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Automatic Transmission Removal & Installation: Application Pontiac Sunfire I

Automatic Trans 9 illustrations ~1214 words

APPLICATION

ApplicationTransaxle Model (RPO Code)
Cavalier4T40-E (MN4)
Sunfire4T40-E (MN4)

TRANSAXLE APPLICATION

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTIONWhen battery is disconnected, vehicle computer may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

Note. Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Scheme 70

Scheme 70: Removal
Scheme 70: Removal

Scheme 71

Scheme 71
Scheme 71

Scheme 72

Scheme 72
Scheme 72

Scheme 73

Scheme 73
Scheme 73

Scheme 74

Scheme 74
Scheme 74

Scheme 75

Scheme 75
Scheme 75

Scheme 76

Scheme 76
Scheme 76
  1. Disconnect the negative (-) battery cable.
  2. Disconnect the air duct hose from the intake plenum.
  3. Install the engine support fixture.
  4. Disconnect the transaxle wiring harness from the transaxle and the PNP switch. (Scheme 70)
  5. Remove the upper transaxle-to-engine bolts and stud. (Scheme 71)
  6. Raise and support the vehicle.
  7. Remove the front wheel and tire assemblies.
  8. Remove the left front fender liner.
  9. Disconnect the engine strut from the lower engine mount strut bracket.
  10. Remove the wiring harness from the retaining clips.
  11. Remove the steering gear mounting bolts and secure the steering gear with mechanics wire.
  12. Disconnect the wheel speed sensor wires from the both front wheels and unclip from the frame.
  13. Separate the ball joints from the steering knuckles. See appropriate FRONT article in SUSPENSION.
  14. Remove the lower suspension support. See «LOWER SUSPENSION SUPPORT»(ref-153277-S27613964642003043000000).
  15. Remove the 2 bolts from the transaxle brace. (Scheme 72)
  16. Disconnect the shift cable from the shift linkage. (Scheme 73)
  17. Disconnect the cable from the bracket.
  18. Remove the flywheel inspection cover. (Scheme 74)
  19. Remove the starter. See appropriate STARTERS article in ELECTRICAL.
  20. Mark the relationship of the flywheel to the torque converter for reassembly.
  21. Use the appropriate flywheel holding tool to prevent the crankshaft from rotating.
  22. Remove the torque converter-to-flywheel bolts. (Scheme 75)
  23. Remove the transaxle cooler lines by removing the nut holding the bracket to the transaxle case.
  24. Disconnect the VSS wiring harness from the sensor. (Scheme 76)
  25. Disconnect the wheel drive shafts from the transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
  26. Lower the vehicle.
  27. Remove the body-to-transaxle mount bolts.
  28. Lower the transaxle and engine with the engine support fixture enough to remove the transaxle.
  29. Raise the vehicle.
  30. Remove the oil pan to drain the transaxle. See LUBRICATION in appropriate SERVICING article as follows: For 2002 models: see SERVICING - A/T article. For 2003 models: see «SERVICING - A/T»(ref-151429) article.
  31. Install the oil pan.
  32. Support the transaxle with a suitable jack.
  33. Remove the transaxle-to-engine nut. (Scheme 71)
  34. Separate the engine and the transaxle.
  35. Remove the transaxle from the vehicle.
  36. Remove the PNP switch.
  37. Remove the shifter cable bracket.
  38. Remove the lower transaxle-to-engine stud.
  39. Remove the transaxle mount.
  40. Flush the transaxle cooler and the lines with appropriate flushing equipment, whenever the transaxle has been removed for overhaul or replacement. See LUBRICATION in appropriate SERVICING article as follows: For 2002 models: see SERVICING - A/T article. For 2003 models: see «SERVICING - A/T»(ref-151429) article.

