Automatic Transaxle Overhaul & Testing - 4T40-E & 4T45-E: Other Daewoo Nubira II

GEAR RATIOS

TRANSAXLE GEAR RATIOS

REAR SECTION

1. Thoroughly clean transaxle exterior. Drain fluid, and remove torque converter. Remove input shaft "O" ring from input shaft. Place transaxle in holding fixture. Remove and discard snap ring from end of axle stub shaft. Attach slide hammer to shaft removal tool.
2. Install shaft removal tool into snap ring groove on stub shaft. Secure removal tool to stub shaft. Pull on stub shaft and rotate until stub shaft snap ring at differential seats in taper on differential side gear. Pull stub shaft out using slide hammer.

LOWER SECTION

1. Remove output speed sensor stud, output speed sensor and "O" ring. (Scheme 42) Rotate transaxle so case side cover is facing upward to drain most transaxle fluid through stub shaft end of transaxle. Rotate transaxle with oil pan facing upward.
2. Remove bottom oil pan and gasket. Remove oil level control valve. Remove oil filter and filter seal from transaxle case. Remove 4 oil feed tube bolts and oil feed tube assembly. Feed tube seal rings are glued in place and should remain with feed tube assembly. Seal rings are reusable.

Scheme 42

CASE SIDE COVER

Rotate transaxle so case side cover is facing upward. Remove side cover bolts and/or studs. Remove transaxle side cover. Remove 2 side cover gaskets and side cover-to-driven sprocket support thrust washer, if not removed with side cover. (Scheme 42)

OUTPUT SHAFT SLEEVE

Remove snap ring from output shaft. Install legs of Output Shaft Sleeve Puller (J-41227) under output shaft sleeve. (Scheme 43) Tighten center bolt of output shaft sleeve puller to remove output shaft sleeve. Discard output shaft sleeve.

Scheme 43

OIL PUMP & CONTROL VALVE

Note. For oil pump, control valve assembly and channel plate bolt identification and length, see BOLT IDENTIFICATION table.

1. Remove 8 bolts from oil pump. (Scheme 44) Remove oil pump assembly and oil pump shaft. Disconnect wiring harness connectors from Pressure Switch Assembly (PSA), Pressure Control Solenoid (PCS), TCC solenoid and shift solenoids.
2. Remove 6 bolts from Transmission Fluid Pressure (TFP) switch assembly. Remove TFP switch assembly from control valve assembly. Pressure switch "O" rings are reusable and should remain with pressure switch assembly. Remove 12 remaining control valve assembly bolts. Remove control valve assembly and valve body-to-spacer plate gasket. Discard gasket. (Scheme 42)
3. Remove 2 spacer plate support bolts and spacer plate support. Remove spacer plate with spacer plate filter attached. Remove and discard spacer plate-to-channel plate gasket. Remove 7 check balls in channel plate. (Scheme 45) DO NOT use a magnet to remove check balls. Magnet may cause check balls to become magnetized and attract metallic particles.

BOLT IDENTIFICATION (1)

Scheme 44

Scheme 45

CHANNEL PLATE, GASKET & ACCUMULATORS

Disconnect manual valve clip and link from manual valve. (Scheme 46)

Remove 10 channel plate bolts. (Scheme 44) Remove channel plate assembly with drive sprocket-to-channel plate thrust washer, accumulator pistons and pins, manual valve and detent lever spring and bolt. Remove and discard channel plate-to-case gasket. Remove 3 accumulator springs from case. (Scheme 47)

Scheme 46

Scheme 47

DRIVE & DRIVEN SPROCKETS, & DRIVE LINK

Lift and remove drive sprocket, driven sprocket and drive link assembly as a complete unit. (Scheme 48) Note direction chain is facing when removed. Chain should be installed in same direction during assembly to prevent excessive noise. Remove drive sprocket-to-drive sprocket support thrust washer. Driven sprocket-to-driven sprocket support thrust washer should remain with driven sprocket support assembly.

Scheme 48

FORWARD CLUTCH

1. Remove snap ring from clutch housing assembly. Remove backing plate, 7 friction plates, 7 steel plates and one waved plate. (Scheme 49) Using Spring Compressor (J-23327), compress forward clutch return spring assembly. Remove snap ring and spring compressor.
2. Remove forward clutch return spring assembly. Remove forward clutch piston assembly. Inspect forward clutch inner sleeve and seal assembly for damage. If inner sleeve and seal assembly is damaged, place Disc (J-41097-2) on inner hub of clutch housing. Install puller with jaws aligned with slots in inner sleeve and seal assembly. Remove inner sleeve and seal assembly.

Scheme 49

CONTROL VALVE BODY

Note. Each valve is held in control valve body by a retainer clip. Clip can be removed using screwdriver. Use care not to score valve body when removing clips and valves. Ensure each valve moves freely in valve body bore prior to disassembly.