Automatic Transmission Servicing: Maintenance Pontiac Aztek I

SERVICE INTERVALS

Change the ATF and filter every 50,000 miles if the vehicle is mainly driven under one or more of these conditions

1. In heavy traffic where the outside temperature regularly reaches 90°F (32°C) or higher.
2. In hilly or mountainous terrain.
3. When doing frequent towing.
4. Uses such as found in taxi, police or delivery service.

If the vehicle is not used under any of these conditions, change the fluid and filter every 100,000 miles.

CHECKING FLUID LEVEL & CONDITION

1. Start the engine and allow the engine to idle until the transaxle has reached 180-200°F (82-93°C). Depress the brake pedal and move the shift control lever through the gear ranges, pausing a few seconds in each gear. Is the fluid Red or Light Brown? If so, go to step 4 . If not, go to next step.
2. Does the fluid have a burnt odor or a Dark Brown color? If so, go to step 11 . If not, go to next step.
3. Does the fluid have a cloudy or milky appearance? If so, go to step 10 . If not, go to next step.
4. Check the fluid level. The vehicle must be level, with the engine running and the shift control lever in the Park range. Check both sides of the fluid level indicator, and read the lower level. The proper fluid level should be in the middle of the cross-hatch. Is the fluid level too high? If so, go to step 9 . If not, go to next step.
5. Is the fluid level low? If not, system is okay. If so, go to next step.
6. Add appropriate fluid in increments of 17 oz. (0.5L) until the fluid is in the middle of the cross-hatch. Check both sides of the fluid level indicator, and read the lower level. Did you add more than 51 oz. (1.5L) to the transaxle? If not, go to step 9 . If so, go to next step.
7. Check for external leaks. Did you find any leaks? If not, go to step 15 . If so, go to next step.
8. Correct the leak condition. Did you correct the leak condition? If so, go to step 15 .
9. Remove any excess fluid to the proper level, the middle of the cross-hatch. Is the fluid level satisfactory? If so, system is okay.
10. The transaxle is contaminated with engine coolant. Replace the cooler. Is the replacement complete? If so, go to step 12 .
11. Drain the fluid to determine if the fluid is contaminated. A very small amount of material in the bottom pan is a normal condition, but large pieces of metal or other material in the bottom pan require a transaxle overhaul. Was the fluid contaminated? If so, go to step 13 . If not, go to next step.
12. Overhaul the transaxle. See appropriate OVERHAUL article. Is the overhaul complete? If so, go to next step.
13. Flush the cooler. See «OIL COOLER FLUSHING»(ref-153939-S02962935422003042900000) . Has the cooler been flushed? If so, go to next step.
14. Change the fluid and the filter. See «DRAINING & REFILLING»(ref-153939-S24508323162003042900000) . Is the procedure complete? If so, go to next step.
15. Add new fluid to the proper level, in the middle of the cross-hatch. Is the procedure complete? If so, system is okay.

RECOMMENDED FLUIDS

Manufacturer recommends DEXRON-III(R) ATF. Fill transaxle with appropriate quantity. See FLUID CAPACITIES .

