Automatic Transaxle Overhaul & Testing - 4T40-E: Diagnosis Oldsmobile Cutlass VI

TROUBLE SHOOTING

Note. For testing and diagnostic procedures of electronic components, see AUTO TRANS DIAGNOSIS - 4T40-E article.

Note. For clutch and band applications, see the CLUTCH & BAND APPLICATION CHART under TROUBLE SHOOTING.

ELECTRONIC SELF-DIAGNOSTICS & ELECTRONIC TESTING

Note. See AUTO TRANS DIAGNOSIS - 4T40-E article.

ROAD TEST

Note. Shift speed charts reference throttle position angle instead of minimum or wide open throttle position. This measurement is more accurate. A scan tool should be used to monitor throttle position angle. For transaxle model code, refer to metal identification plate attached to transaxle.

HYDRAULIC PRESSURE TEST

1. Before performing hydraulic pressure test, check fluid level and condition. Check manual control linkages for correct adjustment, and ensure engine is properly tuned.
2. Connect scan tool to Data Link Connector (DLC). Apply parking brake and start engine. Check for stored trouble codes. If trouble codes are present, diagnose as necessary. See AUTO TRANS DIAGNOSIS - 4T40-E article. Turn engine off. Connect oil pressure gauge to line pressure test port. (Scheme 23)
3. Start engine and warm to normal operating temperature. With vehicle in Reverse, line pressure should be 58-186 psi (400-1282 kPa). With vehicle in Park, Neutral or Drive, line pressure should be 50-160 psi (345-1103 kPa).
4. Shift transaxle into Park. Access Pressure Control Solenoid (PCS) test on scan tool. Increase DESIRED PCS in 0.1 amp increments and read corresponding line pressure on oil pressure gauge. Allow pressure to stabilize for 5 seconds after each current change. Compare readings to «LINE PRESSURE SPECIFICATIONS»(ref-124186-S38040418302001100100000) table. If pressure readings are not as specified, and no trouble codes are present, internal malfunction exists. See «TROUBLE SHOOTING»(ref-124186-S16985840282001100100000).

Note. Scan tool is only able to control pressure control solenoid in Park and Neutral with vehicle stopped. This protects clutches from extremely high or low pressures in Reverse and Drive.

LINE PRESSURE SPECIFICATIONS

Scheme 23

TCC TESTING

Note. For TCC component testing, see AUTO TRANS DIAGNOSIS - 4T40-E article.

Cleaning & Inspection

Prior to transaxle reassembly, clean transaxle case thoroughly with solvent and air dry. Inspect transaxle case for damage to band lugs, snap ring grooves and bushings. Check for interconnected or damaged oil passages and servo bores. Inspect case for stripped threads in bolt holes or casting porosity. Repair or replace case if necessary.

Note. DO NOT remove actuator guide unless replacement is necessary.

Disassembly & Inspection

1. Place differential and final drive assembly in clean drain pan to prevent needle bearings from being lost if pinion gears are removed. Using a pin punch, remove differential pinion shaft retaining pin. Remove differential pinion shaft. Remove snap ring from end of output shaft and remove output shaft from differential carrier. Discard snap ring.
2. Remove final drive sun gear. Remove differential pinion gears and thrust washers. Remove differential side gears and thrust washers. see scheme 22 Remove final drive carrier spiral retaining ring. NOTE: Note position of pinion gears when removing. Pinion gears should be installed in same direction as removed. Installing pinion gear upside down may cause noise due to change in set wear pattern.
3. Remove 4 planet pinion pins, 4 pinion gears, pinion thrust washers, needle roller bearings and needle bearing spacers. Remove final drive sun gear-to-carrier thrust bearing. see scheme 22
4. Inspect needle bearings, thrust washers, pinion gears and planet pinion pins for excessive wear. Polishing is normal condition for pinion pins and needle bearings. Inspect pinion shaft for spalling or wear. Inspect thrust washers for wear and cracks. Clean and dry final drive carrier and final drive components.

Inspection

Inspect all components for excessive wear or damage. Inspect snap ring for over extension and seal grooves for damage. Check for signs of excessive bearing or bushing wear. Check splines and park lock gear teeth for cracks or excessive wear. Ensure fluid feed holes are not plugged.

