Oil Pump Shaft Removal

1. Remove the eight bolts from the oil pump (8, 9 and 12).
2. Remove the oil pump assembly (10).
3. Remove the oil pump shaft (19).

Wire Harness Disconnect

1. Disconnect the wiring harness connectors from the pressure control solenoid (312).
2. Disconnect the wiring harness connectors from the 1-2 and 2-3 shift solenoids (305).
3. Disconnect the wiring harness connectors from the pressure switch assembly (13)
4. Disconnect the wiring harness connectors from the TCC solenoid (335).

Transmission Fluid Pressure (TFP) Switch Removal

1. Remove the six bolts from the TFP switch assembly (8, 12, and 16).
2. Remove the TFP switch assembly (13) from the control valve body assembly (18). The 4 pressure switch O-rings are reusable and should remain with the TFP switch assembly.

Control Valve Body Assembly and Gasket Removal

1. Remove the remaining twelve bolts (9, 12 and 16) from the control valve body assembly (18).
2. Remove the control valve body assembly (18).
3. Remove and discard the valve body to spacer plate gasket (22).

Spacer Plate and Gasket Removal

1. Remove the two spacer plate support bolts (20).
2. Remove the spacer plate support (21)
3. Remove the spacer plate (23).
4. Remove and discard the spacer plate to channel plate gasket (24).

Scheme 107

Remove the seven checkballs (26) in the channel plate.

Manual Valve Clip Removal

1. Disconnect the manual valve clip (801) from the manual valve.
2. Disconnect the manual valve link (802) from the manual valve.

Channel Plate and Gasket Removal

1. Remove the ten channel plate bolts (8 and 25).
2. Remove the channel plate assembly (27). Keep the following components with the channel plate: The drive sprocket to channel plate thrust washer (34) The three accumulator pistons (29) The manual valve (800) The detent lever spring (804) and bolt (805)
3. Remove and discard the channel plate to case gasket (28).

Scheme 108

Remove the three accumulator springs (31 and 32) from the case (51).

Drive Sprocket, Driven Sprocket, and Drive Link Removal

1. Remove, as an entire unit, the drive sprocket (37), the turbine shaft (39), the driven sprocket (91) and the drive link assembly (36).
2. If the drive sprocket to drive sprocket support thrust washer (38) has not remained with the drive sprocket assembly (37 and 39), remove the drive sprocket to drive sprocket support thrust washer (38). The driven sprocket to driven sprocket support thrust washer (92) should remain with the driven sprocket support assembly (95).

Input Speed Sensor Removal

1. Remove the wiring harness connector at the input speed sensor (46).
2. Remove the input speed sensor bolt (15) and the input speed sensor (46).
3. Remove the wire retainer clip bolt (15) and retainer clip.

Wiring Harness Removal

Tools Required

J 41101 Pass-Through Connector Remover. See Special Tools .

1. Push the J 41101 onto the pass-through connector from the outside of the transmission case in order to compress the pass-through connector's retaining tabs. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. With the retaining tabs compressed, use a screwdriver in order to remove the pass-through connector through the inside of the transmission case.
3. Remove the wiring harness (11).

Driven Sprocket Support Assembly Removal

1. Remove the driven sprocket to driven sprocket support thrust washer (92).
2. Remove the driven sprocket support assembly (95).

Scheme 109

Remove the following plates

1. 2nd clutch wave plate (96)
2. 2nd clutch steel plates (97)
3. 2nd clutch fiber plates (98)
4. 2nd clutch backing plate (99)

Reverse Input Clutch Housing Removal

1. Remove the driven sprocket support to reverse clutch housing thrust washer (101).
2. Remove the reverse input clutch housing and the 2nd roller clutch assembly (102).

Scheme 110

Remove the intermediate 4th band (100).

Scheme 111

Remove the direct/coast clutch and reaction carrier assembly (105).

Input Carrier and Reaction Gear Assembly Removal

1. Remove the input carrier and reaction internal gear assembly (106). A bearing assembly is permanently inside the input carrier.
2. Remove the input carrier to forward clutch hub thrust bearing (107). The input carrier to forward clutch hub thrust bearing may have remained with the input carrier.

Input Internal Gear, Forward Clutch Hub Removal

1. Remove the input internal gear and forward clutch hub assembly (108).
2. If the forward clutch hub to race thrust washer (109) did not remain with the forward clutch hub, remove the forward clutch hub to race thrust washer (109).

Forward Clutch and Low/Reverse Band Removal

1. Remove the forward clutch assembly (110).
2. Remove the low/reverse band (111).

Forward Clutch Support, Low Roller Clutch Removal

Tools Required

J 28585 Snap Ring Screwdriver

1. Remove the forward clutch support snap ring (112) from the transmission case. Use the J 28585 .
2. Remove the forward clutch support and the low roller clutch assembly (114). Keep the forward clutch housing to the forward clutch support thrust bearing (113) with the forward clutch support assembly (114).

Output Shaft and Final Drive Assembly Removal

1. Remove, as one unit, the output shaft (94), the final drive assembly (116), and the final drive sun gear (115).
2. If the differential carrier to case thrust bearing (117) did not remain with the final drive assembly (116), remove the differential carrier to case thrust bearing (117).

Scheme 112

Remove the final drive internal gear (118).

Manual Shift Shaft, Detent Lever, and Park Lock Removal

1. Remove the manual shaft to transmission case pin (803).
2. Remove the manual shaft and detent lever assembly (806) by pushing the manual shaft into the transmission case (51). The parking lock actuator assembly (807) remains attached to the detent lever until you remove the manual shaft and detent lever assembly.
3. Remove the manual shaft seal (809) from the case (51).

Transmission Cooler Line Seals Removal

Tools Required

1. J 41239-10 Cooler Line Seal Removal. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. J 45201 Cooler Line Seal Removal. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

1. Install J 41239-10 between the cooler line seal (49) and the case. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. It may be necessary to pivot J 41239-10 back and forth against the case to remove the seal. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
3. Insert J 45201 collet (2) fully into the cooler line seal bore. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
4. Insert the forcing screw piece of the J 45201 (1) into J 45201 (2) and tighten. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
5. Thread the J 45201 collar (2) onto J 45201 (3) and tighten until the tool has removed the seal. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
6. Use a pair of pliers to remove the cooler line seal from J 45201 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

Torque Converter Seal Removal

Tools Required

1. J 41103 Torque Converter Seal Remover Set. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. J 41103-1 Torque Converter Seal Puller Legs. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
3. J 41103-2 Torque Converter Seal Puller Bridge. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
4. J 41103-3 Torque Converter Seal Support Body. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

1. Insert the three J 41103-1 puller legs under the Torque Converter Seal (54). See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. Insert the J 41103-3 support body over the stator shaft (43). See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
3. Insert the J 41103-2 puller bridge over the J 41103-3 support body. Connect the J 41103-1 puller legs into the slots on the J 41103-2 bridge. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
4. Tighten the forcing screw on the J 41103-2 puller bridge until the J 41103-1 puller legs remove the torque converter seal (54). See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

Drive Sprocket Support Removal

1. Remove the six bolts (53) form the drive sprocket support (43).
2. Remove the drive sprocket support (43) from the case (51).

Right Hand Axle Seal Removal

1. J 6125-1B Slide Hammer
2. J 23129 Universal Seal Remover

Scheme 113

Note. Do not damage the case bore when removing the axle seal.

Assemble J 23129 onto J 6125-1B . Use J 6125-1B and J 23129 to remove the axle seal.

Case Inspection

Note. Use J 36850 or equivalent during assembly in order to retain checkballs or to lubricate components. Lubricants other than the recommended assembly lube changes the transmission fluid characteristics and causes undesirable shift conditions or filter clogging.

1. Thoroughly clean the transmission case and all the case threads with solvent.
2. Inspect the case exterior and the external bores for cracks, sharp edges, porosity and excessive bushing wear.
3. Inspect the case interior for damage at the snap ring grooves, case lugs and band anchor pin.
4. Inspect all the gasket surfaces for surface damage and in order to ensure surface flatness.
5. Inspect the corresponding gasket for proper impressions in order to ensure surface flatness.
6. Inspect the bolt holes and fasteners for thread damage. If necessary, repair or replace any bolt holes or fasteners.
7. Air check the oil passages. For identification of the oil passages, refer to the transmission diagnosis section.

Actuator Guide Replacement

1. Remove the actuator guide roll pin (810) from the case.
2. Remove the actuator guide (812) and O-ring seal (811) assembly from the case (51). For easiest removal, tap the actuator guide (812) into the case (51).
3. Install a new O-ring seal (811) on the actuator guide (812).
4. Install the actuator guide (812) and O-ring assembly (811) into the transmission case (51).
5. Install the actuator guide roll pin (810) into the case (51) in order to secure the actuator guide (812).

Drive Sprocket Support Installation

1. Inspect the drive sprocket support (43) for damage to the stator shaft splines, the journals, the bushings, and the roller bearing.
2. Inspect the converter seal drain holes for blockage.
3. Install the drive sprocket support (43) into the bell housing of the transmission case.
4. Install the six drive sprocket support bolts (53) into the drive sprocket support (43).
5. Hand start the bolts. Tighten: Tighten the bolts to 12 N.m (9 lb ft).

Torque Converter Seal Installation

Tools Required

J 28540-A Torque Converter Seal Installer. See Special Tools .

Scheme 114

Note. Install the seal onto the tool before installing into the case to prevent damage to the seal.

Install a new torque converter seal (54). Use the J 28540-A . See Special Tools .

Transmission Cooler Line Seals Installation

Tools Required

J 41239-1 Cooler Line Seal Installer. See Special Tools .

1. Lubricate the inside surface of both cooler line seals (49) with automatic transmission fluid DEXRON® III.
2. Place a new cooler line seal (49) in the case bore.
3. Install the J 41239-1 on the transmission case (51) at the cooler line bracket bolt hole. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
4. Press the new cooler line seal (49) in by tightening the seal pressing bolt on the J 41239-1 until the seal bottoms out in the case bore. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
5. Repeat steps 2-4 for the second cooler line seal (49).

Manual Shift Shaft, Detent Lever, and Park Lock Installation

Tools Required

J 41229 Manual Shaft to Case Pin Installer. See Special Tools .

1. Install a new manual shaft seal (809) into the case (51). Use a 13 mm socket.
2. With the manual valve to detent lever link (802) and the parking lock actuator assembly (807) attached, install the manual shaft and detent lever assembly (806) into the case.
3. Ensure that the parking lock actuator rod is correctly positioned into the actuator guide.
4. Install the manual shaft pin (803) into the case. Use the J 41229 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

Final Drive Assembly Disassemble

1. Remove the differential pinion shaft retaining pin (704). Use a pin punch.
2. Remove the differential pinion shaft (703).
3. Remove the snap ring (57) from the end of the output shaft (94).
4. Remove the output shaft (94) from the differential carrier (702).
5. Remove the final drive sun gear (115).
6. Remove the differential pinion gears (707) and the thrust washers (706).
7. Remove the differential side gears (709) and the thrust washers (708).
8. Remove the final drive carrier spiral retaining ring (701).
9. Remove the four planet pinion pins (714).
10. Remove the four pinion gears (711).
11. Remove the pinion thrust washers (710).
12. Remove the needle roller bearings (712).
13. Remove the needle bearing spacers (713).
14. Remove the final drive sun gear to carrier thrust bearing (700).
15. Inspect the needle bearings (712), the thrust washers (710), the pinion gears (711), and the planet pinion pins (714) for excessive wear. Polishing is a normal condition for the pinion pins and the needle bearings.
16. Inspect the pinion shaft (714) for spalling or for wear.
17. Inspect the thrust washers (710) for wear and for cracks.
18. Clean and dry the final drive carrier and the final drive components.

Final Drive Assembly Assemble

Tools Required

J 36850 TRANSJEL™

1. Install the pinion gear needle bearing spacer (713) onto the planet pinion gear (711).
2. Place a thrust washer (710) on the bottom of the planet pinion (711) in order to retain the bottom row of needle bearings.
3. Use J 36850 or equivalent in order to aid in the assembly and in order to keep the needle roller bearings (712) in the race.
4. Install the needle roller bearings (712) one at a time into the planet pinion (711).
5. Install the sun gear to final drive carrier thrust bearing (700) onto the final drive carrier (116). Retain the thrust bearing with J 36850 or equivalent.
6. Assemble the pinion gear thrust washers (710) and the planet pinion gears into the final drive carrier (702).
7. Install the planet pinion gear pins (714) into the final drive carrier (702) in order to retain the planet pinion gears (711).
8. Install the final drive carrier spiral retaining ring (701) in order to retain the planet pinion gear pins.
9. Assemble the thrust washers (708) onto the differential side gears (709).
10. Install the differential side gears into the final drive carrier (702).
11. Assemble the thrust washers (706) onto the pinion gears (707). Retain the thrust washers with J 36850 or equivalent.
12. With the thrust washers (706) attached, install the pinion gears (707) into the final drive carrier (702).
13. Rotate the pinion gears (707) into position, and install the pinion shaft (703) through the final drive carrier (702) and through the pinion gears (707).
14. Position the pinion shaft (703) in order to allow installation of the retaining pin.
15. Install the retaining pin (704) through the final drive carrier (702) and through the pinion shaft (703) in order to retain the pinion shaft (703).

