Automatic Transaxle - 4t40-e/4t45-e - Introduction, Service & Replacement Chevrolet Malibu VI

Transmission Fluid Temperature (TFT) Sensor Specifications

Transmission Fluid Temperature (TFT) Sensor Specifications

Fastener Tightening Specifications

Fastener Tightening Specifications

Transmission General Specifications

Transmission General Specifications

Fluid Capacity Specifications

Fluid Capacity Specifications (4T40-E)

Range Reference

Range Reference

Shift Solenoid Valve State and Gear Ratio

Shift Solenoid Valve State and Gear Ratio (4T40-E)

Shift Speed

Shift Speed

Transmission Fluid Pressure (TFP) Manual Valve Position Switch Logic

TFP Manual Valve Position Switch Logic

Transmission Range Switch Logic

Transmission Range Switch Logic

Line Pressure

Line Pressure

Component Resistance

Component Resistance

Automatic Transmission Schematic Icons

Automatic Transmission Schematic Icons Icon Icon Definition NOTE: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. IMPORTANT: Twisted-pair wires provide an effective "shield" that helps protect sensitive electronic components from electrical interference. If the wires were covered with shielding, install new shielding. In order to prevent electrical interference from degrading the performance of the connected components, you must maintain the proper specification when making any repairs to the twisted-pair wires shown : The wires must be twisted a minimum of 9 turns per 31 cm (12 in) as measured anywhere along the length of the wires The outside diameter of the twisted wires must not exceed 6.0 mm

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Automatic Transmission Inline 20-Way Connector End View

Transmission Inline 20-Way Connector End - Engine Side Connector Part Information 12160493 20-Way F Micro-Pack 100 Series (GY) Pin Wire Color Circuit No. Function A L-GN 1222 1-2 Shift Solenoid Valve Control B YE/BK 1223 2-3 Shift Solenoid Valve Control C OG/BK 1228 Pressure Control (PC) Solenoid Valve High Control D L-BU/WH 1229 PC Solenoid Valve Low Control E PK 39 Ignition 1 Voltage F-K - - Not Used L YE/BK 1227 Transmission Fluid Temperature (TFT) Sensor Signal M TN 2762 Low Reference N - - Not Used P OG 1226 TFP Manual Valve Position Switch Signal C R D-BU 1225 TFP Manual Valve Position Switch Signal B S OG/BK 1230 Input Speed Sensor (ISS) High Signal T BN 418 Torque Convertor Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Control U YE 657 TCC Release Switch Signal V D-BU/WH 1231 ISS Low Signal W - - Not Used

Scheme 47

Transmission Inline 20-Way Connector End - Transmission Side Connector Part Information 12160782 20-Way M Micro-Pack 100 Series (GY) Pin Wire Color Circuit No. Function A L-GN 1222 1-2 Shift Solenoid Valve Control B YE 1223 2-3 Shift Solenoid Valve Control C PU 1228 Pressure Control (PC) Solenoid Valve High Control D L-BU 1229 PC Solenoid Valve Low Control E RD 839 Ignition 1 Voltage F-K - - Not Used L BN 1227 Transmission Fluid Temperature (TFT) Sensor Signal M GY 452 Low Reference N - - Not Used P OG 1226 TFP Manual Valve Position Switch Signal C R D-BU 1225 TFP Manual Valve Position Switch Signal B S BK 1230 Input Speed Sensor (ISS) High Signal T TN 418 Torque Convertor Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Control U WH 1804 TCC Release Switch Signal V D-GN 1231 ISS Low Signal W - - Not Used

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Automatic Transmission Internal Connector End Views

Automatic Transmission Fluid Pressure Manual Valve Position Switch Connector End - Wiring Harness Side Connector Part Information 12146095 Conn 6F Micropack 150.2 P2S (NA) Pin Wire Color Circuit No. Function A - - Not Used B D-BU 1225 TFP Manual Valve Position Switch Signal B C OG 1226 TFP Manual Valve Position Switch Signal C D WH 1804 Torque Converter Clutch Release Switch Signal E BN 1227 Transmission Fluid Temperature (TFT) Sensor Signal F GY 452 Low Reference

1-2 Shift Solenoid (SS) Valve Connector End - Wiring Harness Side Connector Part Information 12162201 Conn 2F M/P 150.2 P2S (NA) Pin Wire Color Circuit No. Function A RD 839A Ignition 1 Voltage B L-GN 1222 1-2 Shift Solenoid Valve Control

2-3 Shift Solenoid (SS) Valve Connector End - Wiring Harness Side Connector Part Information 12162201 Conn 2F M/P 150.2 P2S (NA) Pin Wire Color Circuit No. Function A RD 839B Ignition 1 Voltage B YE 1223 2-3 Shift Solenoid Valve Control

Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector End - Wiring Harness Side Connector Part Information 12162202 Conn 2F M/P 150.2 P2S (BU) Pin Wire Color Circuit No. Function A RD 839C Ignition 1 Voltage B TN 418 Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Control

Pressure Control Solenoid Valve Connector End - Wiring Harness Side Connector Part Information 12146094 Conn 2F Micropack 150.2 P2S (GY) Pin Wire Color Circuit No. Function A PU 1228 Pressure Control (PC) Solenoid Valve High Control B L-BU 1229 PC Solenoid Valve Low Control

Input Speed Sensor (ISS) Connector End - Wiring Harness Side Connector Part Information 12162201 Conn 2F M/P 150.2 P2S (NA) Pin Wire Color Circuit No. Function A BK 1230 Input Speed Sensor (ISS) High Signal B D-GN 1231 ISS Low Signal

Automatic Transmission Related Connector End Views

Output Speed Sensor (OSS) Connector End - Wiring Harness Side Connector Part Information 12162195 Conn 2F M/P 150.2 P2S (BK) Pin Wire Color Circuit No. Function A PU 401 VSS Low Signal B YE 400 VSS High Signal

Cruise Control Brake Switch Connector End - Wiring Harness Side Connector Part Information 12041433 Conn 2F Micropack 280 (BK) Pin Wire Color Circuit No. Function A BN 341 Ignition 3 Voltage B PU 420 TCC Brake Switch Signal

Park/Neutral Position Switch Connector End Connector Part Information 15419116 Conn 7F GT 150, 280 Sealed (BK) Pin Wire Color Circuit No. Function 1 PU/WH 1035 Starter Relay Coil Supply Voltage 2 WH 776 Transmission Range Signal P 3-7 - - Not Used 8 YE 772 Transmission Range Signal B 9 TN/WH 771 Transmission Range Signal A 10 GY 773 Transmission Range Signal C 11 BK/WH 451 Ground 12 PK 239 Ignition 1 Voltage

Park Lock Cable Adjustment

1. Place the floor shift lever in the PARK position.
2. Turn the column lock cylinder to the LOCK position.
3. If the center console is in place, remove the "pencil tray" from in front of the shift control.
4. While using a small screwdriver to release the adjuster lock tang, rotate the threaded cable adjuster until three threads are showing.
5. Re-check park lock operation. If park lock does not function, fine tune the cable 1/2 turn at a time until the proper operation is achieved.

Removal Procedure

1. Disconnect the negative battery cable.
2. Remove the console. Refer to «Console Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
3. Remove the left sound insulator. Refer to «Closeout/Insulator Panel Replacement - Left»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
4. Remove the knee bolster.
5. Place the transmission shift lever in the P (Park) position.
6. Turn the ignition key to the RUN position.
7. Insert a screwdriver blade into the slot provided in the ignition switch inhibitor.
8. Depress the cable latch. Pull the control cable from the inhibitor.
9. Push the cable connector lock button at the shifter base to the up position.
10. Snap the cable from the park/lock lever pin.
11. Depress the two cable latches. Remove the control cable from the transmission control.

