Automatic Transaxle Servicing: Maintenance Chevrolet Malibu V facelift

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

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 143)
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 143) 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»(ref-137938-S15326562002002031300000). 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»(ref-137938-S28549306882002031400000). Add enough appropriate fluid to bring the fluid level to the bottom of the threaded plug hole. See «RECOMMENDED FLUIDS»(ref-137938-S15326562002002031300000). 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 143) 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»(ref-137938-S29896518822002031300000). 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 143) 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»(ref-137938-S09329941872002031300000). 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»(ref-137938-S09329941872002031300000). Wipe any excess fluid from the transaxle with a rag or shop towel. Is the repair complete? If so, system is okay.

Scheme 143

RECOMMENDED FLUIDS

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

DRAINING & REFILLING

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 144)

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 145)
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 146) 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»(ref-137938-S09329941872002031300000).
5. Fill transaxle with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-137938-S15326562002002031300000) and «FLUID CAPACITIES»(ref-137938-S41616007372002031300000). 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»(ref-137938-S09329941872002031300000).

Scheme 144

Scheme 145

Scheme 146

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.

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 147) 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 148) 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. see scheme 6 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 147

Scheme 148

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).