Final Drive Pinion End Play Check

1. Inspect the end play with a feeler gauge for proper clearance. Proper clearance is 0.24-0.62 mm (0.009-0.024 in).
2. If the clearance is out of specification on the low side, repair the differential assembly as necessary.
3. If the clearance is out of specification on the high side, replace the differential assembly (116).

Fretting Ring, Final Drive Internal Gear Install

1. If the fretting ring (119) has been removed, install the fretting ring (119) into the small groove in the transmission case (51).
2. Install the final drive internal gear (118) into the transmission case (51).

Final Drive and Differential Assembly Install

Tools Required

J 36850 TRANSJEL™

1. Install the final drive carrier to case thrust bearing (117) onto the final drive carrier. Retain the bearing with J 36850 .
2. Install the complete final drive carrier assembly (116) into the transmission case (51).
3. Install the final drive sun gear (115) into the final drive carrier (116).

Output Shaft Inspect

1. Inspect the output shaft (94) for damage to the splines, snap ring grooves and the journals.
2. Clean and dry the output shaft.

Output Shaft Installation

1. Install a new snap ring (57) into the snap ring groove on the final drive end (small machined diameter) of the output shaft (94).
2. Install the output shaft (94) into the final drive assembly. Use a mallet in order to install the shaft (94) through the final drive differential gear.

Forward Clutch Support, Roller Clutch Disassemble

1. Remove the roller clutch assembly (652) from the forward clutch support (656) by turning the roller clutch assembly (652) clockwise and gently lifting upward.
2. Remove the thrust bearing (113) from the forward clutch support (656).
3. Remove the final drive sun gear shaft snap ring (660).
4. Remove the parking pawl gear (659).
5. Remove the forward clutch support to parking pawl gear thrust bearing (658).
6. Remove the forward clutch support (656) from the final drive sun gear shaft (651).
7. Remove and discard the two seals (654) from the forward clutch support (656).
8. Inspect the snap ring for overextension (660).
9. Inspect the seal grooves for damage (656).
10. Inspect for signs of excessive bearing and bushing wear.
11. Inspect the splines and the parking gear teeth for cracks or excessive wear.
12. Inspect the fluid feed holes for the proper opening.
13. Inspect all other components for excessive wear or damage.
14. Clean and dry all of the components.

Forward Clutch Support, Low Roller Clutch Assemble

1. Assemble two new seals (654) on the forward clutch support (656).
2. Assemble the forward clutch support (656) onto the final drive sun gear shaft (651).
3. Assemble the roller bearing (658) onto the forward clutch support (656).
4. Assemble the parking pawl gear (659) onto the final drive sun gear shaft (651) with the raised inner boss facing up, so that the parking pawl properly engages the teeth on the parking pawl gear.
5. Assemble the snap ring (660) to the final drive sun gear shaft (651) in order to retain the parking pawl gear (659).
6. Assemble the lo roller clutch assembly (652) onto the forward clutch support (656). The larger tabs on the cage must face down into the forward clutch support (656). Rotate the cage slightly counterclockwise in order to lock the tabs into the grooves in the forward clutch support (656).
7. Assemble the thrust bearing (113) onto the forward clutch support (656).

Forward Clutch Support, Low Roller Clutch Install

1. Install the forward clutch support and lo roller clutch assembly (114) into the transmission case. Compress the parking pawl spring, and line up the parking pawl with the parking pawl gear.
2. Install the forward clutch support snap ring (112) into the transmission case with the chamfer side up. Use a screwdriver in order to set the snap ring into place.

Forward Clutch Assembly Disassemble

Tools Required

1. J 23327 Return Spring Compressor
2. J 45398 Forward Clutch Inner Seal Puller. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
3. J 25031-A Puller/Inner Seal Remover. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

1. Remove the snap ring (600) from the housing assembly (609).
2. Remove the backing plate (601).
3. Remove the seven fiber plates (602).
4. Remove the seven steel plates (603).
5. Remove the wave plate (604).
6. Compress the forward clutch return spring assembly. Use the J 23327 .
7. Remove the return spring snap ring (605).
8. Remove the J 23327 .
9. Remove the forward clutch return spring assembly (606).
10. Remove the forward clutch piston and seal assembly (607).
11. Inspect the forward clutch inner seal assembly (608) for damage.
12. If the seal is damaged, assemble J 45398-1 (3), which is part of J 45398 , onto the seal. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) . Place the J 45398-2 (2), which is part of J 45398 , on the inner hub of the clutch housing.
13. Use J 25031-A (1) to remove the seal. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
14. Inspect the housing, the plates, the bushings, the splines, the band apply surface, the roller clutch race, and the spring assembly.
15. Inspect fluid feed holes for proper openings.
16. Inspect the retainer and ball assembly for proper openings.
17. Inspect the piston and seal assembly for cut seals or other damage. The piston and seal assemblies are reusable, if not damaged.
18. Clean and dry all of the components.

Forward Clutch Assembly Assemble

Tools Required

1. J 41231 Inner Seal Installer. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. J 23327 Return Spring Compressor

1. Assemble a new inner seal assembly (608) if the old seal was damaged and removed. Use an arbor press and the J 41231 in order to press the inner seal assembly onto the forward clutch housing (609). See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. Assemble the forward clutch piston assembly (607) into the forward clutch housing (609). In order to ease assembly, lubricate the seals with transmission fluid.
3. With the snap ring tabs facing up, assemble the forward clutch return spring assembly (606) into the forward clutch housing (609).
4. Compress the return spring assembly. Use the J 23327 .
5. Assemble the snap ring (605) in order to retain the forward clutch return spring.
6. Remove the J 23327 .
7. Install the forward clutch waved plate (604).
8. Install the seven steel plates (603) and the seven new fiber plates (602) in alternating order beginning with a steel plate (603).
9. Install the forward clutch backing plate (601).
10. Install the forward clutch backing plate snap ring (600) in order to retain the clutch pack.

Scheme 115

With air pressure set at 20 psi, check the forward clutch to verify proper operation of the seals and clutch assembly.

Scheme 116

Install the low/reverse band (111) into the transmission case. Align the servo pin apply surface toward the bottom pan and hook the band into the band anchor pin inside the transmission case.

Forward Clutch Assembly Installation

1. Install the forward clutch assembly (110) into the transmission case.
2. Insert a screwdriver through the reverse servo pin hole in order to verify the correct installation of the lo/reverse band. The screwdriver should compress the band around the forward clutch housing.

Input Internal Gear, Forward Clutch Hub Disassemble

1. If the thrust washer (109) has not been removed, remove the thrust washer (109) from the forward clutch hub (577).
2. Remove the input internal gear to forward clutch hub assembly snap ring (578).
3. Remove the forward clutch hub (577) from the input internal gear (560).
4. Inspect the input internal gear (560) for damage or excessive wear.
5. Inspect the forward clutch hub (577) splines for damage or excessive wear.
6. Inspect the bushing and the thrust washer (109) for damage or excessive wear.
7. Clean and dry all of the components.

Input Internal Gear, Forward Clutch Hub Assemble

Tools Required

J 36850 TRANSJEL™

1. Assemble the forward clutch hub (577) onto the input internal gear (560) and retain it with the snap ring (578).
2. Assemble the thrust washer (109) onto the forward clutch hub (577) with the thrust washer tabs toward the forward clutch hub (577). Retain the thrust washer with J 36850 or equivalent.

Scheme 117

Install the forward clutch hub and input internal gear assembly into the transmission case.

Reaction Internal Gear, Input Carrier Disassemble

1. Remove the thrust bearing (107) from the reaction carrier (562) if the thrust bearing has not been removed.
2. Remove the reaction internal gear (560) to input carrier assembly snap ring (563).
3. Remove the input carrier assembly (562) from the reaction internal gear (560).

Input Carrier Pinion Gear Clearance Check

1. Measure the pinion gear end play for proper clearance. Use a feeler gage. The clearance should be 0.24-0.69 mm (0.01-0.027 in).
2. Inspect the reaction internal gear and the input carrier assembly for damage or excessive wear. Specifically inspect the condition of the pinion gears, the washers, and the thrust bearings.
3. Clean and dry each of the components.

Reaction Internal Gear, Input Carrier Assemble

Tools Required

J 36850 TRANSJEL™

1. Assemble the input carrier assembly (562) to the reaction internal gear (560.
2. Retain the input carrier assembly with the snap ring (563).
3. Assemble the thrust bearing (107) onto the input carrier assembly.
4. Retain the thrust bearing with J 36850 or equivalent. You will find another thrust bearing permanently retained in the input carrier assembly (562).

Scheme 118

Install the reaction internal gear and input carrier assembly (106) into the transmission case.

Direct/Coast Clutch, Reaction Carrier Disassemble

Tools Required

1. J 23327 Clutch Spring Compressor
2. J 41232 Direct Clutch Return Spring. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
3. J 41236 Coast Cutch Return Spring Compressor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

1. Remove the selective thrust bearing (103) and the thrust washer (104) from the input shaft of the direct and coast clutch assembly (105).
2. Remove the input sun gear to input sun gear shaft snap ring (534).
3. Remove the input sun gear (533) from the input sun gear shaft (511).
4. Remove the thrust bearing (532) from the reaction carrier assembly (531).
5. Remove the reaction carrier assembly (531). You will find a thrust bearing permanently installed in the reaction carrier assembly under the pinion gears.
6. Remove the reaction sun gear and shell assembly (529).
7. Remove the thrust bearing (527) from the reaction carrier shaft and shell assembly (526).
8. Remove the reaction carrier shaft and shell assembly (526).
9. Remove the thrust bearing (524) from the top of the sprag race assembly.
10. Remove the clutch retaining snap ring (517).
11. Remove the direct clutch plates from the direct coast clutch input housing. The direct clutch consists of a backing plate (523), steel plates (521) and fiber plates (522).
12. Lift up on the input sun shaft (511) in order to remove the input sun shaft (511) and the sprag (512) as an assembly.
13. Remove the inner race to input housing thrust bearing (510) if the inner race to input housing thrust bearing did not remain with the input sun shaft and sprag assembly.
14. Remove the coast clutch plates from the input housing (502). The coast clutch consists of four steel plates (508) and four fiber plates (509).
15. Compress the direct clutch return spring assembly. Use the J 41232 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
16. Remove the spring retaining snap ring (520).
17. Remove the J 41232 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
18. Remove the direct clutch return spring (519).
19. Remove the direct clutch piston and seal assembly (518).
20. Compress the coast clutch return spring. Use the J 41236 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
21. Remove the spring retaining snap ring (507).
22. Remove the J 41236 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
23. Remove the coast clutch return spring retainer (506) and the release spring (505).
24. Remove the coast clutch piston and seal assembly (504).
25. Remove and discard the four Teflon™ oil seals (500) from the input shaft assembly (502).
26. Remove the input sprag assembly (512 and 514-516) from the input sun gear shaft (511).
27. Remove the snap ring (516) from the sprag assembly (515).
28. Remove the sprag clutch assembly (515) from the sprag outer race (512).
29. Remove the two end bearings (514) from the sprag clutch assembly (515).
30. Inspect the piston (518 and 504) and seal assemblies for damage or cut seals.
31. Inspect the clutch spring assemblies (519 and 505) for distortion or missing springs.
32. Inspect the direct clutch and coast clutch retainer and ball assemblies for leaks or damage.
33. Inspect the oil passages for blockage.
34. Inspect the bushings and bearings for excessive wear.
35. Inspect the seal grooves on the input shaft for nicks or damage.
36. Inspect the splines, housings and clutch plates for cracks, excessive wear or damage.
37. Inspect all other components for damage or excessive wear.

Reaction Carrier Pinion Clearance Check

1. Measure the reaction carrier pinion gear end play for proper clearance. Use a feeler gauge. The clearance is 0.24-0.69 mm (0.01-0.027 in).
2. Clean and dry each of the components.

