Automatic Transaxle Servicing: Other Chevrolet Malibu V facelift

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 150)
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 151)
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 150)and (Scheme 151). Turn ON the water supply at the faucet.

Scheme 150

Scheme 151

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). see scheme 9
2. Confirm the transaxle is filled with ATF. See «CHECKING FLUID LEVELS»(ref-137938-S19464054452002031300000). 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. see scheme 9 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.

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»(ref-137938-S09329941872002031300000) . Ensure the engine will only start in the PARK and NEUTRAL positions.

SHIFT CONTROL CABLE

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 152)
4. Push on the cable adjuster (4) in order to adjust cable in the cable mounting bracket. (Scheme 152) Check for proper shifter operation.

Scheme 152