Automatic Transaxle Overhaul & Testing - 4T40-E & 4T45-E: Overhaul Pontiac Sunfire I

SERVO ASSEMBLIES

Remove 3 bolts from intermediate-4th and low-reverse servo covers. Remove servos and servo return springs. see scheme 3

COMPONENT DISASSEMBLY, REASSEMBLY & TRANSAXLE REASSEMBLY

Note. The 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, refer to illustrations. (Scheme 12)and (Scheme 13).

Scheme 12

Scheme 13

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 14)
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.

Scheme 14

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-127817-S12490565602001102600000) . Using Seal Installer (J-28540-A), install NEW torque converter seal.

Transaxle Cooler Line Seals (Reassembly)

Seals were removed during transaxle disassembly procedure. For reassembly, lubricate cooler line seals with transmission fluid. Place NEW seal in transaxle case bore. Position Cooler Line Seal Installer (J-41239-1) on transaxle case at cooler line bracket bolt hole. (Scheme 15) Press cooler line seal into case by tightening seal pressing bolt on cooler line seal installer until seal bottoms out in case bore. Repeat procedure to install second cooler line seal.

Scheme 15

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 14 Ensure parking lock actuator rod is positioned properly into actuator guide. Using Height Tool (J-41229), install manual shaft-to-case pin to correct height. (Scheme 16)

Scheme 16

Reassembly

1. Install needle bearing spacer onto planet pinion gear. Needle bearing spacer must be assembled between 2 rows of needle bearings. To aid in assembly of needle bearings, place needle bearing spacer and planet pinion gear onto planet pinion pin. Place thrust washer on bottom of planet pinion gear to retain bottom row of needle bearings. Use petroleum jelly to keep needle bearings in place. Install needle bearings one at a time into planet pinion gear.
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. Install thrust washers onto differential side gears. Install differential side gears into final drive carrier. Use petroleum jelly to position thrust washers onto differential pinion gears. Install differential pinion gears and thrust washers into final drive carrier.
4. Rotate differential pinion gears into position and install differential pinion shaft through final drive carrier and differential pinion gears. Position of differential pinion shaft must allow retaining pin to be installed. Install differential retaining pin.
5. Using feeler gauge, measure end play between final drive carrier and planet pinion gear thrust washers. (Scheme 17) End play should be.009-.024" (.23-.62 mm). If clearance is out of specification on low side, repair or replace final drive components as necessary. If clearance is out of specification on high side, replace final drive carrier.
6. Install fretting ring into small groove in transaxle case (if removed). Install final drive internal gear into transaxle case. see scheme 13 Final drive internal gear should be assembled in same direction as removed. Install final drive carrier-to-case thrust bearing onto final drive carrier. Retain final drive carrier-to-case thrust 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 17

Disassembly

Turn low roller clutch assembly clockwise while gently lifting upward to remove from forward clutch support. (Scheme 18) Remove forward clutch support thrust bearing (front). Turn forward clutch support over. Remove final drive sun gear shaft snap ring. Remove park lock gear and thrust bearing. Remove forward clutch support from final drive sun gear shaft. Turn forward clutch support over. Remove and discard 2 "O" rings from forward clutch support.

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

Scheme 18

1. Install 2 NEW "O" rings on forward clutch support. (Scheme 18) Install forward clutch support onto final drive sun gear shaft. Turn forward clutch support over. Install park lock gear thrust bearing. Install park lock gear onto final drive sun gear shaft with raised inner boss facing up so parking pawl properly engages teeth on park lock gear. Install snap ring to final drive sun gear shaft to retain park lock gear. Ensure clearance between park lock gear and snap ring is.120" (3.05 mm).
2. Turn forward clutch support over. 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 forward clutch support thrust bearing (front).
3. Install forward clutch support and low roller clutch assembly into transaxle case. Compress parking pawl return spring and align 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.

1. Install NEW inner sleeve and seal assembly if old inner sleeve and seal assembly was removed or damaged. Using arbor press and seal installer, press inner sleeve and seal assembly onto forward clutch housing. Lubricate forward clutch piston assembly seals with transaxle fluid. Install forward clutch piston assembly into forward clutch housing.
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 in alternate order beginning with steel plate.
3. Install forward clutch backing plate. Install snap ring to retain clutch plates. Using compressed air, check forward clutch to verify proper operation of seals and clutch assembly. Apply compressed air at specified location. (Scheme 19) If clutch assembly does not operate properly, check component installation.
4. Install low-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-reverse band by inserting screwdriver through reverse servo pin hole. Screwdriver should compress band around forward clutch housing.

