Automatic Transmission Servicing: Maintenance Pontiac Sunfire I

LUBRICATION

Note. The 4T40-E automatic transaxle is not equipped with a dipstick.

SERVICE INTERVALS

This transaxle is not equipped with transaxle fluid dipstick. Check transaxle fluid level only when leaks have occurred. Under continuous extreme operating conditions (trailer towing, heavy city traffic with ambient temperature more than 90°F (32°C) or delivery service), fluid and filter should be changed every 50,000 miles. If the vehicle is not used under these extreme conditions, the fluid and filter do not require changing.

CHECKING FLUID LEVEL

Note. The transaxle fluid may darken with normal use and does not always indicate contamination or oxidation.

1. Start the engine and allow the engine to idle until the transaxle fluid temperature has reached 86-122°F (30-50°C). Depress the brake pedal and move the shift lever through the gear ranges, pausing a few seconds in each range. Return the shift lever to the Park range. Raise the vehicle on a hoist. The vehicle must be level with the engine running and the shift lever in the Park range. Remove the transaxle plug. (Scheme 61) Check the fluid color. If necessary, use a small screwdriver as a dipstick. Is the fluid color clear red or light brown with no burnt odor? 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 8. If not, go to next step.
3. Does the fluid have a cloudy or milky appearance? If so, go to step 7. If not, go to step 8.
4. Check the fluid level. The fluid level should be even with the bottom of the threaded plug hole. Is the fluid level low? If so, go to next step. If not, go to step 11.
5. Add appropriate automatic transaxle fluid in increments of 0.5L until the fluid drains from the plug hole. See «RECOMMENDED FLUIDS»(ref-151429-S38035437572002121900000). Did you add more than 1.5L to the transaxle? If so, go to next step. If not, go to step 11.
6. The transaxle may have a leak. Inspect as necessary. Was a transaxle fluid leak found? If so, go to step 9. If not, go to step 11.
7. The transaxle fluid is contaminated with engine coolant. Repair or replace the transaxle cooler in the radiator. Is the transaxle cooler repair complete? If so, go to step 9.
8. Drain the fluid by removing the bottom pan. Check the bottom pan for any excessive debris. Was excessive debris found? If so, go to next step. If not, go to step 10.
9. Repair the transaxle if required (in some cases, overhaul may be required). See appropriate OVERHAUL article. Flush the transaxle oil cooler and pipes and check flow. See «OIL COOLER FLUSHING & FLOW TEST»(ref-151429-S22787040112002121900000). Add enough fluid to bring the fluid level to the bottom of the threaded plug hole. Start the engine and allow the engine to idle until the transaxle fluid temperature has reached 86-122°F (30-50°C). Depress the brake pedal and move the shift lever through the gear ranges, pausing a few seconds in each range. Return the shift lever to the Park range. Raise the vehicle on a hoist. The vehicle must be level with the engine running and the shift lever in the Park range. Remove the transaxle plug. If needed, add fluid in increments of 0.5L until the fluid drains from the threaded plug hole. Allow fluid to finish draining out of the plug hole. Install the plug and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000). Wipe any excess fluid from the transaxle with a rag or shop towel. Is repair complete? If so, road test vehicle. See PERFORMANCE TESTS in appropriate DIAGNOSIS article.
10. Change the fluid and the fluid filter. See «DRAINING & REFILLING»(ref-151429-S26780886332002121900000). Start the engine and allow the engine to idle until the transaxle fluid temperature has reached 86-122°F (30-50°C). Depress the brake pedal and move the shift lever through the gear ranges, pausing a few seconds in each range. Return the shift lever to the Park range. Raise the vehicle on a hoist. The vehicle must be level with the engine running and the shift lever in the Park range. Remove the transaxle plug. If needed, add fluid in increments of 0.5L until the fluid drains from the threaded plug hole. Allow fluid to finish draining out of the plug hole. Install the plug and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000). Wipe any excess fluid from the transaxle with a rag or shop towel. Is repair complete? If so, road test vehicle. See PERFORMANCE TESTS in appropriate DIAGNOSIS article.
11. Allow fluid to finish draining out of the plug hole. Install the plug and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000). Wipe any excess fluid from the transaxle with a rag or shop towel. Is repair complete? If so, road test vehicle. See PERFORMANCE TESTS in appropriate DIAGNOSIS article.