Direct/Coast Clutch, Reaction Carrier Assemble

1. J 23327 Clutch Spring Compressor
2. J 41236 Coast Clutch Return Spring Compressor Adapter. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
3. J 41232 Direct Clutch Return Spring Compressor Adapter. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
4. J 36850 TRANSJEL™
5. J 41234-1 Input Shaft Seal Installer Pusher. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
6. J 41234-2 Input Shaft Seal Installer Protector. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
7. J 41234-3 Input Shaft Seal Installer Sizer. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

1. In order to aid in the assembly, lubricate the seal with transmission fluid.
2. Assemble the coast clutch piston and seal assembly (504) into the input housing (502).
3. Assemble the coast clutch release spring (505) and spring retainer (506) into the input housing (502).
4. Compress the coast clutch return spring retainer (506). Use the J 41236 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
5. Assemble the coast clutch spring retainer snap ring (507) onto the input housing (502).
6. Remove the J 41236 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
7. In order to aid in the assembly, lubricate the seal with transmission fluid.
8. Assemble the direct clutch piston and seal assembly (518) into the input housing (502).
9. Assemble the direct clutch return spring assembly (519) into the input housing with the snap ring retaining tabs facing up.
10. Compress the direct clutch spring assembly. Use the J 41232 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
11. Assemble the direct clutch snap ring (520) into the input housing (502).
12. Remove the J 41232 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
13. Assemble the 4 steel coast clutch plates (508) and the 4 new fiber coast clutch plates (509) into the input housing in alternating order, beginning with a steel plate (508).
14. Place the sprag outer race (512) on the bench with the flat side down and the side with the snap ring groove up.
15. Place one end bearing (514) into the outer race.
16. While rotating the sprag slowly, assemble the sprag clutch (515) into the sprag outer race. Keep the grooved edge up and the flat side down.
17. Assemble the other end bearing (514) on top of the sprag clutch.
18. Assemble the snap ring (516) into the sprag outer race (512) in order to retain the sprag clutch and end bearings.
19. While rotating the input sun gear shaft clockwise in order to help seat the sprags, assemble the sprag clutch and outer race assembly onto the input sun gear shaft (511).
20. Verify the correct operation of the sprag clutch by holding the sprag clutch outer race (512) and rotating the input sun gear shaft (511).
21. Assemble the thrust bearing (510) on the underside of the input sun gear shaft.
22. Retain the thrust bearing with J 36850 or equivalent.
23. Assemble the input sun gear shaft and sprag clutch assembly (511 and 512) into the input housing. The splines on the input sun gear shaft engage with the coast clutch fiber plates.
24. Assemble the steel (521) and new fiber 522) direct clutch plates into the input housing in alternating order beginning with a steel plate (521). Refer to «Clutch Plate Selection Specifications»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__clutch-plate-selection-specifications) .
25. Assemble the direct clutch backing plate (523) onto the input housing with the flat side down.
26. Assemble the snap ring (517) in order to retain the input sun shaft and sprag clutch assembly and the direct clutch plates.
27. Assemble the thrust bearing (524) on the top of the sprag clutch assembly. Retain with J 36850 or equivalent.
28. Assemble the reaction carrier shaft and shell assembly (526) onto the input housing. The splines on the inside of the shell engage the direct clutch fiber plates.
29. Assemble the thrust bearing (527) onto the top of the reaction carrier shaft and shell assembly.
30. Assemble the reaction carrier sun gear and shell assembly (529) onto the reaction shaft shell.
31. Assemble the reaction carrier assembly (531) onto the reaction sun gear.
32. Assemble the reaction carrier assembly to input sun gear thrust bearing (532) onto the reaction carrier assembly.
33. Assemble the input sun gear (533) onto the input sun gear shaft.
34. Assemble the input sun gear snap ring (534) onto the input sun gear shaft.
35. Slide the J 41234-2 over the input shaft, and position the J 41234-2 at the seal groove closest to the housing. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) . Coat the J 41234-2 with transmission fluid.
36. Guide a new seal onto the J 41234-2 and slide the seal into the seal groove with the J 41234-1 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
37. Repeat the above procedure for each seal. Adjust the J 41234-2 as necessary for each seal groove. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
38. Size the seals with the J 41234-3 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
39. Leave the J 41234-3 in place for at least five minutes. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) . If possible, leave the J 41234-3 in place until you install the assembly (105) into the transmission case.

Direct and Coast Clutch Functional Air Checks

1. Air check the direct clutch in order to verify the proper operation of the seals and clutch assembly.
2. Air check the coast clutch in order to verify the proper operation of the seals and clutch assembly.

Scheme 119

Install the direct/coast clutch and reaction carrier assembly (105) into the transmission case (51).

Selective Washer Measurement and Installation

Tools Required

J 34673 Gage Block

1. Place the J 34673 across the machined surface of the case.
2. Measure the distance between the top of the direct/coast clutch housing (105) and the machined surface of the case (record measurement).
3. Note the recorded measurement and choose the correct selective washer. Refer to «End Play Specifications»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__end-play-specifications) .
4. Assemble the selective thrust washer (104) onto the top of the input housing.
5. Assemble the thrust bearing (103) over the input shaft and onto the top of the selective thrust washer (104).

Reverse Input and Second Roller Clutch Disassemble

Tools Required

1. J 23327 Clutch Spring Compressor
2. J 41232 Return Spring Compressor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
3. J 41097-1 Inner Seal Remover Adapter. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
4. J 41097-2 Inner Seal Remover Adapter Ring. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
5. J 25031-A Inner Seal Remover. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
6. J 4646 Pliers. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

1. Remove the reverse clutch snap ring (464).
2. Remove the reverse clutch plates (one backing plate (463), three steel plates (461), three fiber plates (462), and a waved plate (460).
3. Compress the reverse clutch return spring. Use the J 41232 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
4. Remove the reverse clutch return spring and the retainer snap ring (459).
5. Remove the J 41232 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
6. Remove the reverse clutch return spring and retainer assembly (458).
7. Remove the reverse clutch piston and seal assembly (457).
8. Inspect the reverse clutch inner seal (456).
9. If the seal assembly is damaged, perform the following procedure in order to remove the seal assembly: Use the J 4646 or equivalent in order to install the J 41097-1 under the outer lip of the reverse clutch inner seal (456). See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) . Place the J 41097-2 on the inner hub of the reverse clutch housing (454). See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) . Use the puller J 25031-A in order to remove the seal. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
10. Remove the 2nd roller clutch (452) and roller clutch retainer (450) by prying up on the roller clutch assembly with two screwdrivers. The second roller clutch retainer is pressed onto the reverse clutch housing (454) and is not reusable after removal.
11. Remove the 2nd roller clutch (452) from the inside of the roller clutch cam (451).
12. Inspect the reverse housing (454) for excessive band wear and damaged splines.
13. Inspect the retainer and ball capsule for damage or clogging.
14. Inspect the fluid feed holes for proper opening.
15. Inspect the roller clutch for excessive wear (451 and 452).
16. Inspect the spring assembly for dislocated or damaged springs (458).
17. Inspect all components for damage and excessive wear.
18. Clean and dry each of the components.

Reverse Input and Second Roller Clutch Assemble

Tools Required

1. J 23327 Clutch Spring Compressor
2. J 41232 Return Spring Compressor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
3. J 41233 Inner Seal Installer. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

1. If the reverse clutch inner seal assembly (456) was damaged and removed, install a new reverse clutch inner seal assembly (456). Use the J 41233 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. Assemble the reverse clutch piston and seal assembly (456). In order to aid in the assembly, lubricate the seal with transmission fluid.
3. Assemble the reverse clutch return spring and retainer assembly (458) with the smaller outside diameter down.
4. Compress the reverse clutch return spring. Use the J 41232 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
5. Assemble the return spring snap ring (459).
6. Remove the J 41232 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
7. Assemble the wave plate (460).
8. Assemble the three steel plates (461) and the three new fiber plates (462) in alternating order beginning with a steel plate (461).
9. Measure the distance between the top of the snap ring groove and the top friction plate (record measurement).
10. Assemble the reverse clutch backing plate with the beveled edge up.
11. Assemble the snap ring in the reverse clutch housing in order to retain the reverse clutch plates.

Reverse Clutch Functional Air Check

Tools Required

J 41235 Second Roller Clutch Installer. See Special Tools .

1. Air check the reverse clutch in order to verify the proper operation of the seals and clutch assembly.
2. Assemble the 2nd roller clutch assembly (452) into the roller clutch cam (451).
3. While rotating the roller clutch in order to properly engage the rollers, assemble the 2nd roller clutch onto the reverse clutch housing (454).
4. Assemble a new 2nd roller clutch retainer (450) onto the 2nd roller clutch assembly. Use the J 41235 in order to press the retainer and roller clutch assembly into place on the reverse clutch housing and roller clutch inner race. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
5. Hold the reverse clutch housing, and ensure that the roller clutch cam rotates clockwise only.

Reverse Input and Second Roller Clutch Installation

1. While rotating the reverse clutch housing (102) in order to align the clutch plates, install the reverse clutch and 2nd roller clutch assembly into the transmission case.
2. Assemble the reverse clutch thrust washer (101) onto the top of the 2nd roller clutch. The tabs must face down onto the housing.

Intermediate Fourth Band Assembly Installation

1. Assemble a new Intermediate/Fourth band (100) into the transmission case.
2. In order to verify the proper positioning of the band, insert a screwdriver through the Intermediate/Fourth servo bore. The screwdriver should press on the servo pin rest and compress the band around the reverse clutch housing.

Second Clutch Plate Installation

1. Inspect the 2nd clutch plates for excessive wear.
2. Clean and dry each of the components.
3. Assemble the 2nd clutch backing plate (99) with the flat side facing up.
4. Assemble the three steel (97) and the three new fiber plates (98) in alternating order beginning with a fiber plate (98).
5. Assemble the 2nd clutch wave plate (96).

Driven Sprocket Support Assembly Disassemble

Tools Required

1. J 23327 Clutch Spring Compressor
2. J 41232 Return Spring Compressor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

1. Remove the two seal rings (403) from the driven sprocket support (401).
2. Discard the two seal rings (403).
3. Compress the 2nd clutch spring and retainer assembly (405). Use the J 41232 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
4. Remove the 2nd clutch spring retainer snap ring (406).
5. Remove the J 41232 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
6. Remove the 2nd clutch spring and retainer assembly (405).
7. Remove the 2nd clutch piston and seal assembly (404). If not damaged, the piston and seal assembly is reusable.
8. Inspect the piston and seal assembly (404) for damaged seals
9. If the seal is cut or damaged replace the seal with a new piston and seal assembly.
10. Inspect the bushing and bearing for damage or excessive wear.
11. Inspect the driven sprocket support (401) for plugged feed holes, damaged seal grooves, stripped bolt holes, and a damaged machined surface.
12. Inspect the reverse intermediate clutch housing valve assembly (407) for free operation.
13. Using Automatic Transmission fluid, inspect the reverse intermediate clutch housing valve assembly (407) for leaks.
14. Using a 6.25 mm (1/4 in) drift and a mallet, remove the valve assembly (407) from the driven sprocket support (401).
15. Using a 6.25 mm (1/4 in) drift and a mallet, install the valve assembly (407) in the driven sprocket support (401).
16. Inspect the spring assembly (405) for dislocated or damaged springs.
17. Clean and dry each of the components.

Drive Sprocket Support Assemble

Tools Required

1. J 23327 Clutch Spring Compressor
2. J 41232 Return Spring Compressor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

1. In order to aid in the assembly, lubricate the seal with transmission fluid.
2. Assemble the 2nd clutch piston and seal assembly (404) into the driven sprocket support (401).
3. Assemble the 2nd clutch spring and retainer assembly (405) into the driven sprocket support.
4. Compress the 2nd clutch spring assembly. Use the J 41232 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
5. Assemble the 2nd clutch spring retainer snap ring (406).
6. Remove the J 41232 and J 23327 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
7. Assemble two new seal rings (403) onto the driven sprocket support.

Scheme 120

Air check the 2nd clutch (95) in order to verify proper operation of the seals and piston assembly.

Scheme 121

Install the driven sprocket support and 2nd clutch assembly (95) into the transaxle case (51). When installed properly, the driven sprocket support sits slightly below the machined surface of the transaxle case (51).

Wiring Harness Connection

1. Inspect the wiring harness (11) for damage.
2. Inspect the pass thru connector pins and o-ring seal for damage.
3. Assemble the wiring harness pass thru connector into the transaxle case bore from the inside of the transaxle case.

Input Speed Sensor Installation

1. Assemble the input speed sensor (46) to the transmission case.
2. Install the input speed sensor bolt (15). Hand start the bolts. Tighten: Tighten the input speed sensor bolt to 12 N.m (9 lb ft).
3. Route the input speed sensor wiring harness in the case channel.
4. Connect the input speed sensor connector to the input speed sensor.
5. Install the wire harness retainer and wire harness retainer bolt. Tighten: Tighten the wire harness retainer bolt to 12 N.m (9 lb ft).

Drive, Driven Sprockets and Drive Link Disassemble

1. Remove the turbine shaft to drive sprocket snap ring (35).
2. Remove the drive sprocket (37) from the turbine shaft (39).
3. Remove the three Teflon seals (33 and 40) from the turbine shaft.
4. Discard the Teflon seals (33 and 40).
5. Inspect the drive sprocket (37), the driven sprocket (91), the drive link assembly (36), and the turbine shaft (39) for damage or excessive wear.
6. Inspect the seal grooves for damage.
7. Inspect the thrust washers for damage or excessive wear.
8. Clean and dry each of the components.

Drive, Driven Sprockets and Drive Link Assemble

Tools Required

1. J 29569-1 Turbine Shaft Seal Installer. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. J 29569-2 Turbine Shaft Seal Sizer. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
3. J 29829-1 Turbine Shaft Seal Installer. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
4. J 29829-2 Turbine Shaft Seal Sizer. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

1. Assemble the drive sprocket (37) onto the turbine shaft (39).
2. Retain the drive sprocket with the turbine shaft to drive sprocket snap ring (35).
3. In order to assemble three new Teflon seals (33, 40) onto the turbine shaft (39), perform the following procedure: Slide the J 29569-1 over the large spline of the turbine shaft. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) . Coat the J 29569-1 with transmission fluid. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) . Use your fingers in order to guide the new Teflon™ seals over the J 29569-1 and into the seal ring grooves on the turbine shaft. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) . Remove the J 29569-1 when the seals are in place. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) . Size the new Teflon™ seals. Use both halves of the J 29569-2 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) . In order to properly size the seals, keep the J 29569-2 in place for five minutes. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) . Repeat steps 3.1 thru 3.6 with J 29829-1 and J 29829-2 on the small splined side of the turbine shaft. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .

Drive Sprocket, Driven Sprocket, and Drive Link Installation

Tools Required

J 36850 TRANSJEL™

1. Install the drive sprocket to drive sprocket support thrust washer (38) to the drive sprocket (37). Place the tabs on the thrust washer into the holes on the drive sprocket.
2. Retain the thrust washer with J 36850 or equivalent.
3. Install the driven sprocket to driven sprocket support thrust washer (92) onto the driven sprocket support (95).
4. Install the drive link assembly (36) to the drive and driven sprockets (37 and 91).
5. Install as a complete assembly, the drive sprocket (37) the driven sprocket (91), and the drive link assembly (36) onto the transmission.

Channel Plate Assembly Disassemble

1. Remove the three accumulator pistons (29) from the channel plate (27).
2. Remove the 1-2 accumulator assist spring (125).
3. Remove the 2-3 accumulator assist spring (47).
4. Remove the seals (30) from the accumulator pistons (29).
5. Discard the accumulator piston seals (30).
6. Remove the manual valve (800) from the channel plate (27).
7. Inspect the channel plate (27) for damage.
8. Inspect the channel plate (27) passages for debris.
9. Inspect the accumulator pistons (29), the assist springs (47, 125), and the pins for damage.
10. Inspect the channel plate sleeve for wear from the turbine shaft.
11. Inspect the channel plate (27) bolt holes for stripped threads and debris.
12. Inspect the channel plate machined surface for nicks or scratches that could cause a fluid leak.
13. Inspect the manual valve (800) for freedom of movement.
14. Inspect the drive sprocket to channel plate thrust washer (34).
15. Clean and dry each component.

Channel Plate Assembly Assemble

Tools Required

J 36850 TRANSJEL™

1. Assemble the new accumulator piston seals (30) on the three accumulator pistons (29).
2. Install the 1-2 and 2-3 accumulator assist springs (47, 125).
3. Install the accumulator pistons (29) into the channel plate over the guide pins. The pistons are identical. You can assemble the pistons in any of the three accumulator bores.
4. In order to retain the pistons, apply J 36850 onto the piston seals.
5. Install the manual valve (800) into channel plate.

Accumulator Springs Installation

Install the two remaining accumulator springs into the transmission case accumulator bores.

Channel Plate Assembly Installation

Tools Required

J 36850 TRANSJEL™

1. Install the channel plate to drive sprocket thrust washer (34) onto the channel plate (27).
2. Retain the thrust washer (34) with J 36850 or equivalent.
3. Install a new channel plate to case gasket (28) onto the transmission case (51).
4. Install the channel plate assembly onto the transmission case (51). The channel plate should fit tightly over the guide pins (45) located on the transmission case (51).
5. Install the two channel plate to driven sprocket support bolts (25). Tighten: Tighten the two channel plate to driven sprocket bolts (25) to 14 N.m (10.5 lb ft).
6. Install the six channel plate to case bolts (25). Hand tighten the bolts. Tighten: Tighten the six channel plate to case bolts and the two channel plate to driven sprocket support bolts to 12 N.m (9 lb ft).
7. Install the two channel plate to case bolts (8). Hand tighten bolts. Tighten: Tighten the two channel plate to case bolts (8) to 14 N.m (10.5 lb ft).

Manual Valve Link Installation

1. Connect the manual valve link (802) to both the manual valve and detent lever.
2. Install the manual valve clip (801) onto the manual valve.

Checkballs Installation

Install the seven checkballs into the proper locations on the channel plate.

Spacer Plate and Gaskets Installation

1. Inspect the spacer plate for damage.
2. If damaged, replace the spacer plate (23).
3. Install a new spacer plate to channel plate gasket (24) onto the channel plate.
4. Install the spacer plate (23) on top of the gasket and channel plate.
5. Install the spacer plate support (21) and the two bolts (20) onto the spacer plate. Hand start the bolts. Tighten: Tighten the bolts to 14 N.m (10.5 lb ft).

Control Valve Body Disassemble

1. Remove the 3-4 shift valve retainer clip (304), the bore plug (321), with O-ring (320), the 3-4 shift valve (319) and the 3-4 shift valve spring (318).
2. Remove the actuator feed limit valve retainer clip (304), the bore pug (317), the actuator feed limit spring (316) and the actuator feed limit valve (315).
3. Remove the actuator oil filter retainer clip (304), and the actuator oil filter (314) with O-ring (313).
4. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308).
5. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306).
6. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301).
7. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340).
8. Remove the TCC control valve retainer clip (304), the bore plug (317), the spring (333), and the TCC control valve (334).
9. Remove the pressure regulator valve retainer clip (304), the bushing (324), the pressure regulator boost valve (325), the isolator spring (326), the pressure regulator valve spring (327), and the pressure regulator valve (328).
10. Remove the 1-2/3-4 accumulator valve retainer clip (304), the plug (341), and the accumulator valve (323).
11. Inspect the valve body passages for debris.
12. Inspect the machined surfaces for nicks or scratches. Some polish is normal for the machined surfaces.
13. Inspect the valves for nicks or scratches that could cause sticking valves or fluid leaks.
14. Inspect the springs, bushings, O-rings, screens and solenoids for damage.
15. Clean and dry the valve body and valve body components.

Control Valve Body Assemble

1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304).
2. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304).
3. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304).
4. Install the actuator oil filter (314), with the O-ring (313) and the actuator oil filter retainer clip (304).
5. Install the actuator feed limit valve (315), the actuator feed limit spring (316), the bore plug (317) and the actuator feed limit valve retainer clip (304).
6. Install the 3-4 shift valve spring (318), the 3-4 shift valve (319), the bore plug (321), with O-ring (320) and the 3-4 shift valve retainer clip (304).
7. Install the accumulator valve (323), the plug (341) and the 1-2/3-4 accumulator valve retainer clip (304).
8. Install the pressure regulator valve (328), the pressure regulator valve spring (327), the isolator spring (326), the pressure regulator boost valve (325), the bushing (324) and the pressure regulator valve retainer clip (304).
9. Install the TCC control valve (334), the spring (333), the bore plug (317) and the TCC control valve retainer clip (304).
10. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304).

Control Valve Assembly and Transmission Fluid Pressure (TFP) Switch Installation

1. Install the control valve body to spacer plate gasket (22) onto the spacer plate (23).
2. Install the control valve body assembly (18) onto the gasket (22).
3. Inspect the TFP switch assembly (13) in order to verify the condition and correct location of the 4 pressure switch O-rings.
4. If necessary replace the pressure switch O-rings.
5. Install the TFP switch assembly (13) onto the control valve body assembly.
6. Install the 18 control valve body assembly bolts.
7. Hand start the bolts. Tighten: Tighten the bolts to 14 N.m (124 lb in).

Scheme 122

Connect the wiring harness assembly to the following components

1. The TFP switch assembly (13)
2. The pressure control solenoid (312) - red connector
3. The 1-2 shift solenoid (305) - white connector
4. The 2-3 shift solenoids (305) - white connectors
5. The TCC solenoid (335)

Oil Pump Cleaning and Inspection

1. Inspect the bearing on the flange for excessive wear or damage.
2. Inspect the machined surfaces for scratches or nicks that may cause a fluid leak.
3. Thoroughly flush the oil pump assembly (10) with clean transmission fluid through the pump inlet and outlet passages.
4. Drain excess fluid from the oil pump assembly.

Oil Pump Assembly Installation

1. Install the oil pump shaft (19) into the control valve body assembly (18).
2. Install the oil pump assembly (10) onto the oil pump shaft (19) and the control valve body.
3. Install the eight oil pump bolts (8, 9, 12). Hand start the bolts. Tighten: Tighten the bolts to 12 N.m (9 lb ft).

Side Cover/Gaskets, Disassemble, Assemble, Install

Tools Required

J 36850 TRANSJEL™

1. Remove the side cover gaskets (5 and 6) and the thrust washer (7) from the side cover (1).
2. Remove the side cover axle seal (2). Use the handle end of a hammer.
3. Inspect the side cover for cracks or damage to the seal grooves and mounting bosses.
4. Inspect the side cover seals for damage. The side cover seals are reusable if not damaged.
5. Thoroughly clean the side cover and the side cover seals.
6. Clean and dry the seal grooves and the axle seal bore.
7. Install the side cover gaskets (5 and 6) into the grooves on the side cover (1).
8. Retain the seals with J 36850 or equivalent.
9. Install the side cover to drive sprocket thrust washer (7) onto the side cover.
10. Retain the thrust washer with J 36850 or equivalent.
11. Install the side cover assembly onto the transmission case.
12. Install the 11 side cover bolts (3) or studs (4) (model dependent).
13. Refer to the graphic in order to find the correct installation points of the bolts and the stud.
14. Hand start the bolts. Tighten: Tighten the side cover bolts and stud to 28 N.m (22 lb ft).

Side Cover Axle Seal Installation

Tools Required

J 41102 Axle Seal Installer. See Special Tools .

1. Install a new side cover axle seal (2) into the side cover. Use the J 41102 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. In order to prevent damage to the shaft splines during vehicle operation, add Polyurea grease (part number 7843867) to the splines on the output shaft.

Output Shaft Sleeve Assembly Installation

Tools Required

J 41228 Output Shaft Sleeve Installer. See Special Tools .

1. Place a NEW sleeve (56) over the end of the output shaft (94).
2. Install the collet into the output shaft snap ring groove with the collet attached to the threaded collet shaft.
3. Place the NEW sleeve installing tube over the collet. Be sure the small outside diameter of the tube fits securely into the sleeve.
4. Install the bearing and nut onto the threaded collet shaft.
5. In order to move the installing tube and press the sleeve onto the output shaft, hold the end of the threaded collet shaft while tightening the nut down.
6. Remove the J 41228 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
7. Install a new snap ring (57) into the output shaft snap ring groove.

Stub Shaft Sleeve Assembly Installation

1. Inspect the stub shaft (58) for damage to the splines, the snap ring grooves, and the journals.
2. Inspect the sleeve (56) for excessive wear, scratches or nicks the could cause a leak or damage the seal portion.
3. Clean and dry the stub shaft and sleeve assembly.
4. Place a NEW sleeve (56) over the end of the stub shaft (58).
5. Install the collet into the stub shaft snap ring groove with the collet attached to the threaded collet shaft.
6. Place the sleeve installing tube over the collet. Be sure the small outside diameter of the tube fits securely into the sleeve.
7. Install the bearing and nut onto the threaded collet shaft.
8. In order to move the installing tube and press the sleeve onto the stub shaft, hold the end of the threaded collet shaft while tightening the nut down.
9. Remove the J 41228 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
10. Install the two new snap rings (57) on the stub shaft (58). The snap rings (57) are not reusable after you remove the shaft (58).
11. Install the stub shaft into the transmission. Use a mallet in order to install the shaft through the final drive differential gear.

Right Hand Axle Seal Assemble

Tools Required

J 41102 Axle Seal Installer. See Special Tools .

1. Install a new right hand axle seal (2) into the transmission case. Use the J 41102 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-trans/#automatic-transaxle-overhaul-4t40-e4t45-e__special-tools) .
2. In order to prevent damage to the shaft splines during vehicle operation, add Polyurea grease (part number 7843867) to the splines on the output shaft.

Output Shaft Speed Sensor Installation

1. Inspect the vehicle speed sensor (62) for damage to the sensor, the electrical connector, or the O-ring (63).
2. Clean and dry the vehicle speed sensor (62).
3. Install the O-ring (63) onto the speed sensor (62).
4. Install the speed sensor (62) into the transmission case.
5. Install the speed sensor stud (61). Tighten: Tighten the speed sensor stud to 12 N.m (9 lb ft).

Intermediate/Fourth Servo Disassemble

1. Remove the piston and pin assembly (76 and 77) from the servo cover (80).
2. Remove the snap ring (70) from the servo pin (76).
3. Remove the piston (77) and the servo cushion springs (68) from the servo pin (76).
4. Remove the servo piston seals (78, 79) from the servo cover (80).
5. Discard the servo piston seals (78 and 79). Do not reuse the servo piston seals.
6. Inspect all components for damage.
7. Inspect the fluid feed holes for proper opening.
8. Inspect the bolt hole threads for debris and stripping.
9. Inspect the seal grooves for damage.
10. Clean and dry each component.

Intermediate/Fourth Servo Assemble and Installation

1. Install the servo cushion springs (68) and the servo piston (77) onto the servo pin (76).
2. Install the snap ring (70) onto the servo pin (76) in order to retain the springs (68) and piston (77).
3. Install the new seals (78 and 79) onto the servo piston (77) and the servo cover (80).
4. Install the servo piston assembly into the servo cover (80). Lubricate the piston seals with transmission fluid in order to aid in assembly.
5. Install the servo return spring (75) into the transmission case (51).
6. Install the servo cover (80) and the piston assembly over the servo return spring (75).
7. Install the three servo cover bolts (25). Hand start the bolts. Tighten: Tighten the bolts to 12 N.m (9 lb ft).

