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Automatic Transaxle Servicing Chevrolet Malibu V рестайлинг

Automatic Trans 24 illustrations ~3418 words

APPLICATION

ApplicationTransaxle Model (RPO Code)
Malibu4T40-E (MN4)

TRANSAXLE APPLICATION

Identifying Oil Pan Gasket (Hydra-Matic 4T40-E). Scheme 129

Scheme 129: Identifying Oil Pan Gasket (Hydra-Matic 4T40-E)
Scheme 129: Identifying Oil Pan Gasket (Hydra-Matic 4T40-E)

LUBRICATION

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

SERVICE INTERVALS

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

CHECKING FLUID LEVELS

WARNINGThe engine must be running when the transmission fluid fill plug is removed, or excessive fluid loss will occur. (Scheme 130) Transmission fluid may be hot. Since the actual fluid level is unknown, stand clear when removing the fill plug. Have a container ready to capture any lost fluid. Do not turn the engine off with the fill plug removed, as you can be injured by hot transmission fluid being expelled out of the oil fill opening. Fluid should be at least 140°F (40°C).
  1. Start the engine and allow the engine to idle until the transmission fluid has reached operating temperature.
  2. Depress the brake pedal and move the shift lever through the gear ranges, pausing a few seconds in each range. Return the shift lever to the PARK range.
  3. Raise the vehicle on a hoist. The vehicle must be level, with the engine running and the shift lever in the PARK range.
  4. Ensure transmission fluid is at least 140°F (40°C). Remove the transaxle oil level control plug. (Scheme 130)
  5. Check the fluid color. If necessary, use a small screwdriver as a dipstick. Is the fluid color clear Red or Light Brown with no burnt odor? If so, go to step 8. If not, go to next step.
  6. Does the fluid have a burnt odor or a Dark Brown color? If so, go to step 12. If not, go to next step.
  7. Does the fluid have a cloudy or milky appearance? If so, go to step 11. If not, go to step 12.
  8. Check the fluid level. The fluid level should be even with the bottom of the threaded plug hole. (Scheme 130) Is the fluid level low? If so, go to next step. If not, go to step 15.
  9. Add appropriate fluid in increments of one pt. (0.5L) until the fluid drains from the plug hole. See «RECOMMENDED FLUIDS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__recommended-fluids). Did you add more than 3 pts. (1.5L) to the transaxle? If so, go to next step. If not, go to step 15.
  10. The transaxle may have a leak. Was a transaxle fluid leak found? If so, go to step 13. If not, go to step 15.
  11. The transaxle fluid is contaminated with engine coolant. Repair or replace the transaxle cooler in the radiator. After repairs, go to step 13.
  12. Drain the fluid by removing the bottom pan. Check the bottom pan for any excessive debris. Was excessive debris found? If so, go to next step. If not, go to step 14.
  13. Perform the following: Repair the transaxle if required. In some cases, overhaul may be required. See appropriate OVERHAUL article in AUTOMATIC TRANSMISSIONS. Flush the transaxle oil cooler and pipes and check flow. See «OIL COOLER FLUSHING»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__oil-cooler-flushing). Add enough appropriate fluid to bring the fluid level to the bottom of the threaded plug hole. See «RECOMMENDED FLUIDS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__recommended-fluids). Start the engine and allow the engine to idle until the transaxle fluid has reached operating temperature. Depress the brake pedal and move the shift lever through the gear ranges, pausing a few seconds in each range. Return the shift lever to the PARK range. Raise the vehicle on a hoist. The vehicle must be level, with the engine running and the shift lever in the PARK range. Remove the transaxle plug. (Scheme 130) If needed, add appropriate fluid in increments of one pt. (0.5L) until the fluid drains from the threaded plug hole. NOTE: Before installing the fill plug, apply Sealant (GM P/N 12345382, GM P/N Canada 10953489) to the threads of the fill plug. Allow fluid to finish draining out of the plug hole. Install the plug and tighten. Wipe any excess fluid from the transaxle with a rag or shop towel. Is the repair complete? If so, system is okay.
  14. Perform the following: Change the fluid and the fluid filter. See «DRAINING & REFILLING»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__draining-refilling). Start the engine and allow the engine to idle until the transmission fluid temperature has reached the value specified. Depress the brake pedal and move the shift lever through the gear ranges, pausing a few seconds in each range. Return the shift lever to the PARK range. Raise the vehicle on a hoist. The vehicle must be level with the engine running and the shift lever in the PARK range. Remove the transaxle plug. (Scheme 130) If needed, add ATF in increments of one pt. (0.5L) until the fluid drains from the threaded plug hole. NOTE: Before installing the fill plug apply Sealant (GM P/N 12345382, GM P/N Canada 10953489) to the threads of the fill plug. Allow fluid to finish draining out of the plug hole. Install the plug and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications). Wipe any excess fluid from the transaxle with a rag or shop towel. Is the repair complete? If so, system is okay.
  15. Allow fluid to finish draining out of the plug hole. Install the plug and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications). Wipe any excess fluid from the transaxle with a rag or shop towel. Is the repair complete? If so, system is okay.

