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Automatic Transmission Servicing: Removal & Installation Pontiac Sunfire I

Automatic Trans 10 illustrations ~1326 words

REMOVAL & INSTALLATION

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 AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
WARNINGTo avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Before disconnecting battery, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION.
CAUTIONUse 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.

Removal

  1. Raise and support the vehicle. Remove the left front wheel and tire assembly.
  2. Remove the left front fender liner. Install a jackstand and a block of wood to support the transaxle.
  3. Remove the expansion bolt from the transaxle mount. (Scheme 51) Remove the 4 transaxle mount bolts. (Scheme 52) Remove the mount.

Installation

  1. Transfer the mount bracket to the new mount. Position the mount and start the 4 bolts into the threads. (Scheme 52) Tighten the mount bolts to 49 ft. lbs. (66 N.m).
  2. Install the mount expansion bolt. (Scheme 51) Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000). Remove the jackstand and the wood block.
  3. Install the left fender liner. Install the left tire and wheel assembly. Lower the vehicle.

Scheme 51

Scheme 51
Scheme 51

Scheme 52

Scheme 52
Scheme 52
  1. Raise and support the vehicle.
  2. Remove the oil pan and filter. See «DRAINING & REFILLING»(ref-151429-S26780886332002121900000) under LUBRICATION.
  3. Remove the oil feed pipes. See «OIL FEED PIPES»(ref-151429-S27590801652002121900000).
  4. Remove the 2 intermediate/4th servo cover bolts, the servo and the spring. (Scheme 53)
  5. Disassemble, clean and inspect the intermediate/4th servo assembly.

Scheme 53

Scheme 53
Scheme 53
  1. Assemble the intermediate/4th servo assembly.
  2. Install the intermediate/4th band servo piston spring, the servo and the servo cover bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000) .
  3. Install the oil feed pipes. See «OIL FEED PIPES»(ref-151429-S27590801652002121900000) .
  4. Install the filter and the pan. See «DRAINING & REFILLING»(ref-151429-S26780886332002121900000) under LUBRICATION.
  5. Lower the vehicle.
  6. Fill the transaxle with appropriate fluid to proper level. See «LUBRICATION»(ref-151429-S10314925802002121900000) .
  7. Connect the negative battery cable.
  8. Inspect the transaxle oil level. See «CHECKING FLUID LEVEL»(ref-151429-S29763732592002121900000) under LUBRICATION.
  1. Remove the oil feed pipes. See «OIL FEED PIPES»(ref-151429-S27590801652002121900000).
  2. Remove the 3 low-reverse band servo cover bolts, the servo and the spring. (Scheme 54)
  3. Disassemble, clean and inspect the low reverse servo assembly. See appropriate OVERHAUL article.

Scheme 54

Scheme 54
Scheme 54
  1. Assemble the low reverse servo assembly. See appropriate OVERHAUL article.
  2. Install the low-reverse band servo and cover. (Scheme 54) Install and tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000).
  3. Install the oil feed pipe. See «OIL FEED PIPES»(ref-151429-S27590801652002121900000).

Note. Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss.

  1. Raise and support the vehicle.
  2. Position the drain pan.
  3. Remove the transaxle oil cooler pipe at the transaxle. (Scheme 55)
  4. Remove the transaxle oil cooler pipe fittings at the radiator. (Scheme 56)
  5. Remove the transaxle oil cooler pipe clip bolt.
  6. Remove the transaxle oil cooler pipes.

Scheme 55

Scheme 55
Scheme 55

Scheme 56

Scheme 56
Scheme 56
CAUTIONThe correct thread engagement is critical. Cross-threaded fittings can achieve proper tightness value and still leak.
  1. Install the transaxle oil cooler pipes.
  2. Install the transaxle oil cooler pipe clip bolt. Tighten the transaxle oil cooler pipe clip bolt to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000) .
  3. Install the transaxle oil cooler pipe fittings at the radiator. Tighten the transaxle oil cooler pipe fittings to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000) .
  4. Install the transaxle oil cooler hoses to the pipes.
  5. Lower the vehicle. CAUTION: Do not overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle.
  6. Fill transaxle with appropriate fluid to proper level. See «LUBRICATION»(ref-151429-S10314925802002121900000) .
  7. Inspect for proper completion of the repairs.
  8. Inspect for fluid leaks.
  1. Remove the transaxle oil filter assembly. See «DRAINING & REFILLING»(ref-151429-S26780886332002121900000).
  2. Remove the oil feed pipe bolts. (Scheme 57)
  3. Inspect the 8 oil feed pipe seal rings.
  4. Replace the seal rings only if the seal rings are cut, swollen or damaged.
  5. Remove the low-reverse band oil pipe assembly.
  6. Remove the 8 low-reverse band oil pipe assembly seals.
  7. Inspect the oil feed pipes for plugged passages, bent pipes, or cracks.
  8. Inspect the oil feed pipe seal rings. Verify the proper location of the seal rings. Replace the seal rings if these are cut, swelled or damaged.

