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Automatic Transmission (Af 40-6): Component Locations Saab 9-4X I

Automatic Trans 89 illustrations ~3729 words

Special Tools

Illustration Tool Number/Description DT-498-B GE-498-B KM-498-B CH-48027 J-21867-A Pressure Measuring Equipment DT-519 KM-519 Oil Seal/Ring Installer DT-674-A KM-674-A J-29077 Installer DT-6328 KM-6328 Adapter DT-6329 KM-6329 J-21867-50 Adapter DT-41623-B KM-J-41623-B J-41623-B 8792806 Disconnect Tool DT-45096 J-45096 TransFlow Cooler Flush Machine DT-45096-30 J-45096-30 TransFlow Adapter EN-328-B KM-328-B J-6125-1B Pin Remover EN-469-A KM-469-A J-23129 Remover/Installer J-41239-1A Seal Installer J-45000 Seal Remover J-45201 Seal Remover

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Scheme 10: Special Tools

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Scheme 14: Transmission Identification Information

For automatic transmission AF40, the identification plate is on the top of the transmission housing.

PositionData
1Aisin Warner transmission type
2Fabrication line 1 = 000001 - 500000 Fabrication line 2 = 500001 - 999999
3Transmission type (AF40)
4Model code
5GM parts number
6Production serial number 04 = Year of production (2004) F = Month of production A: January B: February C: March D: April E: May F: June G: July H: August J: September K: October L: November M: December 38 = Model Designation 00001 = Production Serial Number
  1. DT-498-B Pressure Measuring Equipment
  2. DT-6329 Adapter

For equivalent regional tools, refer to SPECIAL TOOLS .

  1. DT-45096 TransFlow Cooler Flush Machine
  2. DT-45096-30 TransFlow Adapter

For equivalent regional tools, refer to SPECIAL TOOLS .

GM studies indicate that plugged or restricted transmission oil coolers and pipes cause insufficient transmission lubrication and elevated operating temperatures which can lead to premature transmission failure. Many repeat repair cases could have been prevented by following published procedures for transmission oil cooler flushing and flow checking. This procedure includes flow checking and flushing the auxiliary transmission oil cooler, if equipped.

Note. Use the DT-45096 TransFlow Cooler Flush Machine or equivalent to flush and flow test the transmission oil cooler and the oil cooler pipes after the transaxle is removed for repairs or replacement. Use only GM Goodwrench DEXRON VI automatic transmission fluid in the DT-45096 TransFlow Cooler Flush Machine. In AF40-6 automatic transmission fluid AW-1 is used. After performing flushing and flow test, remove remaining DEXRON VI in the oil cooler by carefully blowing with compressed air.

Time allowance for performing the cooler flow checking and flushing procedure is included in the appropriate labor time guide operations. The service procedure steps for oil cooler flushing and flow testing are as follows

  1. DT-45096 TransFlow Cooler Flush Machine
  2. DT-45096-30 TransFlow Adapter
  3. Shop air supply with water/oil filters, regulator and pressure gauge - minimum 90 psi
  4. Eye protection
  5. Rubber gloves

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Scheme 15: Machine Set-up

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Scheme 17
  1. Verify that the main power switch (1) is in the OFF position.
  2. Place the main function switch (2) in the IDLE position.
  3. Connect DT-45096 flush machine to the vehicle 12V DC power source by connecting the red battery clip to the positive, +, battery post on the vehicle and connect the negative lead to a known good chassis ground.
  4. Turn the main power switch to the ON position.
  5. WARNING: Do not overfill the supply vessel. Damage to the unit may result. To verify the fluid level, view the LCD screen display while filling the unit, to ensure the fluid level does not exceed 30 L (32 qt). Fill the supply tank with Dexron®VI through the fill port.
  6. Reinstall and tighten the fill cap.
  7. Connect a shop air supply hose to the quick-disconnect on the rear panel marked SUPPLY AIR.