Installation Procedure

1. Cut the park lock cable adjuster and cable off at the location just before the end of the retaining barb.
2. Tie the inhibitor end of the new cable to the old cable in an overlapping fashion using zip ties or electrical tape.
3. Carefully use the old cable to route the new cable. If the cable becomes stuck, move the lower part of the cable toward the RH side of the vehicle while pulling the upper half gently.
4. The cable is routed between the HVAC plenum and the vehicle cowl.
5. Place the shift lever in P (Park).
6. Snap the control cable connector into the automatic transmission control.
7. Place the ignition key in the RUN position.
8. Snap the control cable into the inhibitor housing until the snap lock is seated.
9. Turn the key to the LOCK position.
10. Snap the control cable end onto the shift park/lock lever pin.
11. Raise and connect the steering column.
12. Tighten the lower steering column bracket bolts.
13. Install the knee bolster.
14. Install the left sound insulator. Refer to «Closeout/Insulator Panel Replacement - Left»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
15. Install the console. Refer to «Console Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
16. Connect the negative battery cable.

Tools Required

J 36346 Fascia Retainer Remover. See Special Tools and Equipment .

1. Remove the console. Refer to «Console Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
2. Using a J 36346 , disconnect the shifter cable from the control assembly pin. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
3. Remove the shifter cable from the control assembly.
4. Disconnect the park lock cable assembly from the pin on the control assembly.
5. Remove the indicator bulb by rotating the bulb a quarter turn and pulling out.
6. Disconnect the control assembly electrical connectors.
7. Remove the nuts from the control assembly.
8. Remove the control assembly and replace if necessary.

1. Install the control assembly.
2. Install the control assembly bolts. Tighten: Tighten the control assembly bolts to 25 N.m (18 lb ft).
3. Connect the control assembly electrical connectors.
4. Install the indicator bulb by inserting and rotating one-quarter turn.
5. Install the park lock cable onto the control assembly.
6. Connect the park lock cable onto the control assembly pin.
7. Install the shifter cable onto the control assembly.
8. Connect the shifter cable onto the control assembly pin.
9. Install the console. Refer to «Console Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) Instrument Panel, Gages, and Console.

1. Remove the console. Refer to «Console Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
2. Press the tabs on the control cable and remove the cable from the control assembly.
3. Disconnect the control cable from the transaxle range switch lever.
4. Press the 2 tabs on the control cable and remove the cable from the control cable bracket.
5. Remove the control cable grommet from the dash panel.
6. Remove the control cable from the vehicle.

1. Guide the control cable through the pass-through in the dash panel.
2. Secure the control cable grommet by pressing the cable into the pass-through hole in the dash panel.
3. Install the control cable into the transmission bracket, push down until the tabs lock the cable to the bracket.
4. Install the cable to the transmission range switch lever by pressing down until the cable snaps into place.
5. Connect the control cable end to the control assembly lever.
6. Connect the control cable to the pin on the control assembly.
7. Secure the control cable into the control assembly by pushing into place.
8. Install the console. Refer to «Console Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
9. Adjust the control cable assembly. Refer to «Shift Control Cable Adjustment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement__shift-control-cable-adjustment) .

Shift Control Cable Adjustment

1. Raise the hood.
2. Clean the area around where the shift cable attaches to the transmission, if necessary.
3. Push the shift cable adjustment retainer into the released position.
4. Place the transmission range selector lever into the PARK position.
5. From inside the vehicle, place the floor shift control into the PARK position.
6. With both levers in the PARK position, push the shift cable adjustment retainer into the locked position.
7. Confirm proper operation of the shift control system and repeat the adjustment procedure if the shift position detents feel vague or if there are shift concerns.

1. Remove the center console. Refer to (Center Console Replacement) in Interior Trim.
2. Remove the shift control shaft trim by sliding it downward on the shift control assembly shaft.
3. Remove the shift knob setscrew and raise the shift knob off of the shift control assembly shaft.
4. Disconnect the shift knob electrical connector.
5. Remove the shift knob wiring harness from the retaining tabs on the shift control assembly.
6. Remove the shift knob and shift control shaft trim as an assembly and then remove the knob wiring from the shift control shaft trim.

1. Install the new shift knob wiring through the shift control shaft trim and reinstall the shift knob and trim as an assembly.
2. Install the shift knob wiring harness in the retaining tabs on the shift control assembly.
3. Connect the shift knob electrical connector.
4. Install the shift knob on the shift control shaft and reinstall the setscrew. Tighten: Tighten the shift knob setscrew to 2 N.m (17 lb in).
5. Install the shift control shaft trim by pushing up until it snaps onto the lower portion of the shift knob.
6. Install the center console. Refer to (Center Console Replacement) in Interior Trim.

1. Remove the center console. Refer to (Center Console Removal) in Interior Trim.
2. Remove the shift knob. Refer to «Shift Control Knob Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
3. Remove the illumination lamp from the shift indicator.
4. Depress the retaining tabs holding that retain the shift indicator, using a screwdriver or other appropriate tool.
5. Raise the shift indicator off of the shift control base.

1. Install the new shift indicator over the shift control shaft and snap in the retaining features to the shift control base.
2. Install the illumination lamp into the shift indicator.
3. Install the shift knob. Refer to «Shift Control Knob Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
4. Install the center console. Refer to (Center Console Removal) in Interior Trim.

J 41545 Park/Neutral Switch Aligner. See Special Tools and Equipment .

1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch.
2. Remove the shift control cable from the transaxle range switch lever.
3. Disconnect the electrical connectors from the transaxle range switch.
4. Remove the transaxle range switch lever nut and lever.
5. Remove the transaxle range switch bolts and remove the switch.

Installation Procedure (Old Switch)

1. Make sure the transaxle manual shaft is in the Neutral position.
2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch.
3. Loosely install the transaxle range switch bolts.
4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
5. Tighten the transaxle range switch bolts. Tighten: Tighten the range switch bolts to 20 N.m (15 lb ft).
6. Remove the alignment tool.
7. Install the transaxle range switch lever and nut. Tighten: Tighten the transaxle range switch lever retaining nut to 35 N.m (26 lb ft).
8. Connect the transaxle range switch electrical connectors.
9. Install the shift control cable to transaxle range switch lever and verify proper operation.
10. Install the shift control cable to transaxle range switch lever and verify proper operation.

Installation Procedure (New Switch)

1. Make sure the transaxle manual shaft is in the Neutral position.
2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch.
3. Tighten the transaxle range switch bolts. Tighten: Tighten the range switch bolts to 20 N.m (15 lb ft).
4. Install the transaxle range switch lever and nut. Tighten: Tighten the transaxle range switch lever retaining nut to 35 N.m (26 lb ft).
5. Install the shift control cable to transaxle range switch lever and verify proper operation.

1. Position the vehicle on a hoist and raise the vehicle.
2. Place a drain pan under the transaxle oil pan.
3. Remove the oil pan bolts from the front and sides only.
4. Loosen the rear oil pan bolts approximately 4 turns.
5. Lightly tap the oil pan with a rubber mallet or carefully pry in order to allow the oil to drain.
6. Remove the remaining oil pan bolts and the oil pan.
7. Remove the oil pan gasket.
8. Remove all traces of the old gasket material. Clean the transaxle case and oil pan gasket surfaces with solvent, and allow to air dry.

1. Install the oil pan gasket, the oil pan, and hand start the oil pan bolts. Tighten: Tighten the oil pan bolts to 12 N.m (9 lb ft).
2. Lower the vehicle.
3. Refill the transaxle using DEXRON® III P/N 21019223 transaxle fluid or equivalent to the specified refill capacity. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) . Specification: The bottom pan removal capacity is approximately 6.5 L (6.9 qt). The complete overhaul capacity is approximately 9 L (9.5 qt). The dry capacity is approximately 12.2 L (12.9 qt).
4. Start the engine. Warm up the transaxle, and check for leaks.
5. Inspect for proper fluid level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

1. Position the vehicle on a hoist and raise the vehicle.
2. Place a drain pan under the transaxle oil pan.
3. Remove the oil pan bolts from the front and sides only.
4. Loosen the rear oil pan bolts approximately 4 times.
5. Lightly tap the oil pan with a rubber mallet or carefully pry in order to allow the oil to drain.
6. Remove the AIR. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .
7. Inspect the fluid color.
8. Remove the remaining oil pan bolts and the oil pan.
9. Remove the oil pan gasket.
10. Remove the oil level control valve.
11. Remove the oil filter and oil filter O-ring seal. The seal may stay in case when filter is removed.
12. Using a chisel, indent the top of the filter neck seal to relax the press fit.
13. Remove the filter neck seal from the transaxle case and discard.
14. Remove all traces of the old gasket material.
15. Clean the transaxle case and oil pan gasket surfaces with solvent, and allow to air dry.