Low and Reverse Servo Disassemble

1. Remove the piston pin assembly (67-70) from the servo cover (73).
2. Remove the snap ring (70) from the servo pin (67).
3. Remove the piston (69) and the servo cushion springs (68) from the servo pin (67).
4. Remove the servo piston seals (71, 72) from the cover (73).
5. Discard the servo piston seals (71 and 72).
6. Inspect all the components for damage.
7. Inspect the fluid feed holes for the proper opening.
8. Inspect the bolt hole threads for debris or stripping.
9. Inspect the seal grooves for damage.
10. Clean and dry each component.

Low and Reverse Servo Assemble and Installation

1. Assemble the servo cushion springs (68) and the servo piston (69) onto the servo pin (67).
2. Install the snap ring onto the servo pin (67) in order to retain the servo cushion springs (68) and the servo piston (69).
3. Assemble the new seals (71, 72) onto the servo piston (69) and the servo cover (73).
4. Assemble the servo piston assembly (67-70) into the servo cover (73). Lubricate the piston seals with transmission fluid in order to aid in assembly.
5. Install the servo return spring (66) into the transmission case (51).
6. Install the servo cover and piston assembly over the servo return spring (66).
7. Install the three servo cover bolts (25). Hand start the bolts. Tighten: Tighten the bolts to 12 N.m (9 lb ft).

Oil Feed Pipes Assemble

1. Inspect the oil feed pipes (83) for plugged passages, bent pipes, or cracks.
2. Inspect the oil feed pipe seal rings (82) in order to verify the proper location of the seal rings (82).
3. Replace the seal rings (82) only if they are cut, swelled or damaged.
4. Clean and dry the oil feed pipes.
5. Install new oil feed pipe seal rings (82) if necessary.
6. Retain any newly installed oil feed pipe seal rings (82) with J 36850 or equivalent.
7. Install the oil feed pipe assembly (83) onto the transmission case (51).
8. Install the four oil feed pipe bolts (81). Hand start the bolts. Tighten: Tighten the bolts to 12 N.m (9 lb ft).

Filter Assembly and Seal Installation

1. Lubricate the oil filter seal (84) with transmission fluid.
2. Install a new oil filter seal (84) into the transmission case (51). You may use a large socket as an installer in order to tap on the seal.
3. Install a new filter assembly (85) into the filter seal (84). If necessary, twist the filter slightly during installation.

Scheme 123

Install the oil level control valve into the transmission case (51). Push straight down on the center of the oil level control valve in order to prevent damage to the case bore.

Oil Pan and Gasket Installation

1. Inspect the oil pan (88) for cracks, dents or damage to the gasket sealing surface.
2. Inspect the gasket (87) for cuts or other damage. The bottom pan gasket is reusable if not damaged.
3. Clean and dry the bottom pan, gasket and magnet (89).
4. Install the gasket (87) and bottom pan (88) onto the transmission case.
5. Install the twelve bottom pan bolts (81).
6. Hand start the bolts. Tighten: Tighten the bottom pan bolts to 14 N.m (124 lb in).

Torque Converter Installation

Tools Required

J 21366 Torque Converter Holding Strap

1. Install a new turbine shaft O-ring (41) on the end of the turbine shaft.
2. Install the torque converter onto the transmission.
3. Install the J 21366 .
4. Remove the transmission from the holding fixture.

Park or Neutral - Engine Running (W/o Electronic Range Select Mode)

When the gear selector lever is in the Park (P) position and the engine is running, fluid is drawn into the oil pump. Line pressure is directed to the pressure regulator valve.

Pressure Regulator Valve

The pressure regulator valve regulates the pump output (line pressure) in response to a torque signal fluid pressure, which acts on the boost valve, the spring force, and the line pressure acting on the end of the valve. Line pressure is directed to the manual valve, to both accumulator valves, to the torque signal regulator valve, to the TCC regulated apply valve, to the temperature sensor in the Automatic Transmission Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.), and to the actuator feed limit valve. Also, line pressure feeds the converter feed fluid circuit through the pressure regulator valve.

Actuator Feed Limit (AFL) Valve

Line pressure is routed through the valve and into the actuator feed fluid circuit. The valve limits the actuator feed fluid pressure to a maximum pressure. Actuator feed fluid is routed to the pressure control solenoid and to each of the shift valves. The fluid also feeds the 1-2 signal and the 2-3 signal fluid circuits.

Pressure Control Solenoid (PCS) Valve

Controlled by the PCM, the PCS valve regulates the filtered actuator feed fluid pressure which acts on the end of the torque signal regulating valve.

Torque Signal Regulating Valve

The torque signal regulating valve regulates the line pressure into the torque signal fluid circuit. Filtered actuator feed fluid pressure from the PCS controls this regulation. Torque signal fluid pressure is routed to the accumulator valves and to the boost valve in order to control shift feel.

Manual Valve

The gear selector lever mechanically controls the manual valve, which is in Park (P) position. The manual valve directs line pressure into the PRND4 and the PRN fluid circuits.

Automatic Transmission Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly

PRND4 fluid is routed to the PRND4 fluid pressure switch in the TFP Val. Position Sw. Assembly, which signals the PCM that the transmission is in the Park (P) position. Line pressure is routed to the A/T Fluid Temperature Sensor in the TFP Val. Position Sw. Assembly.

1-2 Shift Solenoid Valve

Energized by the PCM, the normally open 1-2 shift solenoid valve is On and blocks the 1-2 signal fluid from exhausting. The 1-2 signal fluid pressure acts on the 1-2 and the 3-4 shift valves.

1-2 Shift Valve

The 1-2 signal fluid pressure holds the valve in the downshifted position against a spring force. Low/PRN fluid is routed through the 1-2 shift valve and into the Low band fluid circuit.

Low and Reverse Servo

Low band fluid is routed to the inner area of the servo piston. Low band fluid pressure moves the servo piston and pin assembly against a spring force in order to apply the low/reverse band.

2-3 Shift Solenoid Valve

The normally open 2-3 shift solenoid is Off and the 2-3 signal fluid is exhausted through the solenoid.

2-3 Shift Valve

A spring force holds the 2-3 shift valve in the downshifted position.

3-4 Shift Valve

The 1-2 signal fluid pressure holds the 3-4 shift valve against a spring force in the First and the Fourth gear positions.

Lube 2

The lube 2 fluid circuit is fed by line pressure at the pressure regulator valve. Lube 2 fluid is routed through the oil feed pipes and into the forward clutch support. Lube 2 fluid provides lubrication in the rear of the transmission.

1-2/3-4 Accumulator Valves

Line pressure is regulated into accumulator fluid pressure. Torque signal fluid pressure acting on the end of the valve basically controls this regulation.

1-2, and 3-4 Accumulator Assemblies

Accumulator fluid is routed to each of the accumulator assemblies in preparation for upshifts. The fluid which is routed to the 1-2 and to the 3-4 accumulators is orificed by the #4 and the #7 checkballs. The 2-3 accumulator fluid circuit does not use a checkball in order to orifice accumulator fluid to the 2-3 accumulator.

Torque Converter/Cooler and Lube Circuits

Refer to reverse range for a complete description of these circuits.

Scheme 124

Park or Neutral - Engine Running (With Electronic Range Select Mode)

When the gear selector lever is in the Park (P) position and the engine is running, fluid is drawn into the oil pump. Line pressure is directed to the pressure regulator valve.

The pressure regulator valve regulates the pump output (line pressure) in response to a torque signal fluid pressure, which acts on the boost valve, the spring force, and the line pressure acting on the end of the valve. Line pressure is directed to the manual valve, to both accumulator valves, to the torque signal regulator valve, to the TCC regulated apply valve, to the temperature sensor in the Automatic Transmission Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.), and to the actuator feed limit valve. Also, line pressure feeds the converter feed fluid circuit through the pressure regulator valve.

Line pressure is routed through the valve and into the actuator feed fluid circuit. The valve limits the actuator feed fluid pressure to a maximum pressure. Actuator feed fluid is routed to the pressure control solenoid and to each of the shift valves. The fluid also feeds the 1-2 signal and the 2-3 signal fluid circuits.

Controlled by the PCM, the PCS valve regulates the filtered actuator feed fluid pressure which acts on the end of the torque signal regulating valve.

The torque signal regulating valve regulates the line pressure into the torque signal fluid circuit. Filtered actuator feed fluid pressure from the PCS controls this regulation. Torque signal fluid pressure is routed to the accumulator valves and to the boost valve in order to control shift feel.

The gear selector lever mechanically controls the manual valve, which is in Park (P) position. The manual valve directs line pressure into the PRND4 and the PRN fluid circuits.

PRND4 fluid is routed to the PRND4 fluid pressure switch in the TFP Val. Position Sw. Assembly, which signals the PCM that the transmission is in the Park (P) position. Line pressure is routed to the A/T Fluid Temperature Sensor in the TFP Val. Position Sw. Assembly.

Energized by the PCM, the normally open 1-2 shift solenoid valve is On and blocks the 1-2 signal fluid from exhausting. The 1-2 signal fluid pressure acts on the 1-2 and the 3-4 shift valves.

The 1-2 signal fluid pressure holds the valve in the downshifted position against a spring force. Low/PRN fluid is routed through the 1-2 shift valve and into the Low band fluid circuit.

Low band fluid is routed to the inner area of the servo piston. Low band fluid pressure moves the servo piston and pin assembly against a spring force in order to apply the low/reverse band. The low band fluid is routed to the 3-4 shift valve. The pressure moves the valve against 1-2 signal fluid.

The normally open 2-3 shift solenoid is Off and the 2-3 signal fluid is exhausted through the solenoid.

A spring force holds the 2-3 shift valve in the downshifted position.

The 1-2 signal fluid pressure holds the 3-4 shift valve against a spring force in the First and the Fourth gear positions.

The lube 2 fluid circuit is fed by line pressure at the pressure regulator valve. Lube 2 fluid is routed through the oil feed pipes and into the forward clutch support. Lube 2 fluid provides lubrication in the rear of the transmission.

Line pressure is regulated into accumulator fluid pressure. Torque signal fluid pressure acting on the end of the valve basically controls this regulation.

Accumulator fluid is routed to each of the accumulator assemblies in preparation for upshifts. The fluid which is routed to the 1-2 and to the 3-4 accumulators is orificed by the #4 and the #7 checkballs. The 2-3 accumulator fluid circuit does not use a checkball in order to orifice accumulator fluid to the 2-3 accumulator.

Refer to reverse range for a complete description of these circuits.

Scheme 125

When you move the gear selector lever from the Reverse position to the Neutral position, the following changes occur to the hydraulic and electrical systems.

The manual valve is moved to the Neutral position, where the valve blocks the line pressure from entering the Reverse fluid circuit. The reverse fluid circuit is opened to an exhaust at the manual valve.

Reverse Clutch

Reverse fluid exhausts from the reverse clutch and the clutch releases. This action shifts the transmission in to Neutral position.

Boost Valve

Reverse fluid exhausts from the boost valve and line pressure regulation returns to the normal operating range.

A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly

Reverse fluid pressure exhausts from the TFP Val. Position Sw. Assembly. This action signals the PCM that the transmission is either in Neutral (N) or Park (P) position.

Low and Reverse Band Remains Applied

As in Park and Reverse positions, the solenoid valve is energized and 1-2 signal fluid pressure acts on the 1-2 shift valve.

The 1-2 signal fluid pressure keeps the 1-2 shift valve in the downshifted position. Low/PRN fluid continues to feed the low band fluid circuit.

Reverse fluid exhausts from the servo. However, low band fluid pressure continues to act on the inner area of the servo piston in order to keep the band applied.

Scheme 126

When you move the gear selector lever from the Reverse position to the Neutral position, the following changes occur to the hydraulic and electrical systems.

The manual valve is moved to the Neutral position, where the valve blocks the line pressure from entering the Reverse fluid circuit. The reverse fluid circuit is opened to an exhaust at the manual valve.

Reverse fluid exhausts from the reverse clutch and the clutch releases. This action shifts the transmission in to Neutral position.

Reverse fluid exhausts from the boost valve and line pressure regulation returns to the normal operating range.

Reverse fluid pressure exhausts from the TFP Val. Position Sw. Assembly. This action signals the PCM that the transmission is either in Neutral (N) or Park (P) position.

As in Park and Reverse positions, the solenoid valve is energized and 1-2 signal fluid pressure acts on the 1-2 shift valve.

The 1-2 signal fluid pressure keeps the 1-2 shift valve in the downshifted position. Low/PRN fluid continues to feed the low band fluid circuit.

Reverse fluid exhausts from the servo. However, low band fluid pressure continues to act on the inner area of the servo piston in order to keep the band applied.

Scheme 127

Reverse (W/o Electronic Range Select Mode)

When you move the gear selector lever to the Reverse (R) position (from the Park position), the following changes occur in the transmission's hydraulic and electrical systems.

With the manual valve in the reverse position, line pressure is directed into the reverse fluid circuit, in addition to the PRND4 and the PRN fluid circuits, which were used in Park position.

Pressure Regulator and Boost Valves

Reverse fluid is routed to the boost valve. Reverse fluid assists torque signal fluid pressure. The addition of reverse fluid pressure increases the operating range of the line pressure in Reverse position.

Reverse fluid is routed through the 1-2 shift valve and to the TFP Val. Position Sw. Assembly, which signals the PCM that the transmission is in Reverse position.

Reverse clutch fluid pressure applies the reverse clutch.

The PCM keeps the solenoid valve energized in Reverse position. The 1-2 signal fluid pressure acts on the 1-2 shift valve.