Scheme 19

Remove thrust washer from forward clutch hub (if necessary). (Scheme 20) Remove input internal gear-to-forward clutch hub assembly snap ring. Remove forward clutch hub from input internal gear.

Scheme 20

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 facing forward clutch hub. Install forward clutch hub and input internal gear assembly into transaxle case. see scheme 3 Rotate assembly while installing to align forward clutch hub spline with forward clutch plates.

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 21)

Scheme 21

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. 2nd thrust bearing is permanently retained in input carrier assembly. Install reaction internal gear and input carrier assembly into transaxle case. see scheme 3 Rotate assembly while installing to mesh input carrier pinion gears to input internal gear.

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. (Scheme 22)
2. Remove reaction carrier assembly. A thrust bearing is permanently installed in reaction carrier assembly under pinion gears. Remove reaction sun shell. Remove thrust bearing from reaction carrier shaft shell. Remove reaction carrier shaft shell. 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. Thrust 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.
5. Using Clutch Spring Compressor (J-23327) and Adapter (J-41232), compress direct clutch spring and retainer assembly. (Scheme 23) Remove direct clutch spring retainer ring. Remove clutch spring compressor and adapter. Remove direct clutch spring and retainer assembly. Remove direct clutch piston assembly.
6. Using clutch spring compressor and Adapter (J-41236), compress coast clutch release spring assembly. Remove snap ring, clutch spring compressor and adapter. Remove coast clutch spring retainer and coast clutch 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.

Scheme 22

Scheme 23

1. Remove reverse clutch snap ring. (Scheme 24) Remove reverse clutch selective backing plate, 3 steel plates, 3 friction plates and one waved plate. Using Clutch Spring Compressor (J-23327) and Adapter (J-41232), compress reverse clutch spring and retainer assembly. (Scheme 25) Remove snap ring, spring compressor and adapter. Remove reverse clutch spring and retainer assembly. Remove reverse clutch piston assembly.
2. Inspect reverse clutch retainer and seal assembly for damage. DO NOT remove seal assembly if seal is not damaged. If seal assembly is damaged, install Seal Remover Snap Ring (J-41097-1) under outer lip of reverse clutch retainer and seal assembly. (Scheme 26) Place Seal Remover Disc (J-41097-2) on inner hub of reverse clutch housing. Using puller, remove reverse clutch retainer and seal assembly.
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 once removed. Rotate 2nd roller clutch assembly clockwise until indexed with roller clutch cam. Remove 2nd roller clutch assembly from inside of roller clutch cam.

Scheme 24

Scheme 25

Scheme 26

Install NEW intermediate-4th band into transaxle case. see scheme 3 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 12 Install NEW friction plate and alternate between friction plates and steel plates. Install 2nd clutch waved plate.

Remove and discard 2 oil seal rings. (Scheme 27) Using Clutch Spring Compressor (J-23327) and Adapter (J-41232), compress 2nd clutch spring assembly and remove spring retaining ring. Remove 2nd clutch spring assembly, spring compressor and adapter. Remove 2nd clutch piston assembly. Clutch piston and seal assembly are reusable if not damaged.

Scheme 27

Scheme 28

1. Check 2nd clutch piston assembly for damage. If seal is damaged, replace 2nd clutch piston 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. (Scheme 28) 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.

1. Lubricate 2nd clutch piston seal with transaxle fluid. Install 2nd clutch piston assembly into driven sprocket support. (Scheme 27) Install 2nd clutch spring assembly into driven sprocket support.
2. Using Clutch Spring Compressor (J-23327) and Adapter (J-41232), compress 2nd clutch spring assembly and install spring retaining ring. Remove spring compressor and adapter. Install 2 NEW oil seal rings onto driven sprocket support. Air check 2nd clutch to ensure proper operation. Apply compressed air to 2nd clutch fluid circuit. (Scheme 28) 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.