Scheme 130

Scheme 130
Scheme 130

RECOMMENDED FLUIDS

Manufacturer recommends Dexron-III ATF. Fill transaxle with appropriate quantity. See FLUID CAPACITIES .

FLUID CAPACITIES

ApplicationRefillOverhaul (1)Dry Fill (2)
4T40-E7.0 (6.6L)9.5 (9.0L)12.9 (12.2L)
(1) With used torque converter. (2) With new torque converter.
(1)With used torque converter.
(2)With new torque converter.

FLUID CAPACITIES

DRAINING & REFILLING

WARNINGWhen the transaxle is at operating temperatures, take necessary precautions when removing the check/fill plug, to avoid being burned by draining fluid.

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

Note. If oil pan bolts are equipped with conical washers, do not reuse bolts if washers have become reversed. (Scheme 131)

  1. Raise and support vehicle. Place drain pan under transaxle oil pan. Remove oil pan bolts from front and side. Loosen rear transaxle oil pan bolts about 4 turns each.
  2. Using a screwdriver, carefully pry pan loose. Allow fluid to drain. Remove bolts, and remove oil pan. Remove and discard old pan gasket, if reusable-type gasket is not used. Remove filter and O-ring or sleeve-type seal. Remove any remaining gasket material on transaxle case. (Scheme 132)
  3. Thoroughly clean pan, magnet and screen (if metal) with solvent, and then dry using compressed air. Replace filter and seal. Lubricate with clean fluid before installation.
  4. Install filter assembly into filter pick-up tube recess. (Scheme 133) Install oil pan and gasket. Use NEW pan gasket if transaxle is not equipped with reusable-type gasket. Tighten pan bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications).
  5. Fill transaxle with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__fluid-capacities). Lower vehicle and start engine. Allow engine to idle until transmission fluid reaches 104°F (20°C). Depress brake pedal and shift gear selector through all gear ranges, pausing a few seconds in each range. Place gear selector lever in Park.
  6. With engine running, raise vehicle and remove transaxle oil check plug. Add fluid in increments of one pint (.5L) until fluid drains from oil check hole. Install oil check plug and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications).

Scheme 131

Scheme 131
Scheme 131

Scheme 132

Scheme 132
Scheme 132

Scheme 133

Scheme 133
Scheme 133

OIL COOLER FLUSHING

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

CAUTIONFlushing Solution (J-35944-22) is environmentally safe, yet powerful enough to cut through transmission fluid to dislodge any contaminants from the cooler. The safety precautions on the label regarding potential skin and eye irritations associated with prolonged exposure are typical precautions that apply to many similar cleaning solutions. It should be noted that according to General Motors, use of other non-approved fluids for cooler flushing can have an adverse reaction to the seals inside the transaxle.

Preparation

  1. After the repair or replacement transaxle is installed in the vehicle, do not reconnect the oil cooler pipes.
  2. Remove the fill cap (9) on the Transmission Oil Cooler and Line Flusher (J-35944-A) and fill the flusher tank (4) with 20-21 oz. (0.6L) of flushing solution using the measuring cup (6). DO NOT overfill. Install the fill cap (9) on the flusher and pressurize the flusher tank (4) to 80-100 psi (550-700 kPa), using the shop air supply at the tank air valve (9). (Scheme 134)
  3. Connect the flusher discharge hose (5) to the oil cooler return pipe (top connector). This may require (J-35944-600). Clip the discharge hose (5) onto the oil drain container. Attach the flusher to the undercarriage of the vehicle with the hook provided, and connect the flushing system feed supply hose (3) from the flusher to the oil cooler feed pipe (bottom connector). This may require (J-35944-600). (Scheme 135)
  4. With the water supply valve (1) on the flusher in the OFF position, connect the water supply hose (7) from the flusher to the water supply at the faucet. (Scheme 134)and (Scheme 135). Turn ON the water supply at the faucet.