The 1-2 signal fluid pressure keeps the 1-2 shift valve in the downshifted position. Low/PRN fluid continues to feed the low band fluid circuit.

Reverse fluid is routed to the outer area of the servo in order to increase the servo apply pressure in the Reverse position.

Pressure Regulator (PR) Valve

Line pressure is routed through the PR valve and into the converter feed fluid circuit. Converter feed fluid is routed to the TCC feed limit valve.

TCC Feed Limit Valve

Converter feed fluid is routed through the valve and into the TCC feed limit fluid circuit.

TCC Regulated Apply Valve

A spring force holds the valve in the release position, thereby blocking line pressure.

TCC Control Valve

A spring force holds the valve in the release position. TCC feed limit fluid is routed into the release fluid circuit. Fluid returns from the converter in the apply fluid circuit. This fluid is routed through the valve and into the cooler fluid circuit.

Torque Converter

Release fluid pressure is routed to the torque converter in order to keep the TCC released. Fluid leaves the converter in the apply fluid circuit.

Lube 1

Cooler fluid is routed through the transmission oil cooler, which is located in the vehicle radiator, and into the lube 1 fluid circuit. Lube 1 fluid is routed through the input shaft in order to lubricate the transmission components in the front of the transmission.

The lube 2 fluid circuit is fed by line pressure at the pressure regulator valve. Lube 2 fluid is routed through the oil feed pipes and into the forward clutch support. Lube 2 fluid provides lubrication in the rear of the transmission. The lube 2 fluid circuit is fed by line pressure at the pressure regulator valve. Lube 2 fluid is routed through the oil feed pipes and into the forward clutch support. Lube 2 fluid provides lubrication in the rear of the transmission.

Scheme 128

Reverse (With Electronic Range Select Mode)

When you move the gear selector lever to the Reverse (R) position (from the Park position), the following changes occur in the transmission's hydraulic and electrical systems.

With the manual valve in the reverse position, line pressure is directed into the reverse fluid circuit, in addition to the PRND4 and the PRN fluid circuits, which were used in Park position.

Reverse fluid is routed to the boost valve. Reverse fluid assists torque signal fluid pressure. The addition of reverse fluid pressure increases the operating range of the line pressure in Reverse position.

Reverse fluid is routed through the 1-2 shift valve and to the TFP Val. Position Sw. Assembly, which signals the PCM that the transmission is in Reverse position.

Reverse clutch fluid pressure applies the reverse clutch.

The PCM keeps the solenoid valve energized in Reverse position. The 1-2 signal fluid pressure acts on the 1-2 shift valve.

The 1-2 signal fluid pressure keeps the 1-2 shift valve in the downshifted position. Low/PRN fluid continues to feed the low band fluid circuit.

Reverse fluid is routed to the outer area of the servo in order to increase the servo apply pressure in the Reverse position. The low band fluid is routed to the 3-4 shift valve. The pressure moves the 3-4 shift valve against the 1-2 signal fluid.

Line pressure is routed through the PR valve and into the converter feed fluid circuit. Converter feed fluid is routed to the TCC feed limit valve.

Converter feed fluid is routed through the valve and into the TCC feed limit fluid circuit.

A spring force holds the valve in the release position, thereby blocking line pressure.

A spring force holds the valve in the release position. TCC feed limit fluid is routed into the release fluid circuit. Fluid returns from the converter in the apply fluid circuit. This fluid is routed through the valve and into the cooler fluid circuit.

Release fluid pressure is routed to the torque converter in order to keep the TCC released. Fluid leaves the converter in the apply fluid circuit.

Cooler fluid is routed through the transmission oil cooler, which is located in the vehicle radiator, and into the lube 1 fluid circuit. Lube 1 fluid is routed through the input shaft in order to lubricate the transmission components in the front of the transmission.

The lube 2 fluid circuit is fed by line pressure at the pressure regulator valve. Lube 2 fluid is routed through the oil feed pipes and into the forward clutch support. Lube 2 fluid provides lubrication in the rear of the transmission. The lube 2 fluid circuit is fed by line pressure at the pressure regulator valve. Lube 2 fluid is routed through the oil feed pipes and into the forward clutch support. Lube 2 fluid provides lubrication in the rear of the transmission.

Scheme 129

Overdrive Range, First Gear (W/o Electronic Range Select Mode)

When you move the gear selector lever to the Overdrive (D) position from the Neutral (N) position, the following changes occur in order to shift the transmission into Overdrive Range - First Gear.

In the Overdrive position, the manual valve directs line pressure into the drive fluid circuit. The manual valve blocks line pressure from entering the PRN fluid circuit and the manual valve opens the PRN fluid circuit in order to exhaust.

Low band fluid pressure exhausts from the servo, releasing the servo and the low and reverse band.

Forward Clutch

Drive fluid is orificed into the forward clutch fluid circuit. Forward clutch fluid pressure applies the forward clutch.

In first gear, the PCM energizes the 1-2 shift solenoid valve and the 1-2 signal fluid pressure acts on the 1-2 shift valve.

The 1-2 signal fluid pressure keeps the 1-2 shift valve in the downshifted position against a spring force. Drive fluid is routed through the 1-2 shift valve.

Drive fluid is routed to the TFP Val. Position Sw. Assembly, which signals the PCM that the transmission is in the Overdrive range.

Scheme 130

Overdrive Range, First Gear (With Electronic Range Select Mode)

When you move the gear selector lever to the Overdrive (D) position from the Neutral (N) position, the following changes occur in order to shift the transmission into Overdrive Range - First Gear.

In the Overdrive position, the manual valve directs line pressure into the drive fluid circuit. The manual valve blocks line pressure from entering the PRN fluid circuit and the manual valve opens the PRN fluid circuit in order to exhaust.

Low band fluid pressure exhausts from the servo, releasing the servo and the low and reverse band.

Drive fluid is orificed into the forward clutch fluid circuit. Forward clutch fluid pressure applies the forward clutch.

In first gear, the PCM energizes the 1-2 shift solenoid valve and the 1-2 signal fluid pressure acts on the 1-2 shift valve.

The 1-2 signal fluid pressure keeps the 1-2 shift valve in the downshifted position against a spring force. Drive fluid is routed through the 1-2 shift valve.

Drive fluid is routed to the TFP Val. Position Sw. Assembly, which signals the PCM that the transmission is in the Overdrive range.

Scheme 131

Overdrive Range, Second Gear (W/o Electronic Range Select Mode)

As vehicle speed increases and operating conditions become appropriate, the PCM de-energizes the 1-2 shift solenoid valve in order to shift the transmission into Second gear. The manual valve remains in the Overdrive (D) position and line pressure is routed into the drive and PRND4 fluid circuits.

The normally open shift solenoid valve is de-energized and 1-2 signal fluid exhausts through the open valve.

With 1-2 signal fluid pressure exhausted, a spring force moves the valve into the upshifted position. Drive fluid is routed into the 2-3 drive fluid circuit. Drive fluid also continues to flow through the valve and to the A/T Fluid Pressure Manual Valve Position Switch.

#2 Checkball (Second Clutch Apply)

The 2-3 drive fluid seats the #2 checkball, forcing the 2-3 drive fluid through the #3 orifice and feeding the second clutch fluid circuit. The #3 and the #4 orifices help to control the apply feel of the second clutch.

Second Clutch

The second clutch fluid pressure applies the second clutch, which shifts the transmission into Second gear.

1-2 Accumulator

Second clutch fluid is also routed to the 1-2 accumulator piston. A combination of second clutch fluid pressure and the 1-2 assist spring force moves the piston against this spring force and the 1-2 accumulator feed fluid pressure. This action absorbs the initial second clutch fluid pressure in order to cushion the second clutch apply. The movement of the 1-2 accumulator piston forces some of the fluid out of the accumulator.

1-2 Accumulator Valve

The 1-2 accumulator feed fluid which is forced from the 1-2 accumulator unseats the #4 checkball. This fluid is then routed back to the 1-2 accumulator valve. This pressure forces the 1-2 accumulator valve against a combination of spring force and torque signal fluid pressure in order to regulate the exhaust of excess accumulator fluid. This regulation provides additional control for the second clutch apply.

TCC Control - Pulse Width Modulated (PWM) Solenoid Valve

Filtered 2-3 drive fluid is routed to the TCC control solenoid valve. Under normal operating conditions the TCC control solenoid valve is Off in Second gear. This valve blocks filtered 2-3 drive fluid from entering the TCC signal fluid circuit.

Torque Converter Clutch

With the TCC control solenoid valve Off, the converter clutch is released in Second gear.

The 2-3 shift solenoid valve remains Off in Second gear, and the 2-3 signal fluid exhausts through the normally open solenoid valve.

A spring force keeps the 2-3 shift valve in the downshifted position. In this position the valve blocks 2-3 drive fluid, in preparation for the upshift into Third gear.

Scheme 132

Overdrive Range, Second Gear (With Electronic Range Select Mode)

As vehicle speed increases and operating conditions become appropriate, the PCM de-energizes the 1-2 shift solenoid valve in order to shift the transmission into Second gear. The manual valve remains in the Overdrive (D) position and line pressure is routed into the drive and PRND4 fluid circuits.

The normally open shift solenoid valve is de-energized and 1-2 signal fluid exhausts through the open valve.

With 1-2 signal fluid pressure exhausted, a spring force moves the valve into the upshifted position. Drive fluid is routed into the 2-3 drive fluid circuit. Drive fluid also continues to flow through the valve and to the A/T Fluid Pressure Manual Valve Position Switch.

The 2-3 drive fluid seats the #2 checkball, forcing the 2-3 drive fluid through the #3 orifice and feeding the second clutch fluid circuit. The #3 and the #4 orifices help to control the apply feel of the second clutch.

The second clutch fluid pressure applies the second clutch, which shifts the transmission into Second gear.

Second clutch fluid is also routed to the 1-2 accumulator piston. A combination of second clutch fluid pressure and the 1-2 assist spring force moves the piston against this spring force and the 1-2 accumulator feed fluid pressure. This action absorbs the initial second clutch fluid pressure in order to cushion the second clutch apply. The movement of the 1-2 accumulator piston forces some of the fluid out of the accumulator.

The 1-2 accumulator feed fluid which is forced from the 1-2 accumulator unseats the #4 checkball. This fluid is then routed back to the 1-2 accumulator valve. This pressure forces the 1-2 accumulator valve against a combination of spring force and torque signal fluid pressure in order to regulate the exhaust of excess accumulator fluid. This regulation provides additional control for the second clutch apply.

Filtered 2-3 drive fluid is routed to the TCC control solenoid valve. Under normal operating conditions the TCC control solenoid valve is Off in Second gear. This valve blocks filtered 2-3 drive fluid from entering the TCC signal fluid circuit.

With the TCC control solenoid valve Off, the converter clutch is released in Second gear.

The 2-3 shift solenoid valve remains Off in Second gear, and the 2-3 signal fluid exhausts through the normally open solenoid valve.

A spring force keeps the 2-3 shift valve in the downshifted position. In this position the valve blocks 2-3 drive fluid, in preparation for the upshift into Third gear.

Scheme 133

Overdrive Range, Third Gear - Torque Converter Clutch (TCC) Not Applied (W/o Electronic Range Select Mode)

As vehicle speed increases and operating conditions become appropriate, the PCM energized the 2-3 shift solenoid valve in order to shift the transmission into Third gear. The manual valve remains in the Overdrive (D) position, and line pressure continues to feed the drive and the PRND4 fluid circuits.

The PCM energizes the normally open 2-3 shift solenoid valve, which blocks the 2-3 signal fluid from exhausting. The 2-3 signal fluid pressure is routed to both of the 1-2 and 2-3 shift valves.

The 2-3 signal fluid pressure moves the valve against a spring force in order to initiate the 2-3 upshift. The 2-3 drive fluid is routed through the valve and into the 3-4 drive fluid circuit.

#5 Checkball (Direct Clutch Apply)

The 3-4 drive fluid pressure seats the #5 checkball, and 3-4 drive fluid is forced through the #26 orifice and into the direct clutch feed fluid circuit. The #26 orifice helps to control the direct clutch apply.

Direct Clutch

The direct clutch fluid pressure applies the direct clutch, causing the transmission to shifts into Third gear.

The 3-4 drive fluid is also routed to the 3-4 shift valve in preparation for a 3-4 upshift.

2-3 Accumulator

Direct clutch feed fluid is also routed to the 2-3 accumulator piston. This fluid pressure moves the piston against a combination of spring force and the 2-3 accumulator feed fluid pressure. This action absorbs the initial direct clutch fluid pressure in order to cushion the direct clutch apply. The movement of the 2-3 accumulator piston forces some of the fluid out of the accumulator.

Torque Converter Clutch (TCC)

Torque Converter Clutch (TCC) Under normal operating conditions the TCC is released in Third gear. However the TCC apply could vary depending upon the vehicle application, and the TCC may be calibrated in order to apply in Overdrive Range - Third gear.

Release fluid pressure routed to the TFP Val. Position Sw. Assembly signals to the PCM that the TCC is released.

Scheme 134

Overdrive Range, Third Gear - Torque Converter Clutch (TCC) Not Applied (With Electronic Range Select Mode)

As vehicle speed increases and operating conditions become appropriate, the PCM energized the 2-3 shift solenoid valve in order to shift the transmission into Third gear. The manual valve remains in the Overdrive (D) position, and line pressure continues to feed the drive and the PRND4 fluid circuits.

