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

SERVO ASSEMBLIES

Remove 3 bolts from intermediate/4th servo, and low and reverse covers. Remove servo cover, servo piston and servo return spring. see scheme 6

OIL PUMP & CONTROL VALVE ASSEMBLY

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 31) 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 pressure switch assembly. Remove pressure switch assembly from control valve assembly. Pressure switch "O" rings are reusable and should remain with pressure switch assembly. Remove remaining 12 control valve assembly bolts. Remove control valve assembly and valve body-to-spacer plate gasket. Discard gasket. see scheme 6
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 32) 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 31

Scheme 32

DRIVE & DRIVEN SPROCKETS, & DRIVE LINK ASSEMBLY

Lift and remove drive sprocket, driven sprocket and drive link assembly as a complete unit. 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-support thrust washer should remain with driven sprocket support assembly. (Scheme 33)

Scheme 33

COMPONENT DISASSEMBLY, REASSEMBLY & TRANSAXLE REASSEMBLY

Note. Following procedures also include transaxle reassembly. Transaxle components are installed into transaxle as components are reassembled. For component seal, thrust bearing and thrust washer locations (Scheme 52)and (Scheme 53).

Actuator Guide (Disassembly & Reassembly)

1. Remove actuator guide roll pin from case. Remove actuator guide and seal from transaxle case by tapping guide into transaxle case. (Scheme 34)
2. Install NEW seal on actuator guide. Install actuator guide into transaxle case. Install actuator guide roll pin into transaxle case to secure actuator guide.

Drive Sprocket Support (Disassembly & Reassembly)

1. If removal of drive sprocket bearing from drive sprocket is necessary, use appropriate bearing puller and slide hammer. Remove support bearing and install NEW bearing.
2. Inspect drive sprocket support for damage to stator shaft splines, journals and bushings. Also inspect converter seal drain holes for blockage. If drive sprocket support replacement is necessary, remove attaching screws and remove support. Install drive sprocket support and tighten attaching screws to specification. See «TORQUE SPECIFICATIONS»(ref-124186-S28272405882001100100000) . Install NEW torque converter seal using appropriate seal installer.

Transaxle Cooler Line Seals (Reassembly)

Seals were removed during transaxle disassembly procedure. For reassembly, place NEW seal in transaxle case bore. Position Seal Installer (J-41239-1) on transaxle case at cooler line bracket bolt hole. Press seal into case by tightening seal pressing bolt on tool until seal bottoms out in case bore.

Manual Shaft, Detent Lever & Actuator Rod (Reassembly)

Components were removed during transaxle disassembly. For component reassembly, install NEW manual shaft seal into transaxle case using 13 mm socket. Install manual shaft and detent lever assembly into transaxle case with manual valve to detent lever link and parking lock actuator assembly attached. see scheme 17 Ensure parking lock actuator rod is positioned properly into actuator guide. Using Height Tool(J-41229), install manual shaft-to-case pin. (Scheme 35)

Note. Manual shaft pin must be installed to correct height to properly secure manual shaft. Tool provides correct installation height. If pin is installed too deep, pin will crack case boss.

Scheme 34

Scheme 35

Reassembly

1. Install needle bearing spacer onto planet pinion gear. Spacer must be assembled between 2 rows of needle bearings. To aid in assembly of needle bearings, place spacer and pinion gear onto planet pinion pin. Install needle roller bearings one at a time into planet pinion. Place thrust washer on bottom of pinion to retain bottom row of needle bearings. Use petroleum jelly to keep bearings in place.
2. Install sun gear-to-final drive carrier thrust bearing onto final drive carrier. Use petroleum jelly to position thrust bearing. Assemble pinion gear thrust washers and planet pinion gears into final drive carrier. Pinion gears should be assembled in same direction as removed to prevent noise due to change in gear wear pattern.
3. Install planet pinion pins into final drive carrier to retain planet pinion gears. Install final drive carrier spiral retaining ring to retain planet pinion pins. Check final drive carrier pinion gears for excessive end play. Use a feeler gauge and measure end play clearance between carrier and pinion gear thrust washer. (Scheme 42) End play should be.009-.025" (.23-.64 mm). Replace components as necessary.
4. Install thrust washers onto differential side gears and install gears into final drive carrier. Using petroleum jelly, position thrust washers onto pinion gears. Install pinion gears and washers onto final drive carrier.
5. Rotate pinion gears into position and install pinion shaft through final drive carrier and pinion gears. Position of pinion shaft must allow retaining pin to be installed. Tap retaining pin into position using a plastic hammer.
6. Install fretting ring into small groove in transaxle case (if removed). Install final drive internal gear into transaxle case. Install final drive carrier-to-case thrust bearing onto final drive carrier. Retain bearing with petroleum jelly. Install final drive carrier assembly into transaxle case. Install final drive sun gear into final drive carrier. Sun gear must be installed with grooved side up (flat side down).