Scheme 134

Scheme 134
Scheme 134

Scheme 135

Scheme 135
Scheme 135

Initial Flush

  1. Turn the flusher water supply valve (1) to the ON position and allow water to flow through the oil cooler and pipes for 10 seconds to remove any remaining transmission fluid. (Scheme 136) If water does not flow through the oil cooler and pipes, the cause of the blockage must be diagnosed and the plugged component must be repaired or replaced. Continue with the cooler flushing and flow check procedure once the blockage is corrected.
  2. Turn the flusher water supply valve (1) to the OFF position and clip the discharge hose (5) onto an appropriate container with a lid, to avoid splashback. (Scheme 137) Turn the flusher water supply valve (1) to the ON position and depress the trigger (8) to mix cooler flushing solution into the water flow. (Scheme 134) Use the clip provided on the handle to hold the trigger (8) down. The discharge will foam vigorously when the solution is introduced into the water stream.
  3. Flush the oil cooler and pipes with water and solution for 2 minutes. During this flush, attach the shop air supply of 120 psi (825 kPa) to the flushing system feed air valve (2) located on the flusher for 3-5 seconds at the end of every 15-20 second interval to create a surging action.
  4. Release the trigger (8) and turn the flusher water supply valve (1) to the OFF position.

Scheme 136

Scheme 136
Scheme 136

Scheme 137

Scheme 137
Scheme 137

Back Flush

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

TRANSAXLE & OIL COOLER FLOW CHECK

  1. Disconnect both hoses from the oil cooler pipes. Connect the oil cooler feed pipe (bottom connector) to the transaxle and the return pipe (top connector) to the discharge hose (5). Clip the discharge hose (5) onto the empty oil drain container. This may require (J-35944-600). (Scheme 137)
  2. Confirm the transaxle is filled with ATF. See «CHECKING FLUID LEVELS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__checking-fluid-levels). Start the engine with the transaxle in PARK and run for 30 seconds. A minimum of 2 qts. (1.9L) must be discharged during this 30-second run time. If fluid flow is greater than 2 qts. (1.9L) in 30 seconds, go to next step. If fluid flow is less than 2 qts. (1.9L) in 30 seconds, go to step 4.
  3. Disconnect the oil cooler feed line at the radiator. Connect the discharge hose (5) to the cooler feed line. Clip the discharge hose (5) to the empty oil drain container. (Scheme 137) Start the engine with the transaxle in PARK range and run for 30 seconds. A minimum of 2 qts. (1.9L) must be discharged during this 30-second run time. Perform the following according to the flow rate: Insufficient feed flow: Inspect the transaxle. Sufficient feed flow: Inspect the oil cooler return pipe and the oil cooler (and auxiliary cooler, if equipped).
  4. Remove the discharge hose (5), reconnect the cooler feed and return pipes to the transaxle and refill the unit to the proper fluid level. Inspect the transaxle oil cooler pipe connections at the radiator, the auxiliary cooler (if equipped) and the transaxle for leaks.

ON-VEHICLE REPAIRS

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

ADJUSTMENTS

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. DO NOT use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.

PARK/NEUTRAL POSITION SWITCH

  1. Place the transaxle control shifter assembly in the NEUTRAL position. Loosen the PNP switch attaching bolts.
  2. Rotate the switch on the shifter assembly in order to align the service adjustment hole with the carrier tang hole.
  3. Insert a 3/32" (2.34 mm) maximum diameter gauge pin to a depth of 9/64" (9.0 mm). Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications) . Ensure the engine will only start in the PARK and NEUTRAL positions.

SHIFT CONTROL CABLE

CAUTIONMisadjusted shift linkage could cause transaxle clutch and/or band failure.
  1. Set the parking brake and chock the wheels.
  2. Place the gearshift lever in the NEUTRAL position. Disconnect cable at transaxle. Place the transaxle in NEUTRAL position by rotating the selector shaft clockwise from PARK through REVERSE to NEUTRAL positions.
  3. Pull the cable adjuster (4) up. (Scheme 138)
  4. Push on the cable adjuster (4) in order to adjust cable in the cable mounting bracket. (Scheme 138) Check for proper shifter operation.