1. Install a new filter neck seal. A large socket can be used as an installation tool as shown. Two mallets can be used as well.
2. Coat the new filter O-ring seal with a small amount of petroleum jelly, and install the filter into the case.
3. Install the oil level control valve.
4. Install the oil pan gasket, the oil pan, and hand start the oil pan bolts. Tighten: Tighten the oil pan bolts to 12 N.m (9 lb ft).
5. Lower the vehicle.
6. Refill transaxle using DEXRON®III P/N 21019223 or equivalent oil to the specified refill capacity. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) . Specification: The bottom pan removal capacity is approximately 6.5 L (6.9 qt). The complete overhaul capacity is approximately 9 L (9.5 qt). The dry capacity is approximately 12.2 L (12.9 qt).
7. Start the engine. Warm up the transaxle and check for leaks.
8. Check for proper fluid level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

1. Position the vehicle on a hoist and raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Disconnect the electrical connector.
3. Remove the output speed sensor stud.
4. Remove the output speed sensor from the transaxle case.
5. Remove the O-ring from the output speed sensor.

1. Install the O-ring onto the output speed sensor.
2. Install the output speed sensor into the transaxle case.
3. Install the output speed sensor stud. Tighten: Tighten the speed sensor stud to 11 N.m (8 lb ft).
4. Connect the electrical connector.
5. Lower the vehicle.

1. Position the vehicle on a hoist and raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the transaxle oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
3. Remove the oil feed pipe-to-low/reverse servo assembly bolt.
4. Remove the low and reverse band servo cover assembly bolts.
5. Pull the oil feed pipe away from the servo cover and remove the servo assembly.

Disassembly Procedure

1. Remove the piston pin assembly from the servo cover.
2. Remove the snap ring from the servo pin.
3. Remove the piston and the servo cushion springs from the servo pin.
4. Remove the servo piston seals from the cover.
5. Discard the servo piston seals.
6. Inspect all 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.

Assembly Procedure

1. Assemble the servo cushion springs and the servo piston onto the servo pin.
2. Install the snap ring onto the servo pin in order to retain the servo cushion springs and servo piston.
3. Assemble new seals onto the servo piston and servo cover.
4. Assemble the servo piston assembly into the servo cover. Lubricate the piston seals with transaxle fluid in order to aid in assembly.

1. Install the servo return spring into the transaxle case.
2. Install the servo cover and piston assembly over the servo return spring.
3. Hand start and install the servo cover bolts. Tighten: Tighten the servo cover bolts to 12 N.m (9 lb ft).
4. Install the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
5. Lower the vehicle.
6. Remove the AIR. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .
7. Add DEXRON® III P/N 21019223 transaxle fluid or equivalent to the specified refill capacity. Specification: The bottom pan removal capacity is approximately 6.5 L (6.9 qt). The complete overhaul capacity is approximately 9 L (9.5 qt). The dry capacity is approximately 12.2 L (12.9 qt).
8. Start the engine, warm up the transaxle, and check for leaks.
9. Inspect for proper fluid level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

1. Position the vehicle on a hoist and raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
3. Remove the oil level control valve. Pull the valve straight down. Do not pry on the valve.
4. Remove the oil filter and oil filter O-ring seal. The seal may stay in the case when the filter is removed.
5. Using a chisel, indent the top of the filter neck seal to relax the press fit.
6. Remove the filter neck seal from the transaxle case and discard.
7. Remove the intermediate/4th servo assembly bolts.
8. Remove the intermediate/4th servo assembly.

1. Remove the piston and pin assembly from the servo cover.
2. Remove the snap ring from the servo pin.
3. Remove the piston and the servo cushion springs from the servo pin.
4. Remove the servo piston seals from the servo cover.
5. Discard the servo piston seals. Do not reuse the servo piston seals.
6. Inspect all components for damage.
7. Inspect the fluid feed holes for obstructions.
8. Inspect the bolt hole threads for debris and stripping.
9. Inspect the seal grooves for damage.
10. Clean and dry each component.

1. Install the servo cushion springs and the servo piston onto the servo pin.
2. Install the snap ring onto the servo pin in order to retain the springs and piston.
3. Install the new seals onto the servo piston and the servo cover.
4. Install the servo piston assembly into the servo cover. Lubricate the piston seals with transaxle fluid in order to aid in assembly.

1. Install the servo return spring into the transaxle case.
2. Install the servo return spring into the transaxle case.
3. Hand start and install the servo cover bolts. Tighten: Tighten the servo cover bolts to 12 N.m (9 lb ft).
4. Install the new filter neck seal into the transaxle case. A large socket can be used as an installation tool. Two mallets can be used as well.
5. Coat the filter O-ring with a small amount of petroleum jelly, and install the filter into the case.
6. Install the oil level control valve.
7. Install the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
8. Lower the vehicle.
9. Remove the AIR. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .
10. Add DEXRON® III P/N 21019223 transaxle fluid or equivalent to the specified refill capacity. Specification: The bottom pan removal capacity is approximately 6.5 L (6.9 qt). The complete overhaul capacity is approximately 9 L (9.5 qt). The dry capacity is approximately 12.2 L (12.9 qt).
11. Start the engine, warm up the transaxle, and check for leaks.
12. Inspect the fluid level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

Scheme 49

1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in).
2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed.
3. Remove the retaining ring from the quick connect fitting.
4. Discard the retaining ring.
5. Pull the cooler line straight out from the quick connect fitting.

1. Install a new retaining ring into the quick connect fitting using the following procedure
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting.
4. Do not install the new retaining ring onto the fitting by pushing the retaining ring.
5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots.
6. Install the cooler line into the quick connect fitting.
7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt.
8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting.
9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting.
10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting.
11. Ensure that the plastic cap is fully seated against the fitting.
12. Ensure that no gap is present between the cap and the fitting.
13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting.
14. A hidden yellow identification band indicates proper joint seating.
15. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the left radiator air deflector retainers.
3. Remove the left radiator air deflector.
4. Unclip the transmission oil cooler pipe from the fan shroud.
5. Place a drain pan under the transmission oil cooler pipes.
6. Remove the transmission oil cooler pipes attachment nut from the transmission.
7. Remove both transmission oil cooler pipes from the transmission.
8. Remove the transmission oil cooler pipes from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
9. Remove the transmission oil cooler pipes.
10. Remove the transmission oil cooler pipes attachment stud from the transmission if damaged.

1. Install the transmission oil cooler pipes attachment stud to the transmission if removed. NOTE: Refer to «Fastener Notice»(/chevrolet/malibu/vi-2003-2006/remont/oem-general-information/#cautions-and-notices__fastener-notice) in Cautions and Notices. Tighten: Tighten the stud to 7 N.m (62 lb in).
2. Install the transmission oil cooler pipes.
3. Install the transmission oil cooler pipes to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
4. Install both transmission oil cooler pipes to the transmission.
5. Install the transmission oil cooler pipes attachment nut to the transmission. Tighten: Tighten the nut to 7 N.m (62 lb in).
6. Clip the transmission oil cooler pipe to the fan shroud.
7. Install the left radiator air deflector.
8. Install the left radiator air deflector retainers.
9. Lower the vehicle.
10. Inspect the transmission fluid level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

1. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Body - Lighting Systems.
2. Remove the upper transmission oil cooler pipe from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Remove the lower radiator air deflector retainers.
5. Remove the lower radiator air deflector.
6. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) .
7. Remove the right radiator air deflector retainers.
8. Remove the right radiator air deflector.
9. Remove the left radiator air deflector retainers.
10. Remove the left radiator air deflector.
11. Place a drain pan under the transmission oil cooler pipes.
12. Remove the transmission oil cooler pipes attachment nut from the transmission.
13. Remove both transmission oil cooler pipes from the transmission.
14. Remove the transmission oil cooler pipes clip from the fan shroud.
15. Remove the lower transmission oil cooler pipe from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
16. Remove the transmission oil cooler pipes.
17. Remove the transmission oil cooler pipes attachment stud from the transmission if damaged.