The PCM energizes the normally open 2-3 shift solenoid valve, which blocks the 2-3 signal fluid from exhausting. The 2-3 signal fluid pressure is routed to both of the 1-2 and 2-3 shift valves.

The 2-3 signal fluid pressure moves the valve against a spring force in order to initiate the 2-3 upshift. The 2-3 drive fluid is routed through the valve and into the 3-4 drive fluid circuit.

The 3-4 drive fluid pressure seats the #5 checkball, and 3-4 drive fluid is forced through the #26 orifice and into the direct clutch feed fluid circuit. The #26 orifice helps to control the direct clutch apply.

The direct clutch fluid pressure applies the direct clutch, causing the transmission to shifts into Third gear.

The 3-4 drive fluid is also routed to the 3-4 shift valve in preparation for a 3-4 upshift.

Direct clutch feed fluid is also routed to the 2-3 accumulator piston. This fluid pressure moves the piston against a combination of spring force and the 2-3 accumulator feed fluid pressure. This action absorbs the initial direct clutch fluid pressure in order to cushion the direct clutch apply. The movement of the 2-3 accumulator piston forces some of the fluid out of the accumulator.

Torque Converter Clutch (TCC) Under normal operating conditions the TCC is released in Third gear. However the TCC apply could vary depending upon the vehicle application, and the TCC may be calibrated in order to apply in Overdrive Range - Third gear.

Release fluid pressure routed to the TFP Val. Position Sw. Assembly signals to the PCM that the TCC is released.

Scheme 135

Overdrive Range, Fourth Gear - Torque Converter Clutch (TCC) Applied (W/o Electronic Range Select Mode)

When operating conditions are appropriate, the PCM energizes the 1-2 shift solenoid valve in order to shift the transmission into Fourth gear. In addition, the TCC is applied in Fourth gear. The manual valve remains in the Overdrive position and line pressure continues to feed the Drive and the PRND4 fluid circuits.

The PCM energizes the normally open 1-2 shift solenoid valve, which blocks the 1-2 signal fluid from exhausting. The 1-2 signal fluid pressure is routed to both the 1-2 and the 3-4 shift valves.

The 1-2 signal fluid pressure does not affect the 1-2 shift valve. A combination of spring force and the 2-3 signal fluid pressure keeps the 1-2 shift valve in the upshifted position.

The 1-2 signal fluid pressure moves the valve against a spring force and into the Fourth gear position. The 3-4 drive fluid is routed into the fourth band fluid circuit.

Intermediate and Fourth Servo

The 1-2 signal fluid pressure moves the valve against a spring force and into the Fourth gear position. The 3-4 drive fluid is routed into the fourth band fluid circuit.

3-4 Accumulator

The fourth band fluid is also routed to the 3-4 accumulator piston. Fourth band fluid pressure moves the piston against a combination of spring force and 3-4 accumulator feed fluid pressure. This action absorbs initial fourth band fluid pressure in order to cushion the intermediate and Fourth band apply. The movement of the 3-4 accumulator piston forces some fluid out of the accumulator.

3-4 Accumulator Valve

The 3-4 accumulator feed fluid which is forced from the 3-4 accumulator unseats the #7 checkball and the fluid is routed back to the 3-4 accumulator valve. This pressure forces the 1-2/3-4 accumulator valve against a combination of spring force and torque signal fluid pressure in order to regulate the exhaust of excess accumulator fluid. This regulation provides additional control for the intermediate and fourth band apply.

TCC Control Solenoid Valve

When conditions are appropriate, the PCM energized the TCC control solenoid valve in order to initiate the TCC apply. The solenoid valve is pulse width modulated (PWM) in order to provide a smooth TCC apply (Refer to the electrical controls section for a detailed description of the TCC control solenoid valve operation). When energized, the solenoid valve modulates the filtered 2-3 drive fluid into the TCC signal fluid circuit.

TCC Signal fluid pressure modulates the valve against a combination of spring force and TCC regulated apply fluid pressure. This action directs line pressure into the TCC regulated apply fluid circuit in relation to vehicle operating conditions.

Modulated TCC signal fluid pressure moves the valve against a spring force in relation to vehicle operating conditions. This action regulates TCC regulated apply fluid into the apply fluid circuit. At the same time, the release fluid circuit is opened to an orificed exhaust. In this position the valve directs TCC feed limit fluid in order to feed the cooler fluid circuit.

Apply fluid is routed to the torque converter at the same time that release fluid exhausts from the converter. Apply fluid pressure applies the TCC.

Release fluid also exhausts from the TFP Val. Position Sw. Assembly, which signals to the PCM that the TCC is released.

Scheme 136

Overdrive Range, Fourth Gear - Torque Converter Clutch (TCC) Applied (With Electronic Range Select Mode)

When operating conditions are appropriate, the PCM energizes the 1-2 shift solenoid valve in order to shift the transmission into Fourth gear. In addition, the TCC is applied in Fourth gear. The manual valve remains in the Overdrive position and line pressure continues to feed the Drive and the PRND4 fluid circuits.

The PCM energizes the normally open 1-2 shift solenoid valve, which blocks the 1-2 signal fluid from exhausting. The 1-2 signal fluid pressure is routed to both the 1-2 and the 3-4 shift valves.

The 1-2 signal fluid pressure does not affect the 1-2 shift valve. A combination of spring force and the 2-3 signal fluid pressure keeps the 1-2 shift valve in the upshifted position.

The 1-2 signal fluid pressure moves the valve against a spring force and into the Fourth gear position. The 3-4 drive fluid is routed into the fourth band fluid circuit.

The 1-2 signal fluid pressure moves the valve against a spring force and into the Fourth gear position. The 3-4 drive fluid is routed into the fourth band fluid circuit.

The fourth band fluid is also routed to the 3-4 accumulator piston. Fourth band fluid pressure moves the piston against a combination of spring force and 3-4 accumulator feed fluid pressure. This action absorbs initial fourth band fluid pressure in order to cushion the intermediate and Fourth band apply. The movement of the 3-4 accumulator piston forces some fluid out of the accumulator.

The 3-4 accumulator feed fluid which is forced from the 3-4 accumulator unseats the #7 checkball and the fluid is routed back to the 3-4 accumulator valve. This pressure forces the 1-2/3-4 accumulator valve against a combination of spring force and torque signal fluid pressure in order to regulate the exhaust of excess accumulator fluid. This regulation provides additional control for the intermediate and fourth band apply.

When conditions are appropriate, the PCM energized the TCC control solenoid valve in order to initiate the TCC apply. The solenoid valve is pulse width modulated (PWM) in order to provide a smooth TCC apply (Refer to the electrical controls section for a detailed description of the TCC control solenoid valve operation). When energized, the solenoid valve modulates the filtered 2-3 drive fluid into the TCC signal fluid circuit.

TCC Signal fluid pressure modulates the valve against a combination of spring force and TCC regulated apply fluid pressure. This action directs line pressure into the TCC regulated apply fluid circuit in relation to vehicle operating conditions.

Modulated TCC signal fluid pressure moves the valve against a spring force in relation to vehicle operating conditions. This action regulates TCC regulated apply fluid into the apply fluid circuit. At the same time, the release fluid circuit is opened to an orificed exhaust. In this position the valve directs TCC feed limit fluid in order to feed the cooler fluid circuit.

Apply fluid is routed to the torque converter at the same time that release fluid exhausts from the converter. Apply fluid pressure applies the TCC.

Release fluid also exhausts from the TFP Val. Position Sw. Assembly, which signals to the PCM that the TCC is released.

Scheme 137

Overdrive Range, 4-3 Downshift - Torque Converter Clutch (TCC) Not Applied (W/o Electronic Range Select Mode)

When the transmission is operating in Overdrive Range - Fourth Gear, a forced 4-3 downshift will occur following a significant increase in throttle position. At minimum throttle, vehicle speed will decrease gradually (coastdown) and the PCM will command a 4-3 downshift. The PCM will also initiate a 4-3 downshift if the engine load is increased while the throttle position remains the same (for example, driving up a steep hill).

During the downshift, except for a coastdown, the PCM senses the increase in the throttle position or the engine load. When this occurs the PCM increases the PCS duty cycle. The increase in duty cycle increases the output fluid pressure from the PCS, thereby increasing the torque signal fluid pressure at the torque signal regulator valve.

Increased torque signal fluid pressure acting on the boost valve increases line pressure at the pressure regulator valve.

The PCM de-energizes the normally open solenoid valve and the 1-2 signal fluid exhausts.

The 1-2 signal fluid pressure exhausts from the 3-4 shift valve and a spring force moves the valve into the Third gear position. This opens the Fourth band fluid circuit to an orificed exhaust in order to help control the band release.

Fourth band fluid exhausts from the servo and a spring force moves the servo to the release position, thereby releasing the band.

The fourth band fluid exhausts from the accumulator. A combination of spring force and 3-4 accumulator feed fluid pressure moves the accumulator piston to the Third gear position.

1-2/3-4 Accumulator Valve

The accumulator valve regulates line pressure into the 1-2/3-4 accumulator fluid circuit in order to fill the 3-4 accumulator. Torque signal fluid pressure controls this regulation. Increased torque signal fluid pressure regulates accumulator fluid to a higher pressure.

The PCM commands TCC release prior to initiating a 4-3 downshift. When the TCC is in the release position, release fluid pressure is routed to the pressure switch assembly. This fluid pressure signals the PCM that the TCC is in the release position. The TCC is not applied under normal operating conditions in Third gear.

Scheme 138

Drive Range, Manual Third (from Overdrive Range) (W/o Electronic Range Select Mode)

A manual 4-3 downshift is accomplished by moving the gear selector lever to the Manual Third (3) position. In Manual Third the transmission is hydraulically prevented from upshifting into Fourth gear under any conditions. Also, the coast clutch is applied in all manual ranges in order to provide engine compressing braking whenever appropriated. The following information explains the additional changes during a Manual 4-3 downshift as compared to a forced 4-3 downshift. Refer to Overdrive Range, 4-3 Downshift - Torque Converter Clutch (TCC) Not Applied (W/o Electronic Range Select Mode) for a complete description of a 4-3 downshift.

The manual valve moves into the Manual Third (3) position and line pressure enters the D321 fluid circuit. Also the manual valve blocks line pressure from the PRND4 fluid circuit and the PRND4 fluid exhausts past the manual valve.

D321 fluid pressure assists a spring force in order to keep the valve in the Third gear position under any conditions. This opens the Forth band fluid circuit to an orificed exhaust and the Intermediate and Fourth band releases, thereby preventing Fourth gear.

PRND4 fluid exhausts from the TFP Val. Position Sw. Assembly, which signals to the PCM that the manual valve is in the Manual Third position.

Manual Third - Second and First Gears

The transmission operates the same in Manual Third as in Overdrive range with the exception that Fourth gear is prevented. The transmission will upshift and downshift between First, Second, and Third gears as in Overdrive range. However, engine compression braking is not available in Manual Third - First and Second gears, and the vehicle will coast when you release the throttle.

Scheme 139

Manual Third Gear (With Electronic Range Select Mode)

A manual 4-3 downshift is accomplished by moving the gear selector lever to the Manual Third (3) position. In Manual Third the transmission is hydraulically prevented from upshifting into Fourth gear under any conditions. Also, the coast clutch is applied in all manual ranges in order to provide engine compressing braking whenever appropriated. The following information explains the additional changes during a Manual 4-3 downshift as compared to a forced 4-3 downshift. Refer to Overdrive Range, 4-3 Downshift - Torque Converter Clutch (TCC) Not Applied (W/o Electronic Range Select Mode) for a complete description of a 4-3 downshift.

The manual valve moves into the Manual Third (3) position and line pressure enters the D321 fluid circuit. Also the manual valve blocks line pressure from the PRND4 fluid circuit and the PRND4 fluid exhausts past the manual valve.

D321 fluid pressure assists a spring force in order to keep the valve in the Third gear position under any conditions. This opens the Forth band fluid circuit to an orificed exhaust and the Intermediate and Fourth band releases, thereby preventing Fourth gear.

PRND4 fluid exhausts from the TFP Val. Position Sw. Assembly, which signals to the PCM that the manual valve is in the Manual Third position.

The transmission operates the same in Manual Third as in Overdrive range with the exception that Fourth gear is prevented. The transmission will upshift and downshift between First, Second, and Third gears as in Overdrive range. However, engine compression braking is not available in Manual Third - First and Second gears, and the vehicle will coast when you release the throttle.

Scheme 140

Drive Range, Manual Second (from Drive, Manual Third) (W/o Electronic Range Select Mode)

A manual 3-2 downshift is initiated by moving the gear selector lever to the Manual Second (2) position. However, the transmission will not downshift into Second gear until vehicle speed is below approximately 99 km/h (62 mph). At higher vehicle speeds the PCM will keep the 2-3 shift solenoid energized (On) and the transmission will operate in Manual Second - Third Gear as a safety precaution. In Manual Second the transmission is hydraulically prevented from upshifting into Fourth gear under any conditions. Also, the coast clutch remains applied as in Manual Third, and the clutch provides engine compression braking in the Third and the Second gears. The transmission upshifts and downshifts between First and Second gears as in Overdrive gear.