Scheme 36

Disassembly

Remove roller clutch assembly from forward clutch support. Turn roller clutch assembly clockwise while gently lifting up. Remove thrust bearing from forward clutch support. (Scheme 37) Remove final drive sun gear shaft snap ring. Remove park lock gear. Remove forward clutch support-to-park lock gear thrust bearing. Remove forward clutch support from final drive sun gear shaft. Remove and discard 2 seal rings from forward clutch support.

Note. Parking pawl pin has a pressed fit into forward clutch support. Pin is not serviceable and should not be removed.

1. Install 2 NEW seal rings on forward clutch support. Install forward clutch support onto final drive sun gear shaft. Install thrust bearing onto forward clutch support.
2. Install park lock gear onto final drive sun gear shaft with raised inner boss facing up so that parking pawl properly engages teeth on park lock gear. Install snap ring to final drive sun gear shaft to retain park lock gear. (Scheme 37) Ensure clearance between park lock gear and snap ring is.12" (3 mm).
3. Install low roller clutch assembly onto forward clutch support. Larger tabs on cage must face down into forward clutch support. Rotate cage slightly counterclockwise to lock tabs into grooves in forward clutch support. Install thrust bearing onto forward clutch support.
4. Install forward clutch support and low roller clutch assembly into transaxle case. Compress parking pawl return spring and line up parking pawl with park lock gear. Install forward clutch support snap ring into transaxle case with chamfer side up. Snap ring opening must be toward bottom of transaxle case facing bottom pan. Use a screwdriver to set snap ring into place.

Scheme 37

FORWARD CLUTCH ASSEMBLY

1. Remove snap ring from clutch housing assembly. Remove backing plate, 7 friction plates, 7 steel plates and one waved plate. (Scheme 38) 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 seal assembly for damage. If seal is damaged, place Disc (J-41097) on inner hub of clutch housing. Use puller to remove inner seal.

1. Install NEW inner seal if old seal was removed or damaged. Using arbor press and seal installer, press inner seal onto forward clutch housing inner hub. Install forward clutch piston assembly into forward clutch housing. Lubricate seals with transaxle fluid prior to installation.
2. Install forward clutch return spring assembly into forward clutch housing with snap ring tabs facing up. Compress return spring assembly and install snap ring. Remove spring compressor. Install forward clutch waved plate. Install remaining clutch plates starting with steel plate and alternating between steel and friction plates.
3. Install forward clutch backing plate. Install snap ring to retain clutch plates. Using compressed air, air check forward clutch to verify proper operation of seals and clutch assembly. Apply compressed air at specified location. (Scheme 39) If clutch assembly does not operate properly, check component installation.
4. Install low and reverse band into transaxle case. Align band servo pin apply surface toward bottom pan and hook band into band anchor pin in transaxle case. Install forward clutch assembly into transaxle case. Rotate forward clutch assembly counterclockwise during assembly to seat clutch assembly into low roller clutch. When assembly is seated properly, forward clutch assembly should not turn clockwise.
5. Verify proper installation of low and reverse band by inserting screwdriver through reverse servo pin hole. Screwdriver should compress band around forward clutch housing.

Scheme 38

Scheme 39

Remove thrust washer from forward clutch hub (if necessary). Remove input internal gear-to-forward clutch hub assembly snap ring. Remove forward clutch hub from input internal gear. (Scheme 40)

Install forward clutch hub onto input internal gear and retain hub with snap ring. Coat thrust washer with petroleum jelly. Install thrust washer onto forward clutch hub with thrust washer tabs toward forward clutch hub. Install forward clutch hub and input internal gear assembly into transaxle case. see scheme 6 Rotate assembly while installing to align forward clutch hub spline with forward clutch plates.