Scheme 57

Scheme 57
Scheme 57
  1. Install the 8 low-reverse band oil pipe assembly seals.
  2. Install the low-reverse band oil feed pipe assembly onto the transaxle. (Scheme 57)
  3. Hand start the bolts that attach the oil feed pipe assembly to the transaxle. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000).
  4. Install the transaxle oil filter assembly.

Removal (First Design)

  1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch.
  2. Remove the shift control cable from the transaxle range switch lever.
  3. Disconnect the electrical connectors from the transaxle range switch.
  4. Remove the transaxle range switch lever nut and lever. (Scheme 58)
  5. Remove the transaxle range switch bolts and remove the switch.

Scheme 58

Scheme 58
Scheme 58

Installation (First Design - Old Switch)

  1. Make sure the transaxle manual shaft is in the Neutral position.
  2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch.
  3. Loosely install the transaxle range switch bolts.
  4. Insert Alignment Tool (J 41545) as shown and rotate the switch until the tool drops onto position. (Scheme 59)
  5. Tighten the transaxle range switch bolts to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000).
  6. Remove the alignment tool.
  7. Install the transaxle range switch lever and nut. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000).
  8. Connect the transaxle range switch electrical connectors.
  9. Install the shift control cable to transaxle range switch lever and verify proper operation.

Scheme 59

Scheme 59
Scheme 59

Installation (First Design - New Switch)

  1. Make sure the transaxle manual shaft is in the Neutral position.
  2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch.
  3. Tighten the transaxle range switch bolts.
  4. Install the transaxle range switch lever and nut. Tighten the transaxle range switch lever retaining nut to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000) .
  5. Install the shift control cable to transaxle range switch lever and verify proper operation.

Removal (Second Design)

  1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch.
  2. Remove the brake pressure modulator valve bracket.
  3. Remove the shift control cable from the transaxle range switch lever.
  4. Disconnect the electrical connectors from the transaxle range switch.
  5. Remove the transaxle range switch lever nut and lever. (Scheme 58)
  6. Remove the transaxle range switch bolts and remove the switch.

Installation (Second Design - Old Switch)

  1. Make sure the transaxle manual shaft is in the Neutral position.
  2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch.
  3. Loosely install the transaxle range switch bolts.
  4. Insert the Alignment Tool (J 41545) as shown and rotate the switch until the tool drops onto position. (Scheme 59)
  5. Tighten the transaxle range switch bolts to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000).
  6. Remove the alignment tool.
  7. Install the transaxle range switch lever and nut. Tighten the transaxle range switch lever retaining nut to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000).
  8. Connect the transaxle range switch electrical connectors.
  9. Install the shift control cable to transaxle range switch lever and verify proper operation.
  10. Install the shift control cable to transaxle range switch lever and verify proper operation.

Installation (Second Design - New Switch)

  1. Make sure the transaxle manual shaft is in the Neutral position.
  2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch.
  3. Tighten the transaxle range switch bolts to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000) .
  4. Install the transaxle range switch lever and nut. Tighten the transaxle range switch lever retaining nut to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000) .
  5. Install the brake pressure modulator valve bracket.
  6. Install the shift control cable to transaxle range switch lever and verify proper operation.
  1. Disconnect the negative battery cable.
  2. Raise and support the vehicle.
  3. Remove the electrical connector at the vehicle speed sensor.
  4. Remove the retaining stud and the sensor. (Scheme 60) Pull straight out in order to avoid damage to the case.

Scheme 60

Scheme 60
Scheme 60
  1. Clean and dry the vehicle speed sensor.
  2. Install the vehicle speed sensor and the retaining stud. (Scheme 60) Tighten the stud to specification. See «TORQUE SPECIFICATIONS»(ref-151429-S11054608362002121900000).
  3. Install the electrical connector at the sensor.
  4. Lower the vehicle.
  5. Connect the negative battery cable.

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