1. Install the transmission oil cooler pipes attachment stud to the transmission if removed. NOTE: Refer to «Fastener Notice»(/chevrolet/malibu/vi-2003-2006/remont/oem-general-information/#cautions-and-notices__fastener-notice) in Cautions and Notices. Tighten: Tighten the stud to 7 N.m (62 lb in).
2. Install the transmission oil cooler pipes.
3. Install the lower transmission oil cooler pipe to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
4. Install the transmission oil cooler pipes clip to the fan shroud.
5. Install both transmission oil cooler pipes to the transmission.
6. Install the transmission oil cooler pipes attachment nut to the transmission. Tighten: Tighten the nut to 7 N.m (62 lb in).
7. Install the left radiator air deflector.
8. Install the left radiator air deflector retainers.
9. Install the right radiator air deflector.
10. Install the right radiator air deflector retainers.
11. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) .
12. Install the lower radiator air deflector.
13. Install the lower radiator air deflector retainers.
14. Lower the vehicle.
15. Install the upper transmission oil cooler pipe to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
16. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Body - Lighting Systems.
17. Inspect the transmission fluid level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

Oil Cooler Pipe Seals Replacement

Tools Required

1. J 45201 Cooler Line Seal Remover. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
2. J 41239 Cooler Line Seal Remover/Installer

1. Position the vehicle on a hoist.
2. Place a drain pan or suitable container under the vehicle.
3. Raise the vehicle.
4. Remove the transaxle oil cooler line assembly nut from the transaxle.
5. Remove the transaxle oil cooler lines from the transaxle.
6. Insert the collect piece (2) of the J 45201 into the cooler line seal. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
7. Insert the forcing screw piece (1) of the J 45201 into the collet (2). See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
8. Tighten the forcing screw (1) until snug.
9. Thread the collar piece (1) of the J 45201 onto the collet (3) until snug. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
10. Using an adjustable wrench, turn the collar clockwise in order to remove the cooler line seal.
11. Discard the seal.
12. Clean the case bores for the cooler line seals.

1. Coat the new cooler line seal with transmission fluid.
2. Using the J 41239 , install the new cooler line seal.
3. Install the transaxle oil cooler line assembly to the transaxle.
4. Install the transaxle oil cooler line assembly nut. Tighten: Tighten the oil cooler line assembly nut to 7 N.m (62 lb in).
5. Lower the vehicle.
6. Add fluid to the transaxle. Refer to «Oil Filter and Seal Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
7. Start the engine and check for leaks.

1. Disconnect the negative battery cable.
2. Remove the transmission assembly from the vehicle. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
3. Remove the torque convertor assembly from the transmission.
4. Remove the torque convertor O-ring seal from the end of the turbine shaft. Use a screwdriver.

1. Install a new torque convertor O-ring seal on the end of the turbine shaft.
2. Install the torque convertor onto the transmission.
3. Install the transmission into the vehicle. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
4. Connect the negative battery cable.
5. Adjust the transmission oil level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

1. Position the vehicle on a hoist and raise the vehicle.
2. Remove the transaxle oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
3. Remove the oil level control valve. Pull the valve straight down. Do not pry on the valve.
4. Remove the oil filter and oil filter O-ring seal. The seal may stay in the case when the filter is removed.
5. Using a chisel, indent the top of filter neck seal to relax the press fit.
6. Remove the filter neck seal from the transaxle case.
7. Remove the oil feed pipe assembly bolts and remove the assembly.
8. Remove the low and reverse band oil pipe assembly seals.

1. Inspect the oil feed pipes for plugged passages, bent pipes, or cracks.
2. Inspect the oil feed pipe seal rings in order to verify the proper location of the seal rings. IMPORTANT: The oil feed pipe seals are glued into place during the initial assembly. If a seal ring is to be replaced, be sure to thoroughly clean any residual glue from the feed pipes.
3. Replace the seal rings only if they are cut, swelled, or damaged.
4. Install the oil feed pipe assembly.
5. Hand start the oil feed pipe assembly bolts. Tighten: Tighten the oil feed pipe assembly bolts to 12 N.m (9 lb ft).
6. Install the new filter neck seal into the transaxle case. A large socket can be used as an installation tool. Two mallets can be used as well.
7. Coat the filter O-ring seal with a small amount of petroleum jelly, and install the filter into the transaxle case.
8. Install the oil level control valve.
9. Install the transaxle oil pan and gasket. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
10. Lower the vehicle.
11. Add DEXRON® III P/N 21019223 transaxle fluid or equivalent. Specification: The bottom pan removal capacity is approximately 6.5 L (6.9 qt). The complete overhaul capacity is approximately 9 L (9.5 qt). The dry capacity is approximately 12.2 L (12.9 qt).
12. Start the engine, warm up the transaxle, and check for leaks.
13. Check the fluid level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

1. Remove battery tray assembly assembly. Refer to «Battery Tray Replacement»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
2. Disconnect the shift cable from the PNP switch.
3. Remove the shift cable bracket.
4. Remove the PNP switch lever nut and lever.
5. Remove the PNP switch. Refer to «Park/Neutral Position (PNP) Switch Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
6. Remove the transmission upper side cover bolts.
7. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-support-fixture) in Engine Mechanical.
8. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
9. Remove the left front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
10. Remove the left lower control arm. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) in Front Suspension.
11. Remove the wheel drive shaft from the transmission. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
12. Disconnect the steering rack intermediate shaft. Refer to «Power Steering Gear Replacement»(/chevrolet/malibu/vi-2003-2006/remont/manual-power-steering/#power-rack-pinion-steering-system) in Power Steering System.
13. Remove the frame. Refer to «Frame Replacement (W/L61)»(/chevrolet/malibu/vi-2003-2006/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Frame Replacement (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
14. On vehicles equipped with the L61 engine, remove the transmission mount. Refer to «Transmission Mount Replacement - Side (W/L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) or «Transmission Mount Replacement - Side (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
15. Lower the vehicle.
16. Lower the LH side of the engine with the engine support fixture to allow the transmission side cover enough room to get past the left rail.
17. Raise the vehicle.
18. Remove the transmission side cover lower bolts.
19. Remove the transmission side cover.

1. Install the transmission side cover.
2. Hand start the transmission side cover lower bolts. Tighten: Tighten the side cover bolts and stud to 20 N.m (15 lb ft).
3. Lower the vehicle.
4. Raise the engine with the engine support fixture.
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
6. On vehicles equipped with the L61 engine, install the transmission mount. Refer to «Transmission Mount Replacement - Side (W/L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) or «Transmission Mount Replacement - Side (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
7. Install the frame. Refer to «Frame Replacement (W/L61)»(/chevrolet/malibu/vi-2003-2006/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Frame Replacement (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
8. Install the power steering intermediate shaft and tie-rod ends. Refer to «Power Steering Gear Replacement»(/chevrolet/malibu/vi-2003-2006/remont/manual-power-steering/#power-rack-pinion-steering-system) in Power Steering System.
9. Install the wheel drive shaft to the transmission. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
10. Install the left lower control arm to the subframe and steering knuckle. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) in Front Suspension.
11. Install the left front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
12. Lower the vehicle.
13. Remove the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-support-fixture) in Engine Mechanical.
14. Install the PNP switch. Refer to «Park/Neutral Position (PNP) Switch Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
15. Install the PNP switch lever and nut. Tighten: Tighten the nut to 35 N.m (26 lb ft).
16. Install the shift cable bracket.
17. Connect the shift cable to the PNP switch.
18. Install the battery tray assembly. Refer to «Battery Tray Replacement»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
19. Fill the transmission. Refer to «Capacities - Approximate Fluid»(/chevrolet/malibu/vi-2003-2006/remont/lubrication-system/#maintenance-and-lubrication__capacities-approximate-fluid) in Maintenance and Lubrication.

Case Side Cover Seal Replacement

Tools Required

1. J 41227 Output Shaft Sleeve Remover. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
2. J 41228 Output Shaft Seal Installer. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
3. J 41102 Axle Seal Installer. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .

Scheme 50

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the drive axle assembly. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
3. Use a medium screwdriver and a mallet in order to remove the case cover seal.
4. Remove the drive axle retaining clip from the output axle.
5. Use the J 41227 in order to remove the sleeve from the output axle shaft. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
6. Clean and inspect the seal bore.
7. Use fine sand paper in order to remove any burrs or nicks. Clean the entire area after any sanding.

Scheme 51

1. Use the J 41102 and a mallet in order to install the new case cover seal. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
2. Use the J 41228 in order to install a new sleeve on the output axle. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) . Install the J 41228 so that the collar is in the snap ring groove. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
3. Install the axle shaft retaining clip onto the output axle.
4. Install the drive axle assembly. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
5. Lower the vehicle.
6. Inspect the shaft sleeve for leaks.
7. Inspect the transmission oil level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

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

1. Remove the transmission side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
2. Remove the control valve body. Refer to «Control Valve Body Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
3. 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 and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
4. With the retaining tabs compressed, use a screwdriver in order to remove the pass-through connector through the inside of the transmission case.
5. Remove the wiring harness (11).

Scheme 52

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)
6. Install the control valve body. Refer to «Control Valve Body Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
7. Install the transmission side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .

Replacement Procedure

1. Remove the transmission side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
2. 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).

1. 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).
2. Install the transmission side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement)

1. Remove the transmission side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
2. 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).

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 transmission side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .

1. Remove the transmission side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
2. 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).

1. 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).
2. Install the transmission side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .

Scheme 53

1. Remove the transmission side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement)
2. 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).

1. 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).
2. Install the transmission side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .

1. Remove the transaxle case side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
2. Remove the TFP switch assembly bolts.
3. Remove the TFP switch assembly from the control valve body assembly. The TFP switch O-rings are reusable if not damaged and should remain with the switch assembly.

1. Inspect the TFP switch assembly in order to verify the condition and correct location of the pressure switch O-rings. If necessary, replace the O-rings.
2. Install the TFP switch assembly onto the control valve body assembly and install the bolts. Tighten: Tighten the control valve body bolts to 12 N.m (9 lb ft).
3. Install the transaxle case side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
4. Start the engine, warm up the transaxle, and check for leaks.
5. Inspect for proper fluid level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

Scheme 54

1. Remove the transaxle case side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
2. Remove the oil pump bolts and the oil pump assembly.
3. Remove the oil pump shaft.
4. Disconnect the wire harness connectors from the following components: Pressure control solenoid 1-2, 2-3 shift solenoids TFP switch assembly TCC solenoid
5. Remove the TFP switch assembly bolts and remove the switch assembly from the control valve body. The 7 TFP switch O-rings are reusable if not damaged and should remain with the pressure switch assembly.
6. Remove the remaining control valve body bolts and remove the control valve body assembly.
7. Remove and discard the valve body-to-spacer plate gasket.
8. Remove the spacer plate support bolts and remove the spacer plate support.
9. Remove the spacer plate with the spacer plate filter attached.
10. Remove and discard the spacer plate-to-channel plate gasket.

Disassembly/Assembly Procedure

For step by step instructions on how to disassemble/assemble the control valve body, refer to Control Valve Body Disassemble and Control Valve Body Assemble in the Transmission/Transaxle Unit Repair Manual.

1. Make sure the checkballs are in the proper locations on the channel plate. Retain the checkballs with petroleum jelly.
2. Install a new spacer plate-to-channel plate gasket onto the channel plate.
3. Install the spacer plate with the spacer plate filter attached.
4. Hand start the spacer plate support bolts and install the spacer plate support. Tighten: Tighten the spacer plate support bolts to 14 N.m (10 lb ft).
5. Install a new control valve body to the spacer plate gasket onto the spacer plate.
6. Install the control valve body assembly onto the gasket. Hand start the control valve body assembly bolts to hold the valve body in place.
7. Inspect the TFP switch assembly in order to verify the condition and the correct location of the pressure switch O-rings. If necessary, replace the TFP switch assembly O-rings.
8. Install the TFP switch assembly onto the control valve body assembly.
9. Install the remaining control valve body bolts.
10. Hand start the bolts. Tighten: Tighten the control valve body bolts to 12 N.m (9 lb ft).
11. Connect the transaxle wiring harness to the following components: TFP switch assembly Pressure control solenoid (red connector) IMPORTANT: The 1-2 shift solenoid wires are red and green. The 2-3 shift solenoid wires are red and yellow. 1-2 shift solenoid 2-3 shift solenoid TCC solenoid
12. Install the oil pump shaft into the control valve body assembly.
13. Install the oil pump assembly onto the oil pump shaft and the control valve body. Hand start and install the oil pump assembly bolts. Tighten: Tighten the oil pump bolts to 12 N.m (9 lb ft).
14. Install the transaxle case side cover. Refer to «Case Side Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
15. Start the engine, warm up the transaxle, and check for leaks.
16. Inspect for proper fluid level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

Stub Axle Shaft Sleeve and Seal Replacement

Tools Required

1. J 38868 Shaft Removal Tool
2. J 6125-1B Slide Hammer
3. J 23129 Universal Seal Remover. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .
4. J 41102 Axle Seal Installer. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) .

1. Raise and support the vehicle. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
2. Remove the drive axle assembly. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
3. Remove the snap ring from the stub axle shaft. Discard the snap ring. Do not reuse.
4. Remove the stub shaft from the transmission. Use the J 6125-1B and the J 38868 .
5. Pull lightly on the shaft. Rotate the shaft until the stub shaft snap ring at the differential seats in the taper on the differential side gear.
6. Remove inner snap ring.
7. Remove the right hand axle seal from the transmission. Use the J 23129 and the. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) . J 6125-1B .

1. Install the new seal. Use the J 41102 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) . Lubricate the seal lip with a light wipe of transmission oil.
2. Install the two new snap rings on the stub shaft.
3. Install the stub shaft into the transmission. Use a mallet.
4. Install the drive axle assembly. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
5. Lower the vehicle.
6. Inspect the oil level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .
7. Inspect the shaft and the seal for leaks.

Output Axle Shaft Sleeve and Seal Replacement

Tools Required

1. J 41227 Output Shaft Sleeve Remover
2. J 41228 Output Shaft Sleeve Installer

1. Raise the vehicle. Support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the drive axle assembly. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
3. Remove the snap ring from axle.
4. Remove the output axle seal.
5. Use the J 41227 to remove the sleeve from the output axle.

1. Use the J 41228 to install a new sleeve on the output axle shaft. Ensure that the collet is located in the snap ring groove when installing.
2. Install the new output axle seal.
3. Install one new snap ring on the output shaft.
4. Install the drive axle assembly. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
5. Lower the vehicle.
6. Inspect the output axle shaft sleeve for leaks.
7. Inspect the oil level. Refer to «Transmission Fluid Checking Procedure»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-troubleshooting-diagnosis) .

Inspection Procedure

1. Raise the transmission/transaxle in order to relieve tension in the mount.
2. Observe the mount while raising the transmission/transaxle. Raising the transmission/transaxle removes the weight from the mount.
3. Replace the mount if it exhibits any of the following conditions: The hard rubber surface is covered with heat check cracks. The rubber is separated from the outer metal sleeve of the mount. The rubber is split through the center of the transmission mount. The mount is leaking fluid.
4. When replacing the transmission mounts or brackets, refer to the following procedures: «Transmission Mount Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) «Transmission Mount Replacement - Rear»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) «Transmission Mount Replacement - Side (W/L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) or «Transmission Mount Replacement - Side (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement)

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the front transaxle mount through bolt.
3. Remove the transaxle mount-to-transaxle attachment bolts.
4. Remove the transaxle mount from the vehicle.

1. Install the transaxle mount into the vehicle and tighten the bolts. Tighten: Tighten the transaxle mount bolts to 90 N.m (66 lb ft).
2. Install the transaxle mount through bolt. Tighten: Tighten the transaxle mount through bolt to 90 N.m (66 lb ft).
3. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the left tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
3. Using a suitable jack stand, support the rear of the powertrain.
4. Remove the transmission mount to bracket through bolt and nut.
5. Remove the transmission mount to transmission bolts.
6. Disconnect the HO2 sensor Harness from the transmission mount bracket.
7. Remove the transmission mount to frame nuts.
8. Remove the transmission mount and bracket through the left side of the vehicle.