Scheme 40

Remove thrust bearing from reaction carrier (if necessary). Remove reaction internal gear-to-input carrier assembly snap ring. Remove input carrier assembly from reaction internal gear. (Scheme 41)

Install input carrier assembly to reaction internal gear and retain with snap ring. Coat thrust bearing with petroleum jelly. Install thrust bearing onto input carrier assembly. Second thrust bearing is permanently retained in input carrier assembly. Install reaction internal gear and input carrier assembly into transaxle case. see scheme 6 Rotate assembly while installing to mesh input carrier pinion gears to input internal gear.

Scheme 41

Scheme 42

1. Remove selective thrust bearing and thrust washer from input shaft. Remove input sun gear-to-input sun gear shaft snap ring. Remove input sun gear from input sun gear shaft. Remove thrust bearing from reaction carrier assembly. see scheme 29
2. Remove reaction carrier assembly. Thrust bearing is permanently installed in reaction carrier assembly under pinion gears. Remove reaction sun gear and shell assembly. Remove thrust bearing from reaction carrier shaft and shell assembly. Remove reaction carrier shaft and shell assembly. Remove thrust bearing from top of sprag race assembly.
3. Remove coast and direct clutch snap ring. Remove direct clutch plates from clutch input housing. Note number and sequence of plates during removal for reassembly reference. Number of clutch plates may vary depending on vehicle model. Direct clutch consists of a backing plate, steel plates and friction plates.
4. Remove input sun gear shaft and sprag as an assembly by lifting up on input sun gear shaft. Remove inner race-to-input housing thrust bearing from input housing, if necessary. Bearing may remain with input sun gear shaft and sprag when assembly is removed. Remove coast clutch plates from input housing. Coast clutch consists of 4 steel plates and 4 friction plates. see scheme 29
5. Compress direct clutch spring and retainer assembly. Remove retainer ring and spring compressor. Remove direct clutch spring and retainer assembly. Remove direct clutch piston assembly.
6. Compress coast clutch release spring assembly. Remove snap ring and spring compressor. Remove coast clutch release spring retainer and release spring. Remove coast clutch piston assembly. Remove and discard 4 Teflon oil seal rings from input shaft assembly.
7. Remove input sprag assembly from input sun gear shaft. Remove snap ring from sprag assembly. Remove sprag clutch assembly from sprag outer race. Remove 2 end bearings from sprag clutch assembly. see scheme 29

1. Remove reverse clutch snap ring. Remove reverse clutch selective backing plate, 3 steel plates, 3 friction plates and waved plate. Compress reverse clutch spring and retainer assembly. Remove snap ring and spring compressor. Remove reverse clutch spring and retainer assembly. Remove reverse clutch piston assembly.
2. Inspect reverse clutch inner seal for damage. DO NOT remove seal assembly if seal is not damaged. If seal is damaged, place Disc (J-41097) on inner hub of clutch housing. Remove seal.
3. Remove 2nd roller clutch and roller clutch retainer by prying up on roller clutch assembly with 2 screwdrivers. DO NOT score roller clutch inner race with screwdrivers. The 2nd roller clutch retainer is pressed onto reverse clutch housing and is not reusable after being removed. Remove 2nd roller clutch assembly from inside of roller clutch cam. (Scheme 43)

Scheme 43

Install NEW intermediate/4th band into transaxle case. see scheme 6 Ensure band is positioned properly by inserting screwdriver through intermediate/4th servo bore. Screwdriver should press on servo pin rest and compress band around reverse clutch housing.

Install 2nd clutch backing plate with flat side facing up. Install 2nd clutch plates into transaxle case. see scheme 15 Install NEW friction plate and alternate between friction plates and steel plates. Install 2nd clutch waved plate.

Remove and discard 2 seal rings. Compress 2nd clutch spring assembly and remove retaining ring. Remove spring compressor and 2nd clutch spring assembly. Remove 2nd clutch piston and seal assembly. (Scheme 44) Piston and seal assembly are reusable if not damaged.

1. Install 2nd clutch piston and seal assembly into driven sprocket support. Lubricate seal with transaxle fluid prior to installation. Install 2nd clutch spring assembly into driven sprocket support.
2. Compress 2nd clutch spring assembly and install retaining ring. Install 2 NEW seal rings onto driven sprocket support. Air check 2nd clutch to ensure proper operation. Apply compressed air to 2nd clutch fluid circuit. (Scheme 45) If clutch assembly does not operate properly, check component installation.
3. Install driven sprocket support and 2nd clutch assembly into transaxle case. When installed properly, driven sprocket support will sit slightly below machined surface of transaxle case.