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 10
2. Drive sprockets with 32 or 33 teeth have speed sensor connector (Natural) facing bottom pan. Drive sprockets with 35 teeth have speed sensor connector (Black) facing oil fill/vent cap. Install input speed sensor bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-127817-S12490565602001102600000).
3. Inspect wiring, "O" ring seal and pass-through connector pins for damage. Install wire harness pass-through 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. Connect input speed sensor connector.

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

1. Install drive sprocket onto input shaft. Retain drive sprocket to input shaft using snap ring. Slide Input Shaft Seal Guides (J-29569-1 and J-29829-1) over input shaft. (Scheme 29) Coat both halves of input shaft seal guides with transaxle fluid.
2. Guide NEW Teflon "O" ring seals over input shaft seal guides and into seal grooves on input shaft. Remove input shaft seal guides. Using Seal Sizing Tools (J-29829-2 and J-29569-2), size "O" ring seals to input shaft. Allow seal sizer to remain in place for 5 minutes to properly size "O" ring seals.
3. Coat drive sprocket-to-drive sprocket support 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. see scheme 9 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 29

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, keeping 1-2 accumulator assist spring and retainer assembly together. Remove and discard piston seals from accumulator pistons. Remove manual valve from channel plate. (Scheme 30)

Scheme 30

1. Install 3 NEW accumulator piston seals onto accumulator pistons. 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 manual valve into channel plate. Install 3 accumulator springs into transaxle case accumulator bores. see scheme 8 The 1-2 accumulator spring is slightly taller than the other 2 springs and is installed in bore closest to electrical pass-through connector.
3. Coat channel plate-to-drive sprocket 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 6 channel plate-to-transaxle case bolts, and 2 channel plate-to-driven sprocket support bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-127817-S12490565602001102600000).
5. Connect manual valve link to both manual valve and detent lever. Install manual valve clip onto manual valve. see scheme 7

Install 7 check balls into correct locations on channel plate. see scheme 6 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. see scheme 5 Tighten bolts to specification. See TORQUE SPECIFICATIONS.

Thoroughly clean valve body and dry with compressed air. Remove valve body components, noting location of each component. (Scheme 31) Position components on a clean surface in order removed. Remove actuator oil filter and electrical solenoids noting component location.

Scheme 31

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. see scheme 5 Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-127817-S12490565602001102600000).
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. see scheme 5

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 32)

Scheme 32

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. see scheme 5 See TORQUE SPECIFICATIONS.

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 3 Install side cover bolts and/or studs. Install stud at bolt hole to left of oil fill/vent cap. see scheme 1 Tighten bolts and/or studs to specification. See TORQUE SPECIFICATIONS.

Note. Seal Installer (J-41102) must be used to install axle seals. Installer sets seal depth during installation.

Using Axle Seal Installer (J-41102), install NEW axle seal into side cover (left seal) or transaxle case (right seal). (Scheme 33) Lubricate splines of output shaft to prevent damage to shaft during vehicle operation.

Scheme 33

Note. Sleeve Installer (J-41228) must be used to install sleeve onto output shaft. A fluid leak will occur if sleeve installer is not used.

Place output/stub shaft sleeve over end of output shaft. (Scheme 34) Install collet into output shaft snap ring groove with collet attached to threaded collet shaft. Place sleeve installing tube over collet. Ensure small outside diameter of sleeve installing tube fits securely into output/stub shaft sleeve. Install bearing and nut onto threaded collet shaft. Hold end of threaded collet shaft while tightening nut to press sleeve onto output shaft. Remove sleeve installer. Install NEW snap ring into output shaft snap ring groove.

Scheme 34

1. Place output/stub shaft sleeve over end of output shaft. (Scheme 34) Install collet into output shaft snap ring groove with collet attached to threaded collet shaft. Place sleeve installing tube over collet. Ensure small outside diameter of sleeve installing tube fits securely into output/stub shaft sleeve.
2. Install bearing and nut onto threaded collet shaft. Hold end of threaded collet shaft while tightening nut to press sleeve onto output shaft. Remove sleeve installer. 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 3 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. Lubricate piston seals with transaxle fluid. Install servo piston assembly into servo cover.
2. Install servo return spring into 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-127817-S12490565602001102600000) .

Install oil feed tube assembly onto transaxle. see scheme 3 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 3 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 oil pan onto transaxle case. see scheme 3 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.