1. Install the transmission mount and bracket through the left side of the vehicle.
2. Install the transmission bracket to frame bolts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
3. Connect the HO2 sensor harness to the transmission mount bracket.
4. Install the transmission mount to transmission bolts. Tighten: Tighten the bolts to 90 N.m (66 lb ft).
5. Install the transmission mount to bracket through bolt and nut. Tighten: Tighten the bolt and nut to 90 N.m (66 lb ft).
6. Remove the jack stand.
7. Install the left tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
8. Lower the vehicle.

1. Remove the battery and tray. Refer to «Battery Tray Replacement»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
2. Using a floor jack and a block of wood, support the powertrain.
3. Remove the left transmission mount to bracket bolts.
4. Remove the left transmission mount to body bolts.
5. Remove the transmission mount from the vehicle.

1. Install the left transmission mount to the vehicle. Tighten: Tighten the left transmission mount to body bolts to 25 N.m (16 lb ft).
2. Install the left transmission mount to body bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Remove the floor jack supporting the engine.
4. Install the battery and tray. Refer to «Battery Tray Replacement»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the left front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and wheels.
3. Remove the left splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
4. Using a suitable floor jack and block of wood, support the powertrain.
5. Remove the transaxle mount lower nuts from the frame.
6. Remove the transmission mount upper nuts from the transmission mount bracket.
7. Use the floor jack to raise the powertrain enough to remove the transmission mount.
8. Remove the transaxle mount from the frame.

1. Install the transaxle mount to the frame.
2. Install the transmission mount to frame bolts. Hand tighten only.
3. Use the jackstand to lower the transmission mount bracket on to the transmission mount studs.
4. Install the transmission mount to bracket upper nut. Hand tighten only.
5. Tighten the transmission mount nut and bolts. Tighten: Tighten the transmission mount upper nuts to 50 N.m (37 lb ft). Tighten the transmission mount lower bolts to 50 N.m (37 lb ft).
6. Install the left splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
7. Install the left front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
8. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Spray penetrating oil on the exposed threads of both lower ball joint bolts to facilitate their removal later in this procedure.
3. Lower the vehicle.
4. Remove the air intake duct from the throttle body and air cleaner assembly.
5. Remove the battery cover and disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
6. Disconnect the transaxle wiring harness from the transaxle and the park/neutral position (PNP) switch.
7. Remove the shift cable bracket and shift cable from the lever.
8. Remove the transmission wiring harness from the retainer on the transmission.
9. Remove the upper transmission to engine bolts and stud.
10. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-support-fixture) in Engine Mechanical.
11. Support the radiator and condenser from above using the condenser tabs on each side.
12. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
13. Remove the front wheel and tire assemblies. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
14. Remove the steering gear intermediate shaft.
15. Separate the control arm from the frame and the outer tie rod ends from the steering knuckles. Support the lower control arm with mechanics wire or a similar method.
16. Remove the frame. Refer to «Frame Replacement (W/L61)»(/chevrolet/malibu/vi-2003-2006/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Frame Replacement (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
17. Remove the 3 bolts from the transmission brace near the right axle shaft.
18. Remove the oil pan to bell housing bracket (3 bolts).
19. Remove the flywheel inspection cover.
20. Remove the starter. Refer to «Starter Motor Replacement (L61)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) or «Starter Motor Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
21. Mark the relationship of the flywheel to the torque converter for reassembly.
22. Remove the torque converter to flywheel bolts.
23. Remove the transmission cooler lines by removing the nut holding the bracket to the transaxle case.
24. Disconnect the vehicle speed sensor (VSS) wiring harness from the sensor.
25. Disconnect the rear 02 sensor harness from the bracket on the steering gear.
26. Disconnect the wheel drive shafts from the transaxle. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts
27. Remove the front transmission mount bracket from the transmission.
28. Use a transmission jack to support the transmission.
29. Remove the remaining bell housing bolts and studs and separate the transmission from the engine.
30. Lower the transmission with the transmission jack far enough to remove the transmission.
31. If the transmission is being replaced or installed in a holding fixture, remove the rear transmission mount bracket from transmission.
32. Remove the PNP switch from the transmission.

1. Install the PNP switch.
2. Install the torque converter clutch (TCC) lock up clutch O-ring.
3. Install the torque converter.
4. Transfer the transaxle from the bench fixture to transmission jack.
5. Install the side cover transmission mount bracket to the transmission.
6. Install the rear transmission mount bracket to the transmission.
7. Position the transaxle in the vehicle.
8. Install the lower transmission to engine bolts and nuts. Tighten: Tighten the bolts and nuts to 90 N.m (66 lb ft).
9. Install the front transmission mount bracket to the transmission.
10. Connect the wheel drive shafts to the transmission. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
11. Connect the VSS wiring harness to the VSS.
12. Install the torque converter to flywheel bolts. Tighten: Tighten the torque converter bolts to 62 N.m (46 lb ft).
13. Install the starter. Refer to «Starter Motor Replacement (L61)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) or «Starter Motor Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
14. Install the flywheel inspection cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
15. Connect the transaxle cooler pipes to the transaxle. Tighten: Tighten the cooler pipes to 8 N.m (71 lb in).
16. Install the oil pan to bell housing bracket (3 bolts). Tighten: Tighten to 72 N.m (53 lb ft).
17. Install the 3 bolts to the transmission brace at final area and tighten.
18. Remove the transmission jack.
19. Install the frame. Refer to «Frame Replacement (W/L61)»(/chevrolet/malibu/vi-2003-2006/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Frame Replacement (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/frames-subframes-crossmembers/#frame-and-underbody) Frame and Underbody.
20. Install the engine splash shields.
21. Install the front wheel and tire assemblies. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
22. Lower the vehicle.
23. Remove the radiator and condenser support, and the engine support fixture
24. Install the upper transmission to engine bolts and stud. Tighten: Tighten the bolts to 90 N.m (66 lb ft).
25. Install The Shift Cable Bracket And Shift Cable To The Lever.
26. Install the exhaust pipe upper bolts and heat shield.
27. Connect the electrical connectors to the PNP switch and transaxle.
28. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
29. Install the battery cover.
30. Install the air intake duct to the throttle body and air cleaner assembly.
31. Add automatic transmission fluid (ATF) and verify the proper fluid level of transaxle.
32. Road test the vehicle.

How to Use This Section

This section provides the following information

1. General diagnosis information on transmissions
2. Procedures for diagnosing the Hydra-Matic® transmission

When you diagnose any condition of the Hydra-Matic® transmission, begin with Diagnostic Starting Point. This procedure indicates the proper path of diagnosing the transmission by describing the basic checks. This procedure will then refer you to the locations of specific checks. After you have determined the cause of a condition, refer to Repair Instructions for repair procedures. If the faulty component is not serviceable without removing the transmission from the vehicle, refer to the Transmission Unit Repair Manual (TURM) for repair information.

Basic Knowledge

Note. Do not, under any circumstances, attempt to diagnose a powertrain condition without basic knowledge of this powertrain. If you perform diagnostic procedures without this basic knowledge, you may incorrectly diagnose the condition or damage the powertrain components.

You must be familiar with some basic electronics in order to use this section of the service manual. You should also be able to use the following special tools

1. A digital multimeter (DMM)
2. A circuit tester
3. Jumper wires or leads
4. A line pressure gage set

Diagnosis

Note. If you probe a wire with a sharp instrument and do not properly seal the wire afterward, the wire corrodes and an open circuit results.

Diagnostic test probes are now available that allow you to probe individual wires without leaving the wire open to the environment. These probe devices are inexpensive and easy to install, and they permanently seal the wire from corrosion.

Scheme 55

All automatic transmissions have a metal identification (ID) nameplate (1) attached to the case exterior.

Scheme 56

The Hydra-Matic® 4T40-E transmission has a metal identification nameplate (1) attached to the case exterior.