Scheme 44

Scheme 45

1. Install input speed sensor into transaxle case. Tab on sensor housing fits into recess on transaxle case boss. Position of input speed sensor depends on number of teeth on drive sprocket. Number of teeth varies depending on model. see scheme 13
2. Drive sprockets with 32 or 33 teeth have speed sensor connector (sensor housing color is Natural) facing bottom pan. Drive sprockets with 35 teeth have speed sensor connector (sensor housing color is Black) facing oil fill/vent cap. Install input speed sensor bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-124186-S28272405882001100100000).
3. Inspect wiring, "O" ring seal and pass-thru connector pins for damage. Install wire harness pass-thru connector into transaxle case bore from inside of transaxle case. Route input speed sensor wire harness in case channel. Install wire harness retainer and bolt. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-124186-S28272405882001100100000). Connect input speed sensor connector to speed sensor.

Remove input shaft-to-drive sprocket snap ring. Remove drive sprocket from input shaft. Remove 3 Teflon seals from input shaft. see scheme 6 Seals are not reusable and should be discarded.

1. Using Seal Installer Tools (J-29829) for channel plate seals and (J-29569) for drive sprocket support seal, install 3 NEW Teflon seals onto input shaft. Slide Seal Guides (J-29829-1 and J-29569-1) over input shaft and coat with transaxle fluid. (Scheme 46)
2. Guide seals over seal guides and into seal grooves on input shaft. Remove seal guides. Using Seal Sizing Tools (J-29829-2 and J-29569-2), size seals to input shaft. Allow seal sizer to remain in place for 5 minutes to properly size seals.
3. Install drive sprocket onto input shaft. Retain drive sprocket to input shaft using snap ring. Coat thrust washer with petroleum jelly. Install drive sprocket-to-drive sprocket support thrust washer onto drive sprocket. Position tabs on thrust washer into holes on drive sprocket.
4. Install driven sprocket-to-driven sprocket support thrust washer onto driven sprocket support. Install drive link assembly to drive and driven sprockets. Position drive link assembly in same direction as removed. If drive link assembly is NEW, it can be installed in either direction. Install drive sprocket, driven sprocket and drive link assembly onto transaxle as a complete assembly. (Scheme 33)

Scheme 46

Remove 3 accumulator pistons from channel plate. Accumulator pins are pressed into channel plate and should not be removed. Remove 1-2 and 2-3 accumulator assist springs. Remove and discard seals from accumulator pistons. Remove manual valve from channel plate. (Scheme 47)

1. Install 3 NEW accumulator piston seals. Install 1-2 and 2-3 accumulator assist springs. Coat piston seals with petroleum jelly. Install accumulator pistons into channel plate over guide pins. Pistons are identical and can be assembled in any of 3 accumulator bores.
2. Install 3 accumulator springs into transaxle case accumulator bores. see scheme 10 The 1-2 accumulator spring is slightly taller than other 2 springs and is installed in bore closest to electrical pass-thru connector.
3. Coat channel plate thrust washer with petroleum jelly. Install channel plate-to-drive sprocket thrust washer onto channel plate. Install NEW channel plate-to-transaxle case gasket. Install channel plate assembly onto transaxle case. Channel plate should fit tightly over guide pins located on transaxle case.
4. Install 8 channel plate-to-transaxle case bolts, and 2 channel plate-to-driven sprocket support bolts. Tighten 2 bolts located at 1 o'clock and 5 o'clock positions near axle shaft seal to 10.5 ft. lbs. (14 N.m). Tighten all other bolts to 106 INCH lbs. (12 N.m). (Scheme 31)
5. Install manual valve into channel plate. Connect manual valve link to both manual valve and detent lever. Install manual valve clip onto manual valve. see scheme 9

Scheme 47

Install 7 check balls into correct locations on channel plate. (Scheme 32) Install NEW spacer plate-to-channel plate gasket onto channel plate. Install spacer plate on top of gasket and channel plate. Install spacer plate support and 2 bolts onto spacer plate. (Scheme 31) Tighten bolts to specification. See TORQUE SPECIFICATIONS.

CONTROL VALVE ASSEMBLY

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.