Scheme 138

Scheme 138
Scheme 138

REMOVAL & INSTALLATION

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Before disconnecting battery, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION.
CAUTIONUse the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force, and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Removal

  1. Raise and support the vehicle. Support the engine with a jackstand and a block of wood.
  2. Remove the mount-through bolt.
  3. Remove the lower mount bracket bolts and the lower mount bracket.
  4. Remove the front transaxle mount bolts and the front transaxle mount.

Installation

  1. Position the front transaxle mount and install the bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications) .
  2. Position the lower transaxle mount bracket and install the bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications) .
  3. Install the transaxle mount-through bolt. Tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications) .
  4. Remove the jackstand and the wood block. Lower the vehicle.

Raise and support the vehicle. Remove the transaxle oil pan and filter. See DRAINING & REFILLING under LUBRICATION. Remove the oil feed pipes. See OIL FEED PIPES. Remove the 2 intermediate-4th servo cover bolts, the servo and the spring. (Scheme 139)

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

Scheme 139

Scheme 139: Installation
Scheme 139: Installation

Raise and support the vehicle. Remove the transaxle oil pan and filter. See DRAINING & REFILLING under LUBRICATION. Remove the oil feed pipes. See OIL FEED PIPES. Remove the 3 low and reverse band servo cover bolts, the servo and the spring. (Scheme 140)

Install the low-reverse band servo and cover. (Scheme 140) Install and tighten the bolts to specification. See TORQUE SPECIFICATIONS. Install the oil feed pipe. See OIL FEED PIPES. Install the filter and oil pan. See DRAINING & REFILLING under LUBRICATION. Lower the vehicle. Connect the negative battery cable. Fill transaxle with appropriate fluid to proper level. See LUBRICATION.

Scheme 140

Scheme 140: Installation
Scheme 140: Installation
CAUTIONAllow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss.

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

  1. Raise and support the vehicle. Position the drain pan. Remove the transaxle oil cooler pipe at the transaxle. (Scheme 141) Remove the cooler pipe bracket stud. (Scheme 142) Using the cooler line seal remover, remove the oil cooler pipe seals. (Scheme 143)
  2. Remove the transaxle oil cooler pipe fittings at the radiator. (Scheme 144) Remove the transaxle oil cooler pipe clip bolt. Remove the transaxle oil cooler pipes.
CAUTIONThe correct thread engagement is critical. Crossthreaded fittings can achieve proper tightness value and still leak.
  1. Install the oil cooler line seal installer on the transaxle case using cooler pipe bracket stud hole. (Scheme 145) Press the new seals in. Tighten the seal installer until the seal bottoms out in the case bore.
  2. Install the cooler pipe bracket stud. Install the transaxle oil cooler pipes. Install the transaxle oil cooler pipe clip bolt. Tighten the transaxle oil cooler pipe clip bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications).
  3. Install the transaxle oil cooler pipe fittings at the radiator. Tighten the transaxle oil cooler pipe fittings to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications). Install the transaxle oil cooler hoses to the pipes.
  4. Lower the vehicle. Fill transaxle with appropriate fluid to proper level. See «LUBRICATION»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__lubrication). Operate the engine for 2-3 minutes. Re-inspect the transaxle fluid level. Inspect for fluid leaks.

Scheme 141

Scheme 141
Scheme 141

Scheme 142

Scheme 142
Scheme 142

Scheme 143

Scheme 143
Scheme 143

Scheme 144

Scheme 144
Scheme 144

Scheme 145

Scheme 145
Scheme 145

Remove the transaxle oil filter assembly. See DRAINING & REFILLING under LUBRICATION. Remove the oil feed pipe bolts. (Scheme 146) Inspect the 8 oil feed pipe seal rings. Replace the seal rings only if the seal rings are cut, swollen or damaged. Remove the low-reverse band oil pipe assembly.

Remove the 8 low-reverse band oil pipe assembly seals. Inspect the oil feed pipes for plugged passages, bent pipes, or cracks. Inspect the oil feed pipe seal rings. Verify the proper location of the seal rings. Replace the seal rings if these are cut, swelled or damaged.

Install the 8 low-reverse band oil pipe assembly seals. Install the low-reverse band oil feed pipe assembly onto the transaxle. (Scheme 146) Hand start the bolts that attach the oil feed pipe assembly to the transaxle. Tighten the bolts to specification. See TORQUE SPECIFICATIONS. Install the filter and oil pan. Fill transaxle with appropriate fluid to proper level. See LUBRICATION.