Clean all parts and dry with compressed air. Inspect all components for excessive wear or damage. Ensure fluid feed holes and retainer and ball assembly are not plugged. Inspect piston for damage. Inspect for cut seal. Repair or replace components as necessary.

Inspect input internal gear and forward clutch hub splines, bushing and thrust washer for excessive wear or damage. Clean all parts and dry with compressed air.

1. Check input carrier assembly pinion gears for excessive end play. Using a feeler gauge, measure end play clearance between carrier and pinion gear thrust washer. see scheme 28 End play should be.009-.027" (.23-.69 mm). Replace carrier if pinion gear clearance is not within specification. Pinion gears are permanently assembled to carrier and are not serviceable.
2. Inspect reaction internal gear and input carrier assembly for excessive wear or damage. Inspect condition of pinion gears, washers and bearings. Clean all parts and dry with compressed air.

1. Check clutch spring assemblies for distortion or missing springs. Check oil passages for blockage. Check bushings and bearings for excessive wear. Inspect seal grooves on input shaft for nicks or damage.
2. Inspect piston assemblies for cut seals or damage. If pistons or seals are damaged, assembly must be replaced. Check coast and direct clutch retainer and ball assemblies for leaks or damage. Check splines, housings and clutch plates for cracks, excessive wear or damage. Clean all parts and dry with compressed air. Replace components as necessary.
3. Measure reaction carrier pinion gears for excessive end play. Using a feeler gauge, measure end play clearance between carrier and pinion gear thrust washer. see scheme 28 End play should be.009-.027" (.23-.69 mm). Replace carrier if pinion gear clearance is not within specification. Pinion gears are permanently assembled to carrier and are not serviceable.

Scheme 24

Scheme 25

1. Install coast clutch piston assembly into input housing. Lubricate piston seal with transaxle fluid prior to installation. Install coast clutch release spring and spring retainer into input housing. (Scheme 24) Spring retainer must be assembled with inner lip facing up.
2. Compress release spring assembly and install snap ring onto input housing. Remove spring compressor. Install direct clutch piston assembly into input housing. Lubricate piston seal with transaxle fluid prior to installation. Install direct clutch spring and retainer assembly into input housing with snap ring tabs facing up. Compress spring and retainer assembly and install snap ring into input housing. Remove spring compressor.
3. Install coast clutch plates into input housing. Start with steel plate and alternate between 4 steel and 4 NEW friction plates. Steel plates must be assembled with splines in input housing grooves that are machined to piston.
4. Place sprag outer race on bench with flat side down and end with snap ring groove up. Place one end bearing into outer race. Install sprag clutch into sprag outer race with grooved edge up and flat side down. Rotate sprag slowly during assembly. Install other end bearing on top of sprag clutch.
5. Install snap ring into sprag outer race to retain sprag assembly and end bearings. Install sprag clutch and outer race assembly onto input sun gear shaft. Snap ring side of assembly faces up when installing sprag clutch onto input sun gear shaft. Flat side of sprag outer race functions as backing plate for coast clutch. Rotate input sun gear shaft clockwise during assembly to help seat sprags.
6. Ensure correct operation of sprag clutch by holding sprag clutch outer race and rotating input sun gear shaft. Input sun gear shaft should only rotate in clockwise direction. (Scheme 25)
7. Coat thrust bearing with petroleum jelly. Install thrust bearing on back side of input sun gear shaft. Install input sun gear shaft and sprag clutch assembly into input housing. Splines on input sun gear shaft engage with coast clutch friction plates.
8. Install direct clutch plates into input housing. Start with steel plate and alternate between steel plate and NEW friction plates. Ensure same number of steel and friction plates removed are reinstalled. Install direct clutch backing plate onto input housing with flat side down.
9. Install snap ring to retain input sun gear shaft, sprag clutch assembly and direct clutch plates. Coat thrust bearing with petroleum jelly. Install thrust bearing on top of sprag clutch assembly. Install reaction carrier shaft and shell assembly onto input housing. Splines on inside of shell engage direct clutch friction plates.
10. Install thrust bearing onto top of reaction carrier shaft and shell assembly. Install reaction carrier sun gear and shell assembly onto reaction shaft shell. Install reaction carrier assembly onto reaction sun gear. Rotate reaction carrier assembly to mesh sun gear with pinion gears.
11. Install reaction carrier assembly-to-input sun gear thrust bearing onto reaction carrier assembly. Install input sun gear onto input sun gear shaft. Install input sun gear snap ring onto input sun gear shaft.
12. Install 4 NEW Teflon seals onto input shaft. Install seal closest to housing first. Coat seal installer with transaxle fluid. Slide seal installer over input shaft and position at seal groove. Guide NEW seal onto seal installer and slide seal into groove. (Scheme 26)
13. After all seals are installed, use Seal Sizer Tool (J-41234-3) to size seals. Leave tool in place for at least 5 minutes. If possible, leave tool in place until assembly is ready to be installed in transaxle case.
14. Air check coast clutch and direct clutch to ensure proper operation of seals and clutch assemblies. Apply compressed air to specified location to check component operation. (Scheme 27) If clutch assemblies do not operate properly, check component installation.
15. Install coast clutch, direct clutch and reaction carrier assembly into transaxle case. Measure clutch assembly end play. Place gauge block across machined surface of transaxle case. (Scheme 28) Measure distance between top of coast and direct clutch housing and machined surface of transaxle case (Dimension "A"). Choose correct selective thrust washer. See «SELECTIVE THRUST WASHER IDENTIFICATION»(ref-124186-S14042785292001100100000) table.
16. Install selective thrust washer onto top of input housing. Tab on thrust washer must be located in recessed area for retainer and ball assembly. Install thrust bearing over input shaft and onto top of selective thrust washer.

SELECTIVE THRUST WASHER IDENTIFICATION

Scheme 26

Scheme 27

Scheme 28

Check reverse clutch housing for excessive band wear and damaged splines. Check retainer and ball assembly for clogging or damage. Ensure fluid feed holes are not plugged. Check bushings and roller clutch for excessive wear. Check spring assembly for dislocated or damaged springs. Clean all parts and dry with compressed air.

Scheme 29

1. Install NEW reverse clutch inner seal assembly using arbor press and seal installer if seal was removed or damaged. Install reverse clutch piston assembly. Lubricate seal with transaxle fluid prior to installation. Install reverse clutch spring and retainer assembly with smaller outside diameter facing down.
2. Compress reverse clutch spring and retainer assembly and install snap ring. Install reverse clutch plates into clutch housing. Install waved plate, then alternate between steel plates and NEW friction plates.
3. Measure distance between top of snap ring groove and top friction plate (Dimension "A"). (Scheme 29) Select appropriate backing plate. See «BACKING PLATE IDENTIFICATION»(ref-124186-S09289582262001100100000) table. Backing plate identification letter is stamped on beveled side of backing plate. Install appropriate reverse clutch backing plate with beveled side facing up. Install snap ring in reverse clutch housing to retain reverse clutch plates. BACKING PLATE IDENTIFICATION Backing Plate ID Letter Dimension "A" A.35-.37" (8.89-9.40 mm) B.37-.39" (9.40-9.91 mm) C.39-.41" (9.91-10.41 mm)
4. Air check reverse clutch assembly to ensure proper operation of seals and clutch assembly. Apply 40 psi of compressed air to specified location to check component operation. (Scheme 29) If clutch assembly does not operate properly, check component installation.
5. Install 2nd roller clutch assembly into roller clutch cam. Install 2nd roller clutch onto reverse clutch housing with flat side of roller clutch cam facing down toward housing. Rotate roller clutch during assembly to properly engage rollers.
6. Ensure roller clutch operates properly. While holding reverse clutch housing, roller clutch cam should only rotate clockwise. (Scheme 30) Install NEW 2nd roller clutch retainer onto 2nd roller clutch assembly. Using Installer (J-41235), press retainer and roller clutch assembly into place on reverse clutch housing and roller clutch inner race. NOTE: Installer (J-41235) is designed to press roller clutch assembly to a specified depth. If 2nd roller clutch is installed too far down onto inner race, roller clutch may not operate properly.
7. Install reverse clutch and 2nd roller clutch assembly into transaxle case. see scheme 6 Tangs on reverse clutch housing spline to tangs on reaction carrier sun gear and shell assembly. Rotate reverse clutch housing during installation to align clutch plates. Install reverse clutch thrust washer onto top of 2nd roller clutch with tabs facing down onto housing.