Thoroughly clean valve body and dry with compressed air. Remove valve body components noting location of each component. Lay components on a clean surface in order removed. Remove actuator oil filter and electrical solenoids noting component location. (Scheme 48)

1. Reassemble control valve assembly in reverse order of disassembly. Lightly coat valves in transaxle fluid prior to installation. Install control valve assembly-to-spacer plate gasket onto spacer plate. Install control valve assembly onto transaxle case.
2. Check pressure switch assembly to ensure condition and location of "O" rings. Install pressure switch assembly onto control valve assembly. Install 18 control valve assembly bolts. (Scheme 31) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-124186-S28272405882001100100000).
3. Connect wiring harness to pressure switch assembly, pressure control solenoid (Red connector), 1-2 shift solenoid (Red and Light Green wires) 2-3 shift solenoid (Red and Yellow wires) and TCC solenoid. (Scheme 31)

Scheme 48

Oil pump is serviceable as a complete assembly only. Oil pump assembly should not be disassembled. Exploded view of oil pump assembly is provided for reference only. (Scheme 49)

Install oil pump shaft into control valve assembly. Install oil pump assembly onto oil pump shaft and control valve assembly. Rotate oil pump shaft during assembly to engage shaft splines to pump rotor splines. Install 8 oil pump bolts and tighten to specification. (Scheme 31) See TORQUE SPECIFICATIONS.

Scheme 49

Using hammer handle, remove side cover axle seal. DO NOT score or damage side cover bore.

Install side cover gaskets into grooves on side cover. Secure gaskets in place using petroleum jelly. Install side cover-to-driven sprocket thrust washer onto side cover. Secure thrust washer in place using petroleum jelly. Install side cover assembly onto transaxle case. see scheme 6 Install 10 side cover bolts and one stud. Install stud at bolt hole to left of oil fill/vent cap. see scheme 1 Tighten bolts and stud to specification. See TORQUE SPECIFICATIONS.

1. Place sleeve over end of output shaft. Install collet into output shaft snap ring groove with collet attached to threaded collet shaft. (Scheme 50) Position sleeve installing tube over collet with small outside diameter of tube fitting securely into sleeve.
2. Install bearing and nut onto threaded collet shaft. Hold end of threaded collet shaft while tightening nut. This will move installing tube and press sleeve onto output shaft.
3. Install 2 NEW snap rings into output shaft snap ring grooves. DO NOT over extend snap rings during installation. Install output shaft and sleeve assembly into transaxle case. Use a mallet to install shaft through final drive differential gear.

Scheme 50

Using Seal Installer (J-41102), install NEW axle seal into side cover (left seal) or transaxle case (right seal). (Scheme 51) Lubricate splines of output shaft to prevent damage to shaft during vehicle operation.

Scheme 51

Install 2 NEW snap rings on stub shaft. Snap rings are not reusable once shaft is removed. Install stub shaft into transaxle. Use a mallet to install shaft through final drive differential gear.

Remove piston and pin assembly from servo cover. Remove snap ring from servo pin. Remove piston and servo cushion springs from servo pin. see scheme 6 Remove and discard servo piston seals (outer seal from piston and inner seal from cover).

1. Install servo cushion springs and servo piston onto servo pin. Retain spring and piston by installing snap ring onto servo pin. Install NEW seals onto servo piston and seal cover. Install servo piston assembly into servo cover. Lubricate piston seals with transaxle fluid prior to installation.
2. Install servo return spring onto transaxle case. Install servo cover and piston assembly over servo return spring. Install 3 servo cover bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-124186-S28272405882001100100000) .

Install oil feed tube assembly onto transaxle. see scheme 6 Install bolts and tighten to specification. See TORQUE SPECIFICATIONS.

Using socket (same size as seal), install NEW oil filter seal into transaxle case. Tap gently and evenly on seal to prevent damage to case bore and seal. Install NEW oil filter assembly into filter seal. see scheme 6 It may be necessary to twist filter slightly during installation. Install oil level control valve into transaxle case. Push straight down on center of valve to prevent damage to case bore.

Install pan gasket and bottom pan onto transaxle case. see scheme 6 Install 12 oil pan bolts and tighten to specification. See TORQUE SPECIFICATIONS.

Install NEW input shaft "O" ring on end of input shaft. Install torque converter onto transaxle. Install Torque Converter Holding Fixture (J-21366) to secure converter during transaxle installation.

Scheme 52

Scheme 53