Scheme 61

RECOMMENDED FLUIDS

Manufacturer recommends Dexron-III automatic transaxle fluid. Fill transaxle with appropriate quantity. See FLUID CAPACITIES .

DRAINING & REFILLING

Note. Some transaxles are equipped with a reusable-type oil pan gasket. Reusable oil pan gasket is constructed of rubber with metal or plastic backing. On transaxles equipped with reusable-type gasket, sealing surface of oil pan is flat. Transaxles not equipped with reusable-type gasket have a ridge on sealing surface of oil pan. Clean reusable gasket with solvent. Inspect reusable gasket for damage and replace as necessary. Using any other type of gasket in place of reusable-type gasket may result in fluid leaks.

Note. If oil pan bolts are equipped with conical washers, do not reuse bolts if washers have become reversed. (Scheme 62)

Scheme 62

1. Raise and support vehicle. Place drain pan under transaxle oil pan. Remove oil pan bolts from front and side. Loosen rear transaxle oil pan bolts about 4 turns each.
2. Using a screwdriver, carefully pry pan loose. Allow fluid to drain. Remove bolts, and remove oil pan. Remove and discard old pan gasket, if reusable-type gasket is not used. Remove filter and "O" ring or sleeve-type seal. (Scheme 63) Remove any remaining gasket material on transaxle case.
3. Thoroughly clean pan, magnet and screen (if metal) with solvent, and then dry using compressed air. Replace filter and seal. (Scheme 64) Lubricate with clean fluid before installation.
4. Install filter assembly into filter pick-up tube recess. Install oil pan and gasket. Use NEW pan gasket if transaxle is not equipped with reusable-type gasket. Tighten pan bolts to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000).
5. Fill transaxle with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-151429-S38035437572002121900000) and «FLUID CAPACITIES»(ref-151429-S08949577172002121900000). Lower vehicle and start engine. Allow engine to idle until transaxle fluid reaches 104°F (20°C). Depress brake pedal and shift gear selector through all gear ranges, pausing a few seconds in each range. Place gear selector lever in Park.
6. With engine running, raise vehicle and remove transaxle oil check plug. Add fluid in increments of one pint (0.5L) until fluid drains from oil check hole. Install oil check plug and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000).

Scheme 63

Scheme 64

Back Flush

1. Inspect the transaxle oil cooler pipes for kinks or damage. Repair as necessary.
2. Connect the flushing equipment to the oil cooler feed top connector. Use the Cooler Flusher Adapter (J 35944-440).
3. Clip the discharge hose (5) onto the oil drain container. see scheme 8
4. Attach the flushing equipment to the undercarriage of the vehicle with the hook provided and connect the flushing system feed supply hose (3) from the flushing equipment to the bottom connector oil cooler return pipe. Use the cooler flusher adapter.
5. Turn the flushing equipment 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 transaxle fluid. see scheme 8 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.
6. Turn the flushing equipment water supply valve (1) to the OFF position and clip the discharge hose onto a 5 gallon (19 liter) pail with a lid, to avoid splashback. see scheme 8 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 a bucket or similar container.
7. Turn the flushing equipment water supply valve (1) to the ON position and depress the trigger (8) to mix cooler flushing solution into the water flow. 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. see scheme 7and see scheme 8.
8. Flush the oil cooler and pipes with water and solution for 2 minutes. During this flush, attach the shop air supply 120 psi (825 kPa) to the flushing system feed air valve (2) located on the flushing equipment, for 3-5 seconds at the end of every 15-20 second interval to create a surging action. see scheme 7
9. Release the trigger (8) and turn the flushing equipment water supply valve (1) to the OFF position. see scheme 7and see scheme 8.

Forward Flush

1. Disconnect both hoses (3 and 5) from the oil cooler pipes and connect them to the opposite oil cooler pipe. This will allow the oil cooler and pipes to be flushed in the normal flow direction. see scheme 8
2. Repeat steps 6 and 7 of the Back Flush procedure.
3. Release the trigger (8) of the flushing equipment and allow water only to rinse the oil cooler and pipes for one minute. (Scheme 65)
4. Turn the flushing equipment water supply valve (1) to the OFF position and turn off the water supply at the faucet. (Scheme 65)
5. Attach the shop air supply to the flushing system feed air valve (2) on the flushing equipment and blow out the water from the oil cooler and pipes. Continue, until no water comes out of the discharge hose. (Scheme 65)

Scheme 65