The information on the nameplate assists the technician in servicing the transmission and ordering replacement parts from a GM Parts Catalog.

Additional transmission identification information is provided on the Service Parts Identification label. This label shows the regular production options (RPO) as well as the standard and mandatory options. This label is affixed to the inside of each vehicle at the assembly plant.

Transmission General Description

The 4T40-E is a fully automatic front wheel drive electronically controlled transmission. The 4T40-E provides four forward ranges including overdrive and one reverse gear range. The PCM controls shift points by means of two shift solenoids. A vane type pump supplies the oil pressure. The PCM regulates oil pressure by means of the Pressure Control Solenoid (PCS).

You can operate the transmission in any one of the following seven modes

1. P - Park position prevents the vehicle from rolling either forward or backward. For safety reasons, use the parking brake in addition to the park position.
2. R - Reverse allows the vehicle to be operated in a rearward direction.
3. N - Neutral allows the engine to be started and operated while driving the vehicle. If necessary, you may select this position in order to restart the engine with the vehicle moving.
4. D - Overdrive is used for all normal driving conditions. Overdrive provides four gear ratios plus a converter clutch operation. Depress the accelerator in order to downshift for safe passing.
5. 3 - Drive position is used for city traffic, hilly terrain, and trailer towing. Drive provides three gear ranges and prevents the transmission from operating in fourth gear. Depress the accelerator in order to downshift.
6. 2 - Manual Second provides two gear ratios under most operating conditions. Manual Second provides acceleration and engine braking. You may select this range at any vehicle speed, but you cannot downshift the transmission into Second gear until the vehicle speed drops below approximately 100 km/h (62 mph).
7. 1 - Manual Lo provides maximum engine braking. You may select this range at any vehicle speed, but you cannot downshift the transmission into First gear until the vehicle speed drops below approximately 60 km/h (37 mph).

Transmission Component and System Description

The mechanical components of this unit are as follows

1. A torque converter with an electronically controlled capacity clutch (ECCC) This transmission is equipped with an ECCC. The pressure plate does not fully lock to the torque converter cover. Instead, the pressure plate maintains a small amount of slippage, about 20 RPM, in SECOND, THIRD, and FOURTH gears, depending on the vehicle application. ECCC was developed to reduce the possibility of noise, vibration, or chuggle caused by TCC apply. Typical apply speeds are 49-52 km/h (30-32 mph) in THIRD gear and 65-73 km/h (40-45 mph) in FOURTH gear. Full lockup is available at highway speeds on some applications.
2. A drive link assembly
3. Intermediate/4th and Lo/Reverse friction band assemblies
4. Forward, Coast, 2nd, Reverse, and Direct multiple disc clutch assemblies
5. Two planetary gear sets: Input and Reaction
6. Two roller clutches - Lo and 2nd
7. One sprag clutch
8. One vane type oil pump
9. One control valve assembly
10. A final drive and differential assembly

The electrical components of this unit are as follows

1. Two shift solenoid valves, 1-2 and 2-3
2. A torque converter clutch pulse width modulated (TCC PWM) solenoid valve
3. A transmission pressure control (PC) solenoid valve
4. An automatic transmission fluid temperature (TFT) sensor
5. Two speed sensors: input and output speed sensor
6. An automatic transmission fluid pressure (TFP) manual valve position switch assembly
7. An automatic transmission wiring harness assembly
8. A park/neutral position (PNP) switch
9. Floor shift control: includes the electronic range select mode switches

For more information refer to Electronic Component Description .

Scheme 57

The torque converter clutch (TCC) pulse width modulated (PWM) solenoid valve is a normally closed solenoid used to control the apply and release of the converter clutch. The PCM operates the solenoid with a negative duty cycle at a fixed frequency of 42 Hz to control the rate of TCC apply/release. The solenoid's ability to ramp the TCC apply and release pressures results in smoother TCC operation.

When vehicle operating conditions are appropriate to apply the TCC, the PCM immediately increases the duty cycle to approximately 42 percent. The PCM then ramps the duty cycle up to approximately 90 percent to achieve full TCC apply pressure. The rate at which the PCM increases the duty cycle controls the TCC apply. Similarly, the PCM also ramps down the TCC PWM solenoid duty cycle to control the TCC release.

Some operating conditions prevent or enable the TCC apply under various conditions. Also if the PCM receives a high voltage signal from the brake switch, indicating that the brake pedal is depressed, the PCM immediately releases the TCC.

Note that the duty cycles in the graph are for example only. Actual duty cycles vary depending on the vehicle application and the vehicle operating conditions.

The TCC PWM solenoid valve resistance should measure between 10-11 ohms when measured at 20°C (68°F). The resistance would measure approximately 16 ohms at 150°C (300°F).

Scheme 58

The pressure control (PC) solenoid valve is a precision electronic pressure regulator that controls the transmission line pressure. This control is based on the flow of current through the coil windings of the valve. As the flow of current is increased, the magnetic field which is produced by the coil moves the solenoid's plunger further away from the exhaust port. Opening the exhaust port decreases the output fluid pressure regulated by the PC solenoid valve, which ultimately decreases line pressure.

The powertrain control module (PCM) controls the PC solenoid valve based on various inputs, including throttle position, fluid temperature, manifold absolute pressure (MAP) sensor, and gear state.

The PCM controls the PC solenoid valve on a positive duty cycle at a fixed frequency of 614 Hz. Duty cycle is defined as the percent of time current is flowing through the solenoid coil during each cycle. A higher duty cycle provides a greater current flow through the solenoid. The high, positive, side of the PC solenoid valve electrical circuit at the PCM controls the PC solenoid valve operation. The PCM provides a ground path for the circuit, monitors average current and continuously varies the PC solenoid valve duty cycle to maintain the correct average current flowing through the PC solenoid valve.

Electronic Component Description

The resistance on the PC solenoid valve should measure between 3-5 ohms at 20°C (68°F).

Scheme 59

The shift solenoid valves are two identical, electronic exhaust valves that control upshifts and downshifts in all forward gear ranges. These valves are normally open. These shift solenoid valves work together in a combination of ON and OFF sequences in order to control the positions of the 1-2, 2-3, and 3-4 shift valve trains. The powertrain control module (PCM) monitors numerous inputs to determine the appropriate solenoid state combination and transmission gear for the vehicle operating conditions.

Electronic Component Description

The PCM energizes the shift solenoid valves by providing a ground to the solenoid's electrical circuit. This sends current through the coil winding of the solenoid, thereby creating a magnetic field. The magnetic field repels the plunger inside the solenoid. This seats the solenoid metering ball against the fluid inlet port. This action prevents the exhaust of fluid through the solenoid. It then provides an increase in fluid pressure at the end of the shift valves. This fluid pressure initiates an upshift by moving the shift valves. Refer to the oil flow diagrams in Unit Repair for a complete description of the hydraulic control of the shift valves for each gear range.

The resistance on the shift solenoid valves should measure between 19-24 ohms when measured at 20°C (68°F) and between 24-31 ohms when measured at 88°C (190°F).

The shift solenoid valves should energize when the voltage is greater than 7.5 volts. The shift solenoid valves should de-energize when the voltage is less than one volt.

Scheme 60

The automatic transmission fluid pressure (TFP) manual valve position switch assembly is attached to the control valve body. This assembly contains six fluid pressure switches and the automatic transmission fluid temperature sensor.

Five of the fluid pressure switches are normally-open. These are used to indicate the position of the manual valve. The PCM uses this information to control line pressure, TCC apply and release and shift solenoid operation.

The release pressure switch is used as a diagnostic tool to confirm that the TCC is actually OFF when it has been commanded OFF by the PCM. This switch is normally-closed.

Each fluid pressure switch produces either an open or a ground to the PCM depending on the presence of fluid pressure at the switches. The sequence of open and closed switches produces a combination of voltage readings. The PCM monitors these readings.

The PCM measures TFP manual valve position switch signal voltage from each pin to ground and compares the voltage to a TFP manual valve position switch combination table stored in the PCM memory. If the PCM does not recognize the switch sequence, a diagnostic code will be set as a result. A diagnostic code may also set if the TFP manual valve position switch sequence indicates a gear range selection that conflicts with other sensory inputs to the PCM.