DRAINING & REFILLING

1. Raise and support the vehicle. Place a drain pan under the transaxle bottom oil pan. Remove the oil pan bolts (23) from the front. (Scheme 244) Remove the oil pan bolts (23) from the sides. Loosen the rear oil pan bolts (23) approximately 4 turns.
2. Use a rubber mallet to lightly tap the oil pan or use a screwdriver to pry the oil pan loose. Allow the fluid to drain. Remove the remaining oil pan bolts (23). NOTE: Ensure care is taken NOT to damage the mating surfaces of the oil pan and of the case or oil leaks may occur.
3. Remove the oil pan (24). Remove the oil pan gasket (25). Remove the filter (100). Remove the lip ring seal (101) pressed into the case only if replacement is necessary. Inspect the oil pan and the filter screen for the following foreign material: Inspect for metal particles. Inspect for clutch facing material. Inspect for rubber particles. Inspect for engine coolant.
4. Determine the source of the contamination if foreign material is evident. Correct the source of the contamination. Use solvent to clean the screen and blow-dry if reusing. Install a new seal (101). (Scheme 245) Install the filter (100). (Scheme 244)
5. Inspect the oil pan flange (1) for distortion. (Scheme 246) Replace the oil pan (1) if bent or distorted. Do not attempt to straighten. Inspect the washers on the bolts when service requires the removal of the bottom oil pan. Install a new bolt and washer assembly if the washer is inverted. (Scheme 247)
6. Use solvent to clean the case. Air dry the case. Use solvent to clean the oil pan gasket surfaces. Air dry the oil pan gasket surfaces. Ensure all traces of the old gasket material are removed. NOTE: Ensure the oil pan and the case flanges are dry and are free of any oil film or leakage may result.
7. Install the oil pan gasket (25). (Scheme 244) Install the oil pan (24). Install the oil pan bolts (23). (Scheme 247) Tighten the oil pan bolts (23) to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000).
8. Lower the vehicle. Fill transaxle with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-153939-S32720478602003042900000) and «FLUID CAPACITIES»(ref-153939-S28831496572003042900000). Place the gear selector in the Park position. Start the engine. CAUTION: DO NOT overfill the transaxle. Overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle.
9. Run the engine at a slow idle. Do not race the engine. Adjust the fluid level. See «CHECKING FLUID LEVEL & CONDITION»(ref-153939-S12170600872003042900000). Inspect for proper completion of the repairs. Inspect for fluid leaks.

Scheme 244

Scheme 245

Scheme 246

Scheme 247

OIL COOLER FLUSHING

Note. GM studies indicate that plugged or restricted transaxle oil coolers and pipes cause insufficient transaxle lubrication and elevated operating temperatures which can lead to premature transaxle wear-out. Many cases could have been prevented by following published procedures for transaxle oil cooler flushing and flow checking. This procedure includes flushing and flow checking the auxiliary transaxle oil cooler, if equipped. GM requires that transaxle oil cooler flushing and flow checking be performed whenever a transaxle is removed from the vehicle for service within warranty, including: Goodwin, SWAT, major overhaul, torque converter replacement and oil pump replacement.

Initial Flush

1. Turn the transmission oil cooler and line flusher water supply valve (1) to the ON position and allow water to flow through the oil cooler and pipes for 10 seconds to remove any remaining transmission fluid. (Scheme 248) If water does not flow through the oil cooler and pipes, the cause of the blockage must be diagnosed and the plugged component must be repaired or replaced. Continue with the cooler flushing and flow check procedure once the blockage is corrected.
2. Turn the transmission oil cooler and line flusher water supply valve (1) to the OFF position and clip the discharge hose (5) onto an appropriate container with a lid, to avoid splashback. (Scheme 249) Turn the transmission oil cooler and line flusher water supply valve (1) to the ON position and depress the trigger (8) to mix cooler flushing solution into the water flow. see scheme 7 Use the clip provided on the handle to hold the trigger (8) down. The discharge will foam vigorously when the solution is introduced into the water stream.
3. Flush the oil cooler and pipes with water and solution for 2 minutes. During this flush, attach the shop air supply of 120 psi to the flushing system feed air valve (2) located on the transmission oil cooler and line flusher for 3-5 seconds at the end of every 15-20 second interval to create a surging action. NOTE: Flushing for approximately 2 minutes in each cooler line direction will result in a total of about 8-10 gallons of waste fluid. This mixture of water and flushing fluid is to be captured in an appropriate container for proper disposal.
4. Release the trigger (8) and turn the transmission oil cooler and line flusher water supply valve (1) to the OFF position.

Scheme 248

Scheme 249

Back Flush

1. Disconnect both hoses from the oil cooler pipes and then connect them to the opposite oil cooler pipe. This will allow the oil cooler and pipes to be back flushed. Repeat steps 2 and 3 of the INITIAL FLUSH procedure. Release the trigger (8) of the transmission oil cooler and line flusher and allow water only to rinse the oil cooler and pipes for one minute.
2. Turn the transmission oil cooler and line flusher water supply valve (1) to the OFF position and turn off the water supply at the faucet. see scheme 8 Attach the shop air supply to the flushing system feed air valve (2) on the transmission oil cooler and line flusher, and blow out the water from the oil cooler and pipes. Continue until no water comes out of the discharge hose (5).