Scheme 146

Scheme 146: Installation
Scheme 146: Installation
  1. Disconnect the switch electrical connector. (Scheme 147) Remove the attaching bolts and hardware. (Scheme 148)
  2. Remove the PNP switch assembly. (Scheme 149)
  1. Place the shift shaft in the NEUTRAL position. Align the flats of the shift shaft to the flats in the park/neutral switch.
  2. Install the PNP switch mounting bolts and temporarily tighten. Adjust PNP switch. See «PARK/NEUTRAL POSITION SWITCH»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__parkneutral-position-switch) under ADJUSTMENTS.

Scheme 147

Scheme 147
Scheme 147

Scheme 148

Scheme 148
Scheme 148

Scheme 149

Scheme 149
Scheme 149
  1. Remove the cable (4) at the transaxle (2) shift control assembly (3). (Scheme 138)
  2. Remove the cable at the transaxle cable bracket. (Scheme 151)
  3. Remove the center console. See REMOVAL & INSTALLATION in appropriate SHIFT INTERLOCK SYSTEMS article in AUTOMATIC TRANSMISSIONS.
  4. Remove the cable at the shift control assembly. (Scheme 150)
  5. Remove the cable grommet at the cowl. Remove the cable from the vehicle.
  1. Install the cable through the cowl and carpet. Install the cable grommet and the bolts in the cowl. Tighten the grommet bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications).
  2. Install the cable (4) at the shift control assembly (3). (Scheme 151)
  3. Install shift control cable onto floor shift control. (Scheme 150)
  4. Install the cable at the transaxle cable brackets (1). Install the cable at the gearshift lever (2). (Scheme 151)
  5. Adjust the cable. See «SHIFT CONTROL CABLE»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__shift-control-cable) under ADJUSTMENTS.
  6. Install the center console. See REMOVAL & INSTALLATION in appropriate SHIFT INTERLOCK SYSTEMS article in AUTOMATIC TRANSMISSIONS.

Scheme 150

Scheme 150
Scheme 150

Scheme 151

Scheme 151
Scheme 151
  1. Raise and suitably support the vehicle. Remove the left front wheel and tire assembly.
  2. Remove the left front splash shield. Install a jackstand and a block of wood to support the transaxle.
  3. Remove the mount through-bolt from the transaxle mount. Unscrew the rear upper mount bolt and leave in place.
  4. Remove the remaining 3 mount bolts. Remove the mount.
  1. Transfer the rear upper mount to the new mount. Position the mount and start the rear upper bolt into the threads. Install the remaining 3 bolts. Tighten all 4 of the mount bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications) .
  2. Install the mount through-bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/automatic-trans/#automatic-transaxle-servicing__torque-specifications) .
  3. Remove the jackstand and the wood block. Install the left splash shield.
  4. Install the left tire and wheel assembly. Lower the vehicle.

Disconnect the negative battery cable. Raise and support the vehicle. Remove the electrical connector at the vehicle speed sensor. Remove the retaining stud and the sensor. (Scheme 152) Pull straight out in order to avoid damage to the case.

Clean and dry the vehicle speed sensor. Install the vehicle speed sensor and the retaining stud. (Scheme 152) Tighten the stud to specification. See TORQUE SPECIFICATIONS. Install the electrical connector at the sensor. Lower the vehicle. Connect the negative battery cable. Check fluid level. See CHECKING FLUID LEVELS under LUBRICATION.

Scheme 152

Scheme 152: Installation
Scheme 152: Installation

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Front Mount Bolt96 (130)
Front Mount Lower Bolt89 (120)
Front Mount Through-Bolt55 (75)
Oil Cooler Pipe Fitting33 (45)
PNP Switch Mounting Bolt18 (24)
Side Mount Bolt41 (56)
Side Mount Through-Bolt41 (56)
Transaxle Mount Support Bolt55 (75)
Transaxle-To-Body Bolt49 (66)
INCH Lbs. (N.m)
Intermediate-4th Servo Cover Bolt106 (12)
Low-Rerverse Servo Cover Bolt106 (12)
Oil Cooler Clip Bolt27 (3)
Oil Feed Pipe Bolt106 (12)
Oil Pan Bolt124 (14)
Shift Cable Grommet Bolt17 (2)
T.V. Cable Bolt80 (9)
VSS Stud97 (11)

TORQUE SPECIFICATIONS

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