Fluid Pressure and Circuit Combination

Valid combinations for circuits A, B, and C are shown in the table. LOW means that the switch is grounded with a resistance less than 50 ohms at 0 volts; HI means that the switch is open with a resistance greater than 50 K ohms at 12 volts.

Note that resistance should be measured with the engine running. When the transmission's pass through connector is disconnected from the vehicle harness while the engine is running, multiple diagnostic codes will set. Clear these codes when you are finished with this procedure.

Scheme 61

The automatic transmission output (shaft) speed sensor (AT OSS) is a magnetic inductive pickup that relays information relative to vehicle speed to the PCM. Vehicle speed information is used by the PCM to control shift timing, line pressure, and TCC apply and release.

The AT OSS mounts in the case at the speed sensor rotor which is pressed onto the differential. An air gap of 0.27-1.57 mm (0.011-0.062 in) is maintained between the sensor and the teeth on the speed sensor rotor. The sensor consists of a permanent magnet surrounded by a coil of wire. As the differential rotates, an AC signal is induced in the AT OSS. Higher vehicle speeds induce a higher frequency and voltage measurement at the sensor.

Sensor resistance should be 1500-1650 ohms when measured at 20°C (68°F). Output voltage will vary with speed from a minimum of 0.5 volts AC at 25 RPM to 200 volts AC at 1728 RPM.

Scheme 62

The automatic transmission input speed sensor (ISS) is a magnetic inductive pickup that relays information about the transmission input speed to the PCM. The PCM uses this information to control the line pressure, TCC apply and release, and the transmission shift patterns. This information is also used to calculate the appropriate operating gear ratios and TCC slippage.

The ISS mounts on the transmission case under the channel plate next to the drive sprocket. An air gap of 0.26-2.90 mm (0.010-0.114 in) is maintained between the sensor and the teeth of the drive sprocket. The sensor consists of a permanent magnet surrounded by a coil of wire. As the drive sprocket is driven by the turbine shaft, an AC signal is induced in the ISS. Higher engine speeds induce a higher frequency and voltage measurement at the sensor.

Sensor resistance should be 625-725 ohms when measured at 20°C (68°F). Output voltage will vary with speed from a minimum of 0.5 volts AC at 550 RPM, to 200 volts AC at 7000 RPM.

Scheme 63

The automatic transmission fluid temperature (TFT) sensor is a negative temperature coefficient thermistor that provides information to the powertrain control module (PCM) regarding the temperature of the transmission fluid. The TFT sensor (1) is integrated in the automatic transmission fluid pressure (TFP) manual valve position switch assembly which is bolted to the control valve body. The sensor monitors main line pressure from the inside of the control valve body in order to determine the operating temperature of the transmission fluid. The sensor uses an O-ring seal to maintain fluid pressure in the control valve body.

The internal electrical resistance of the sensor varies in relation to the operating temperature of the transmission fluid. The PCM sends a 5-volt reference signal to the sensor. This measures the voltage drop in the electrical circuit. A lower fluid temperature creates a higher resistance in the TFT sensor, thereby measuring a higher voltage signal.

The PCM measures this voltage as another input to help control line pressure, shift schedules and torque converter clutch (TCC) apply. When the TFT reaches 140°C (284°F), the PCM enters hot mode. Above this temperature the PCM modifies the transmission shift schedules and TCC apply in an attempt to reduce fluid temperature by reducing the amount of heat generated by the transmission. During hot mode the PCM applies TCC at all times in Third and Fourth gears. Also, the PCM performs the 2-3 and the 3-4 shifts earlier in order to help reduce the generation of fluid heat. Refer to Transmission Fluid Temperature (TFT) Sensor Specifications .

Scheme 64

The transmission range (TR) switch is part of the park/neutral position (PNP) and back-up lamp switch assembly (1), which is externally mounted on the transmission manual shaft. The TR switch contains four internal switches that indicate the transmission gear range selector lever position. The PCM supplies ignition voltage to each switch circuit. By grounding one or more of the switch circuits, the PCM detects the selected gear range by the state change of the switch input. Refer to Transmission Range Switch Logic . Switch input to the PCM is represented on the scan tool as HI and LOW. HI indicates an ignition voltage signal. LOW indicates a zero voltage signal. The four parameters represent transmission range switch signal A,B,C and Parity.

Scheme 65

The floor shift control is located in the center console assembly. It contains the upshift and downshift switches for the electronic range select mode system. The electronic range select mode system is activated when the floor shift control lever is moved to the right into the Low (L) position from the drive position. When the manual position is selected, an upshift is requested by pushing the upshift switch on the floor shift control lever and a downshift is requested by pushing the downshift switch on the floor shift control lever. When an upshift or a downshift is requested, a signal is sent to the TCM which commands the shift solenoids ON or OFF to achieve the appropriate gear.

Scheme 66

The transmission electrical connector is an important part of the transmission operating system. Any interference with the electrical connection can cause the transmission to set diagnostic trouble codes or affect proper operation.

The following items can affect the electrical connection

1. Bent pins in the connector from rough handling during connection and disconnection
2. Wires backing away from the pins or coming uncrimped, in either the internal or the external wiring harness
3. Dirt contamination entering the connector when disconnected
4. Pins in the internal wiring connector backing out of the connector or pushed out of the connector during reconnection
5. Transmission fluid leaking into the connector, wicking up into the external wiring harness and degrading the wire insulation
6. Moisture intrusion in the connector
7. Low pin retention in the external connector from excessive connection and disconnection of the wiring connector assembly
8. Pin corrosion from contamination
9. Damaged connector assembly

Remember the following points

1. In order to remove the connector, squeeze the two tabs toward each other and pull straight up without pulling by the wires.
2. Limit twisting or wiggling the connector during removal. Bent pins can occur.
3. Do not pry the connector off with a screwdriver or other tool.
4. Visually inspect the seals to ensure that they are not damaged during handling.
5. In order to reinstall the external wiring connector, first orient the pins by lining up the arrows on each half of the connector. Push the connector straight down into the transmission without twisting or angling the mating parts.
6. The connector should click into place with a positive feel and/or noise.
7. Whenever the transmission external wiring connector is disconnected from the internal harness and the engine is operating, DTCs will set. Clear these DTCs after reconnecting the external connector.

Special Tools

Special Tools Illustration Tool Number/Description Scan Tool J 6125-1B Slide Hammer J 23129 Universal Seal Remover J 35616-B GM-Approved Terminal Test Kit J 35944-A Transmission Oil Cooler and Line Flusher J 35944-22 Transmission Oil Cooler Flushing Fluid J 35944-440 Cooler Flushing Adapter J 36346 Facia Retainer Remover J 38868 Output Shaft Assembly Remover and Installer J 39200 Digital Multimeter (DMM) J 41101 Transaxle Connector Remover J 41102 Axle Seal Installer J 41227 Output Shaft Sleeve Remover J 41228 Output Shaft Sleeve Installer J 41239-1 Cooler Line Seal Installer J 41239-10 Cooler Line Seal Remover J 41545 Park/Neutral Switch Aligner J 43653 Flywheel Holding Tool J 44152 Jumper Harness (20 pins) J 44246 Solenoid Testing Kit J 45096 Transmission Oil Cooling System Flush and Flow Test Tool J 45201 Cooler Line Seal Remover J 45239 Needle Bearing Installer

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Scheme 76

See also:
• Console Replacement
• Fastener Notice
• Transmission Fluid Checking Procedure
• Lifting and Jacking the Vehicle
• Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement
• Front Fender Liner Replacement
• Battery Tray Replacement
• Engine Support Fixture
• Tire and Wheel Removal and Installation
• Lower Control Arm Replacement
• Wheel Drive Shaft Replacement
• Power Steering Gear Replacement
• Frame Replacement (W/L61)
• Capacities - Approximate Fluid
• Radiator Air Baffle and Deflector Replacement - Lower
• Park Lock Cable Adjustment
• Special Tools and Equipment
• Shift Control Cable Adjustment
• Transmission Fluid Temperature (TFT) Sensor Specifications
• Transmission Range Switch Logic