Automatic Transmission Servicing: Other Pontiac Sunfire I

TRANSAXLE

The Hydra-Matic(R) 4T40-E transaxle has a metal identification nameplate attached to the case exterior. (Scheme 66) The information on the nameplate assists the technician in servicing the transaxle and ordering replacement parts from a GM Parts Catalog. Additional transaxle identification information is provided on the Service Parts Identification label. This label shows the Regular Production Options (RPO) as well as the standard and mandatory options. This label is affixed to the inside of each vehicle at the assembly plant.

Transaxle has a metal identification plate attached to rear face of transaxle case.

Scheme 66

Scheme 67

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 Transaxle Oil Cooler and Line Flusher (J-35944-A) and fill the flusher tank (4) with 20-21 oz. (0.6L) of flushing solution using the measuring cup (6). DO NOT overfill.
3. Install the fill cap (9) on the flusher and pressurize the flusher tank (4) to 80-100 psi (550-700 kPa), using the shop air supply at the tank air valve (9). (Scheme 68)
4. With the water supply valve (3) on the flushing equipment in the OFF position, connect the water supply hose from the flushing equipment to the water supply at the faucet. (Scheme 69)
5. Turn on the water supply at the faucet.

Scheme 68

Scheme 69

ON-VEHICLE REPAIRS

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

PARK/NEUTRAL POSITION SWITCH

Note. Adjustment procedure is included with component removal and installation procedure. See PARK/NEUTRAL POSITION SWITCH under REMOVAL & INSTALLATION.

OIL COOLER PIPES & SEALS

Note. Use only double-wrapped and use only brazed steel pipe meeting the GM specification 123M or equivalent if replacement of the transaxle oil cooler pipes are required. Ensure the pipe is double-flared.

Note. After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch.