Automatic Transmission Servicing: Other Pontiac Aztek I

TRANSAXLE

Transaxle has a metal identification plate or Service Replacement Transaxle Assembly (SRTA) plate attached to rear face of transaxle. (Scheme 250)

Scheme 250

Scheme 251

Preparation

1. After the repair or replacement transaxle is installed in the vehicle, do not reconnect the oil cooler pipes.
2. Remove the fill cap (9) on the Transmission Oil Cooler and Line Flusher (J-35944-A) and fill the flusher tank (4) with 20 oz. (0.6L) of flushing solution using the measuring cup (6). Do not overfill. Install the fill cap (9) on the transmission oil cooler and line flusher and pressurize the flusher tank (4) to 80-100 psi, using the shop air supply at the tank air valve (9). (Scheme 252)
3. Connect the transmission oil cooler and line flusher discharge hose (5) to the oil cooler return pipe (top connector). Clip the discharge hose (5) onto the oil drain container. Attach the transmission oil cooler and line flusher to the undercarriage of the vehicle with the hook provided, and connect the flushing system feed supply hose (3) from the transmission oil cooler and line flusher to the oil cooler feed pipe (bottom connector).
4. With the water supply valve (1) on the transmission oil cooler and line flusher in the OFF position, connect the water supply hose (7) from the transmission oil cooler and line flusher to the water supply at the faucet. (Scheme 252)and (Scheme 253). Turn on the water supply at the faucet.

Scheme 252

Scheme 253

Flow Check

1. Disconnect both hoses from the oil cooler pipes. Connect the oil cooler feed pipe (vertical/top connector) to the transaxle and the return pipe (horizontal/bottom connector) to the discharge hose (5). Clip the discharge hose (5) onto the empty oil drain container. see scheme 10
2. Confirm the transaxle is filled with fluid. See «CHECKING FLUID LEVEL & CONDITION»(ref-153939-S12170600872003042900000). Start the engine with the transaxle in Park range and run for 30 seconds. A minimum of 2 qts. (1.9L) must be discharged during this 30-second run time. If fluid flow is greater than 2 qts. (1.9L) in 30 seconds, go to next step. If fluid flow is less than 2 qts. (1.9L) in 30 seconds, perform the following diagnosis: Disconnect the oil cooler feed line at the radiator. Connect the discharge hose (5) to the cooler feed line. Clip the discharge hose (5) to the empty oil drain container. see scheme 10 Start the engine with the transaxle in Park range and run for 30 seconds. A minimum of 2 qts. (1.9L) must be discharged during this 30-second run time. Do the following according to the flow rate: Insufficient feed flow: inspect the transaxle. Sufficient feed flow: inspect the oil cooler return pipe and the oil cooler (and auxiliary cooler, if equipped).
3. Remove the discharge hose (5), reconnect the cooler feed and return pipes to the transaxle and refill transaxle with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-153939-S32720478602003042900000) and «FLUID CAPACITIES»(ref-153939-S28831496572003042900000). Inspect the transaxle oil cooler pipe connections at the radiator, the auxiliary cooler (if equipped) and the transaxle for leaks.

Clean-up

Disconnect the water supply hose (7) from the transmission oil cooler and line flusher and bleed any remaining air pressure from the flusher tank (4). (Scheme 252) Remove the fill cap (9) from the transmission oil cooler and line flusher and return any unused flushing solution to its container. Rinse the transmission oil cooler and line flusher with water. DO NOT store the transmission oil cooler and line flusher with flushing solution in it. After every 3rd use, clean the transmission oil cooler and line flusher as described in the instructions included with the tool. Dispose of any waste water/solution and transmission fluid in accordance with local regulations.

ON-VEHICLE REPAIRS

Note. Various components may be serviced without transaxle removal. For servicing of these components, see appropriate component under ADJUSTMENTS and/or REMOVAL & INSTALLATION . For additional information on servicing electrical components, see appropriate DIAGNOSIS article.

SHIFT CABLE

Note. Adjust the shift cable while the transaxle and while the gear selector are in the Neutral position only. Failure to do so may cause misadjustment of shift cable.

1. Set the parking brake. Block the wheels. Use an appropriate tool to pry on the shift cable terminal at the manual control lever pin to remove the shift cable terminal from the manual control lever pin. (Scheme 254)
2. Fully lift the adjuster lock button. Ensure the adjuster is free to move. Rotate the manual control lever fully counterclockwise to the Park gear, then rotate the lever clockwise 2 clicks into the Neutral gear to place the manual control lever in the Neutral gear.
3. Perform the following steps to place the inside car gear shifter in the Neutral position: Rotate the shift control lever to the L1 position, fully down. Push forward on the lever while slowly pushing up. The shift control lever moves up while clicking over the gear over travel stops. Release the shift control lever once the shift control lever stops solidly. The shift control lever is in the Neutral gear.
4. Grasp the shift cable terminal in the underhood. Pull the shift cable terminal toward the pin on the manual control lever. The shift cable adjuster spring should compress as the terminal is moved toward the pin.
5. Carefully push down the pin until the pin snaps to attach the pin to the manual control lever. DO NOT move the manual control lever out of position. DO NOT pull the terminal beyond the pin then push back or the shifter may move out of the Neutral gear.
6. Press the adjuster lock button down flush with the adjuster body. (Scheme 255) Shift to Park. Release the parking brake while applying the service brake. Start the engine. Ensure all the indicated gear positions match the vehicle response.

Scheme 254

Scheme 255

FORWARD SERVO (AWD)

Note. Removal and installation of the transfer case while the transmission is in vehicle may cause improper positioning of the park gear thrust bearing. If the transfer case fasteners are tightened while the park gear thrust bearing is out of position, the park gear thrust bearing, transmission, and/or the transfer case will be damaged.

OIL COOLER HOSES

OUTPUT SHAFT

Note. This procedure is for FWD vehicles ONLY. The output shaft for AWD vehicles is serviced with the transfer case which MUST be serviced with the transaxle removed from the vehicle. For transfer case replacement, see appropriate REMOVAL & INSTALLATION article.