Scheme 30

Check clutch plates for excessive wear and replace as necessary. Clean parts and dry with compressed air.

1. Check piston and seal assembly for damage. If seal is damaged, replace piston and seal assembly. Check bushing and bearing for excessive wear or damage. Check driven sprocket support for plugged feed holes, damaged seal grooves, stripped bolt holes or damaged machined surfaces. Check for dislocated or damaged springs.
2. Inspect valve assembly for free operation. Use ATF to inspect for valve leakage. Ensure valve is in fully seated position prior to checking for leaks. see scheme 38 Remove valve using 1/4" drift and mallet only if inspection indicates a problem or a leak is detected. Clean all parts and dry with compressed air.

Check drive sprocket, driven sprocket, drive link assembly, thrust washers and input shaft for excessive wear or damage. Check seal grooves for damage. Clean all parts and dry with compressed air.

Check channel plate for plugged passages or damage. Check accumulator assist springs, pistons and pins for damage. Check channel plate sleeve for input shaft wear. Check surfaces for nicks or scratches which could cause fluid leaks. Check manual valve for free movement. Clean all parts and dry with compressed air.

Check spacer plate and spacer plate filter for damage or debris. Clean all parts and dry with compressed air.

Check valve body passages for debris and machined surfaces for nicks or scratches. Check valves for nicks or scratches which may result in valves sticking or fluid leaks. Check springs, bushings, "O" rings and solenoids for damage. Clean all components and dry with compressed air. NEVER use shop towels to clean valve body components.

Check bearing on flange for excessive wear or damage. Check machined surfaces for scratches or nicks which may cause fluid leaks. Thoroughly flush oil pump assembly with clean transaxle fluid through pump inlet and outlet passages. While flushing pump, use oil pump drive shaft to rotate oil pump rotor. Allow excess fluid to drain from oil pump assembly.

Check side cover for cracks or damage to seal grooves and mounting bosses. Check side cover gasket for damage. Gaskets are reusable if not damaged. During initial assembly, side cover gaskets are glued into place. Thoroughly clean side cover and gaskets prior to reassembly. Clean and dry gasket grooves and axle shaft bore.

Check output shaft for damage to splines, snap ring grooves and journals. Clean output shaft and dry with compressed air.

Note. Sleeve Installer (J-41228) must be used to install sleeve onto output and stub shafts. Fluid leak may occur if installer is not used.

Check stub shaft for damage to splines, snap ring grooves and journals. Check sleeve for excessive wear, scratches or nicks which may cause a fluid leak or damage to seal. If sleeve appears damaged, replace using procedure for output shaft. See OUTPUT SHAFT & SLEEVE ASSEMBLY . Clean stub shaft and dry with compressed air.

Inspection & Reassembly

Check vehicle speed sensor for damage to sensor or electrical connector. Install NEW "O" ring on speed sensor. Install speed sensor into transaxle case. see scheme 6 Install speed sensor stud and tighten to specification. See TORQUE SPECIFICATIONS.

Check all components for damage. Ensure fluid feed holes are not plugged. Check seal grooves for damage. Clean all parts and dry with compressed air.

Check oil feed tubes for plugged passages, bent tubes or cracks. Check oil feed tube seals. Verify proper location of seals. Replace seals only if they are cut, swelled or damaged. Oil feed tube seals are glued into place during initial assembly. If a seal needs replacement, thoroughly clean any residual glue from oil feed tubes. Clean tubes and dry with compressed air.

Check oil pan for cracks, dents or damage to gasket sealing surface. Check gasket for cuts or damage. Bottom pan gasket may be reused if it is not damaged. Clean pan and gasket and dry with compressed air.