Line pressure is routed into the D21 fluid circuit when the selector lever is moved into the Manual Second (2) position. Line pressure continues to feed the D321 fluid circuit as in Manual Third.

The PCM de-energized the 2-3 shift solenoid valve when the vehicle operating conditions are appropriate for a 3-2 downshift. With the solenoid valve Off, a 2-3 signal fluid exhausts through the 2-3 shift solenoid valve.

A spring force moves the 2-3 shift valve into the Second gear position when the 2-3 signal fluid exhausts. The D21 fluid continues through the valve and the fluid is also routed into the intermediate band feed fluid circuit. The 3-4 drive fluid, which feeds the direct clutch, exhausts past the 2-3 shift valve.

The direct clutch fluid exhausts and the direct clutch releases.

#6 Checkball (Direct Clutch Release)

Exhausting direct clutch fluid seats the #6 checkball. This fluid is forced through the #25 orifice in order to help to control the direct clutch release.

Direct clutch feed fluid exhausts from the 2-3 accumulator, unseats the #5 checkball, and exhausts past the 2-3 shift valve. The 2-3 accumulator feed fluid fills the 2-3 accumulator as the direct clutch feed fluid exhausts.

The 1-2 shift solenoid valve is Off when the PCM commands the Second gear. A spring force holds the 1-2 shift valve in the upshifted position. Intermediate band feed fluid is routed through the valve and into the intermediate band fluid circuit.

#3 Checkball (Intermediate Band Apply)

Intermediate band fluid pressure seats the #3 checkball and is forced through the #8 orifice. This orifice helps to control the intermediate band apply.

Intermediate band fluid pressure is routed to the inner area of the intermediate and Fourth servo piston. This fluid pressure moves the servo piston and apply pin in order to apply the intermediate and Fourth band. The band provides engine compression braking in Manual Second - Second Gear.

The D21 fluid from the 2-3 shift valve is routed to the TFP Val. Position Sw. assembly, which signals to the PCM that the manual valve is in the Manual Second position.

Pressure Control Solenoid Valve

The PCM increases the PCS duty cycle in order to increase the operating range of torque signal fluid pressure in Manual Second. This provides increased line pressure for the additional torque requirements during engine compression braking and increased engine load in Manual Second.

The PCM will release the TCC before downshifting into Manual Second. The TCC will not reapply in Second gear under normal operating conditions.

Scheme 141

Manual Second Gear (With Electronic Range Select Mode)

A manual 3-2 downshift is initiated by moving the gear selector lever to the Manual Second (2) position. However, the transmission will not downshift into Second gear until vehicle speed is below approximately 99 km/h (62 mph). At higher vehicle speeds the PCM will keep the 2-3 shift solenoid energized (On) and the transmission will operate in Manual Second - Third Gear as a safety precaution. In Manual Second the transmission is hydraulically prevented from upshifting into Fourth gear under any conditions. Also, the coast clutch remains applied as in Manual Third, and the clutch provides engine compression braking in the Third and the Second gears. The transmission upshifts and downshifts between First and Second gears as in Overdrive gear.

Line pressure is routed into the D21 fluid circuit when the selector lever is moved into the Manual Second (2) position. Line pressure continues to feed the D321 fluid circuit as in Manual Third.

The PCM de-energized the 2-3 shift solenoid valve when the vehicle operating conditions are appropriate for a 3-2 downshift. With the solenoid valve Off, a 2-3 signal fluid exhausts through the 2-3 shift solenoid valve.

A spring force moves the 2-3 shift valve into the Second gear position when the 2-3 signal fluid exhausts. The D21 fluid continues through the valve and the fluid is also routed into the intermediate band feed fluid circuit. The 3-4 drive fluid, which feeds the direct clutch, exhausts past the 2-3 shift valve.

The direct clutch fluid exhausts and the direct clutch releases.

Exhausting direct clutch fluid seats the #6 checkball. This fluid is forced through the #25 orifice in order to help to control the direct clutch release.

Direct clutch feed fluid exhausts from the 2-3 accumulator, unseats the #5 checkball, and exhausts past the 2-3 shift valve. The 2-3 accumulator feed fluid fills the 2-3 accumulator as the direct clutch feed fluid exhausts.

The 1-2 shift solenoid valve is Off when the PCM commands the Second gear. A spring force holds the 1-2 shift valve in the upshifted position. Intermediate band feed fluid is routed through the valve and into the intermediate band fluid circuit.

Intermediate band fluid pressure seats the #3 checkball and is forced through the #8 orifice. This orifice helps to control the intermediate band apply.

Intermediate band fluid pressure is routed to the inner area of the intermediate and Fourth servo piston. This fluid pressure moves the servo piston and apply pin in order to apply the intermediate and Fourth band. The band provides engine compression braking in Manual Second - Second Gear.

The D21 fluid from the 2-3 shift valve is routed to the TFP Val. Position Sw. assembly, which signals to the PCM that the manual valve is in the Manual Second position.

The PCM increases the PCS duty cycle in order to increase the operating range of torque signal fluid pressure in Manual Second. This provides increased line pressure for the additional torque requirements during engine compression braking and increased engine load in Manual Second.

The PCM will release the TCC before downshifting into Manual Second. The TCC will not reapply in Second gear under normal operating conditions.

Scheme 142

Drive Range, Manual First (from Drive, Manual Second) (W/o Electronic Range Select Mode)

A manual 2-1 downshift is initiated by moving the gear selector lever to the Manual First (1) position. However, the transmission will not downshift into First gear until the vehicle speed is below approximately 60 km/h (37 mph). At higher vehicle speeds the PCM will keep the 1-2 shift solenoid valve de-energized (Off) and the transmission will operate in Manual First - Second Gear. In Manual First the transmission is electronically prevented from upshifting into Third or Fourth gears under any conditions. Also, the coast clutch remains applied, as in Manual Third and Manual Second, and the clutch provides engine compression braking in First and Second gears.

Line pressure is routed into the Low fluid circuit when the selector lever is moved into the Manual First (1) position. Line pressure continues to feed the Drive, the D321, and the D21 fluid circuits as in Manual Second.

Low fluid pressure is routed to the TFP Val. Position Sw. Assembly, which signals to the PCM that the manual valve is in the Manual First position.

#1 Checkball (Low/PRN)

Low fluid pressure seats the #1 checkball against the PRN fluid circuit and this pressure fills the Low/PRN fluid circuit. Low/PRN fluid is routed to the 1-2 shift valve.

The PCM energizes the 1-2 shift solenoid valve when vehicle speed is below approximately 48-56 km/h (30-35 mph). The 1-2 signal fluid is blocked from exhausting through the solenoid valve.

The 1-2 signal fluid pressure shifts the valve into the downshifted position against a spring force, and the following changes occur

1. The 2-3 drive fluid circuit is open to an exhaust past the valve
2. The intermediate band fluid is exhausted past the valve
3. The Lo/PRN fluid is routed into the low band fluid circuit

The Second clutch fluid exhausts from the clutch piston and through the 2-3 drive fluid circuit. This releases the Second clutch, and the transmission operates in First gear.

Second clutch feed fluid exhausts from the 1-2 accumulator, and the fluid exhausts past the #2 checkball and through the 2-3 drive fluid circuit. The 1-2 accumulator feed fluid fills the 1-2 accumulator as the second clutch fluid exhausts.

The accumulator valve regulates the line pressure into the 1-2/3-4 accumulator fluid circuit in order to fill the 1-2 accumulator. Torque signal fluid pressure controls this regulation. Accumulator fluid pressure is regulated to a higher pressure with greater torque signal fluid pressure.

Filtered 2-3 drive fluid exhausts from the solenoid and through the 2-3 drive fluid circuit.

Intermediate band fluid exhausts from the servo piston. A spring force moves the piston and the apply pin, and the intermediate and fourth band releases. However, the intermediate and fourth band remains applied in Manual First - Second Gear in order to achieve engine compression braking.

Low band fluid pressure is routed to the inner area of the Low and Reverse servo in order to apply the Low and Reverse band. The Low and Reverse band provides engine compression braking when the throttle is released in Manual First - First Gear.

Scheme 143

Manual First Gear (With Electronic Range Select Mode)

A manual 2-1 downshift is initiated by moving the gear selector lever to the Manual First (1) position. However, the transmission will not downshift into First gear until the vehicle speed is below approximately 60 km/h (37 mph). At higher vehicle speeds the PCM will keep the 1-2 shift solenoid valve de-energized (Off) and the transmission will operate in Manual First - Second Gear. In Manual First the transmission is electronically prevented from upshifting into Third or Fourth gears under any conditions. Also, the coast clutch remains applied, as in Manual Third and Manual Second, and the clutch provides engine compression braking in First and Second gears.

Line pressure is routed into the Low fluid circuit when the selector lever is moved into the Manual First (1) position. Line pressure continues to feed the Drive, the D321, and the D21 fluid circuits as in Manual Second.

Low fluid pressure is routed to the TFP Val. Position Sw. Assembly, which signals to the PCM that the manual valve is in the Manual First position.

Low fluid pressure seats the #1 checkball against the PRN fluid circuit and this pressure fills the Low/PRN fluid circuit. Low/PRN fluid is routed to the 1-2 shift valve.

The PCM energizes the 1-2 shift solenoid valve when vehicle speed is below approximately 48-56 km/h (30-35 mph). The 1-2 signal fluid is blocked from exhausting through the solenoid valve.

The 1-2 signal fluid pressure shifts the valve into the downshifted position against a spring force, and the following changes occur

1. The 2-3 drive fluid circuit is open to an exhaust past the valve
2. The intermediate band fluid is exhausted past the valve
3. The Lo/PRN fluid is routed into the low band fluid circuit

The Second clutch fluid exhausts from the clutch piston and through the 2-3 drive fluid circuit. This releases the Second clutch, and the transmission operates in First gear.

Second clutch feed fluid exhausts from the 1-2 accumulator, and the fluid exhausts past the #2 checkball and through the 2-3 drive fluid circuit. The 1-2 accumulator feed fluid fills the 1-2 accumulator as the second clutch fluid exhausts.

The accumulator valve regulates the line pressure into the 1-2/3-4 accumulator fluid circuit in order to fill the 1-2 accumulator. Torque signal fluid pressure controls this regulation. Accumulator fluid pressure is regulated to a higher pressure with greater torque signal fluid pressure.

Filtered 2-3 drive fluid exhausts from the solenoid and through the 2-3 drive fluid circuit.

Intermediate band fluid exhausts from the servo piston. A spring force moves the piston and the apply pin, and the intermediate and fourth band releases. However, the intermediate and fourth band remains applied in Manual First - Second Gear in order to achieve engine compression braking.

Low band fluid pressure is routed to the inner area of the Low and Reverse servo in order to apply the Low and Reverse band. The Low and Reverse band provides engine compression braking when the throttle is released in Manual First - First Gear. The low band fluid is routed to the 3-4 shift valve. The pressure moves the 3-4 shift valve against the 1-2 signal fluid.

Scheme 144

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Special Tools

Special Tools Illustration Tool Number/Description J 3289-20 Transmission Holding Fixture Base J 4646 Pliers J 6125-1B Slide Hammer J 21366 Torque Converter Holding Strap J 23129 Universal Seal Remover J 23327 Clutch Spring Compressor J 25031-A Forward and Reverse Clutch Inner Seal Assembly Remover J 28540-A Torque Converter Seal Installer J 28585 Snap Ring Screwdriver J 29569-1 Turbine Shaft Seal Installer J 29569-2 Turbine Shaft Seal Sizer J 29829-1 Turbine Shaft Seal Installer J 29829-2 Turbine Shaft Seal Sizer J 34673 Input Shaft End Play Gage Block J 36850 Assembly Lubricant J 38868 Stub Shaft Sleeve Remover J 41097-1 Inner Seal Assembly Remover - Ring J 41097-2 Inner Seal Assembly Remover - Disc J 41101 Pass Through Connector Remover J 41102 Axle Seal Installer J 41103 Torque Converter Seal Remover Set J 41103-1 Torque Converter Seal Puller Legs J 41103-2 Torque Converter Seal Puller Bridge J 41103-3 Torque Converter Seal Support Body J 41227 Output Shaft Sleeve Remover J 41228 Stub Shaft Sleeve Installer J 41229 Manual Shaft to Case Pin J 41230 Transmission Holding Fixture J 41230-TEM Drill Template J 41231 Forward Clutch Inner Seal Assembly Installer J 41232 Direct Reverse, Second Clutch Return Spring Compressor Adapter J 41233 Reverse Clutch Inner Seal Installer J 41234-1 Input Shaft Seal Installer Pusher J 41234-2 Input Shaft Seal Installer Protector J 41234-3 Input Shaft Seal Installer Sizer J 41235 Second Roller Clutch Installer J 41236 Coast Clutch Return Spring Compressor Adapter J 41239-1 Cooler Line Seal Installer J 41239-10 Cooler Line Seal Remover J 45201 Cooler Line Seal Remover J 45398 Forward Clutch Inner Seal Puller

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See also:
• Special Tools
• Clutch Plate Selection Specifications
• End Play Specifications
• Overdrive Range, 4-3 Downshift - Torque Converter Clutch (TCC) Not Applied (W/o Electronic Range Select Mode)