Scheme 77

Scheme 77: Installation
Scheme 77: Installation
  1. Install the PNP switch.
  2. Install the shifter cable bracket.
  3. Install the lower transaxle-to-engine stud. (Scheme 71)
  4. Install the transaxle mount.
  5. Position the transaxle in the vehicle.
  6. Install the lower transaxle-to-engine bolts and nuts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  7. Using appropriate flushing equipment, flush transaxle oil cooler. See LUBRICATION in appropriate SERVICING article as follows: For 2002 models: see SERVICING - A/T article. For 2003 models: see «SERVICING - A/T»(ref-151429) article.
  8. Lubricate the transaxle cooler pipes before inserting into seals.
  9. Connect the transaxle cooler pipes to the transaxle. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  10. Using appropriate flywheel holding tool, prevent crankshaft from rotating.
  11. Install the torque converter-to-flywheel bolts. (Scheme 75) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  12. Install the wheel drive shafts to the transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
  13. Connect the wiring harness to the VSS. (Scheme 76)
  14. Install the starter. See appropriate STARTERS article in ELECTRICAL.
  15. Install the flywheel inspection cover bolts. (Scheme 74) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  16. Lower the vehicle.
  17. Use the engine support fixture to raise the engine and transaxle assembly.
  18. Install the transaxle mount-to-body bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  19. Raise the vehicle.
  20. Reposition the wiring harness into its clips on the body rail.
  21. Install the front suspension support assembly. (Scheme 77)
  22. Connect the ball joints to the steering knuckles. See appropriate FRONT article in SUSPENSION.
  23. Route and clip the wheel speed sensor wiring into the proper position on both sides.
  24. Install the steering gear to the front suspension crossmember.
  25. Install the steering gear bolts to the front suspension crossmember. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  26. Install the transaxle brace bolts. (Scheme 72) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  27. Install the left front fender liner.
  28. Install the front wheel and tire assemblies. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  29. Lower the vehicle.
  30. Install the upper transaxle-to-engine bolts and stud. (Scheme 71) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  31. Install the engine wiring harness grounds to the transaxle-to-engine mount stud and nut. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  32. Remove the engine support fixture.
  33. Install the shift linkage to the transaxle. (Scheme 73)
  34. Connect the electrical connectors to the PNP switch and transaxle. (Scheme 70)
  35. Connect the air duct hose to the intake plenum.
  36. Connect the negative (-) battery cable. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  37. Inspect the transaxle fluid level. See LUBRICATION in appropriate SERVICING article as follows: For 2002 models: see SERVICING - A/T article. For 2003 models: see «SERVICING - A/T»(ref-151429) article.

Scheme 78

Scheme 78: Removal
Scheme 78: Removal
  1. Raise the vehicle on a hoist.
  2. Remove the tire and wheel assemblies.
  3. Remove the front fender liners.
  4. Remove the engine strut from the lower engine mount and frame.
  5. Remove the front exhaust pipe.
  6. Disconnect the Anti-lock Brake System (ABS) harness from the lower control arms.
  7. Remove the ball joints from the steering knuckles.
  8. Remove the tie rods from the steering knuckles.
  9. On vehicles with a brake pipe running along the support frame, remove the brake pipe from the retainers.
  10. Remove the power steering gear mounting bolts and secure out of the way using mechanic's wire, being sure not to overextend the intermediate shaft.
  11. Remove the front suspension support brace.
  12. Lower the vehicle until the front suspension crossmember rests on jack stands.
  13. Remove the front suspension crossmember mounting bolts.
  14. Raise the vehicle off of the front suspension crossmember.
  15. Remove the lower control arms. (Scheme 78)
  1. Install the lower control arms. (Scheme 78)
  2. Lower the vehicle on to the front crossmember support.
  3. Install the front suspension crossmember mounting bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  4. Install the front suspension support brace. Tighten brace bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  5. Remove the mechanic's wire, and install the power steering gear mounting bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  6. On vehicles with the brake pipe running along the support frame, install the brake pipe into the retainers.
  7. Install the tie rods to the steering knuckle.
  8. Install the ball joints to the steering knuckles.
  9. Connect the ABS harness to the lower control arms.
  10. Install the front exhaust pipe. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).
  11. Install the engine strut to the lower engine mount and frame.
  12. Install the front fender liners.
  13. Install the tire and wheel assemblies. Tighten lug nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153277-S32218516632003032800000).

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