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Scheme 18: Determine Minimum Flow Rate

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Scheme 19
  1. From the machine display, identify the temperature of the automatic transmission fluid that is stored in the supply vessel of DT-45096 flush machine.
  2. Determine whether the transmission oil cooler is steel or aluminum by using a magnet (1) at the cooler flange (2) at the radiator.
  3. Refer to the table below. Using the temperature from step 1 , locate on either the Steel MINIMUM Flow Rate table or the Aluminum MINIMUM Flow Rate table the minimum flow rate in gallons per minutes (GPM). Record the minimum flow rate in GPMs and the supply fluid temperature for further reference. Example: Fluid temperature: 75°F Cooler type: Steel The MINIMUM flow rate for this example would be 0.8 GPM.
  1. Inspect transmission oil cooler lines for damage or kinks that could cause restricted oil flow. Repair as needed and refer to the appropriate GM service manual procedures.

Location (pos)

  1. 01 - Front
  2. 02 - Rear
  3. 03 - Left
  4. 04 - Right Hand
  5. 05 - All
  6. 06 - Upper
  7. 07 - Center
  8. 08 - Lower
  9. 09 - Service Information
  1. 01 - Front
  2. 02 - Rear
  3. 03 - Left
  4. 04 - Right Hand
  5. 05 - All
  6. 06 - Upper
  7. 07 - Center
  8. 08 - Lower
  9. 09 - Service Information

Scheme 20

Scheme 20: Control Lever Knob Replacement
CalloutComponent Name
1Shift Control Knob Bezel NOTE: Removal: Carefully insert a small flat-bladed tool between the bezel (1) and the shift knob (3). Apply careful downward pressure to the bezel to separate the bezel from the shift knob. The bezel will drop down approximately 13.0 mm (0.5 in) exposing the spring clip (2). Installation: Lift the bezel (1) up to the shift knob (3) until a click sound is heard indicating the bezel is secured to the shift knob.
2Shift Control Knob Spring Clip NOTE: Place the shift control in the Drive position, then remove the spring clip from the front of the shift knob.
3Shift Control Knob
NOTE
Removal: Carefully insert a small flat-bladed tool between the bezel (1) and the shift knob (3). Apply careful downward pressure to the bezel to separate the bezel from the shift knob. The bezel will drop down approximately 13.0 mm (0.5 in) exposing the spring clip (2). Installation: Lift the bezel (1) up to the shift knob (3) until a click sound is heard indicating the bezel is secured to the shift knob.
NOTE
Place the shift control in the Drive position, then remove the spring clip from the front of the shift knob.

Scheme 21

Scheme 21: Transmission Control Lever Boot Replacement
CalloutComponent Name
Preliminary Procedures Remove the automatic transmission control knob. Refer to TRANSMISSION CONTROL LEVER KNOB REPLACEMENT .
1Automatic Transmission Control Boot Assembly Procedure Use a flat bladed plastic trim tool in order to release the retaining tabs securing the boot assembly to the front floor console transmission shift opening trim plate.

Scheme 22

Scheme 22: Transmission Control Replacement
CalloutComponent Name
Preliminary Procedures Remove the FRONT FLOOR CONSOLE EXTENSION . Remove the front floor console trim plate. Refer to FRONT FLOOR CONSOLE TRIM PLATE REPLACEMENT . Disconnect the range selector lever cable. Refer to RANGE SELECTOR LEVER CABLE REPLACEMENT . Disconnect the transmission control electrical connector.
1Transmission Control Fasteners (Qty: 4) Refer to FASTENER CAUTION . Tighten 25 Nm (18 lb ft)
2Transmission Control

Scheme 23

Scheme 23: Range Selector Lever Cable Adjustment
  1. NOTE: Adjust the automatic transmission range selector cable while the transmission and the gear selector are in the Park position only. Failure to do so may cause misadjustment. Set the park brake and chock the wheels.
  2. Verify the transmission range select lever is in the park position.
  3. Verify the transmission manual shift lever is in the park position.
  4. If installing a new cable, skip this step and go to the next step. Pull the retaining collar (1) forward, then release the range select cable adjuster clip (2) by pushing up on the adjuster clip from the underside. Depress the adjuster clip (2) locking the adjuster clip completely.
  5. Ensure that the cable adjuster is secured.
  6. Check the transmission range select lever in all gear selections for proper operation.

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Scheme 24: Removal Procedure

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Scheme 26
  1. Set the park brake and chock the wheels.
  2. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin (6).
  3. Slide the retainer (4) rearward to release the transmission range selector lever cable from the bracket.
  4. Remove the front floor console extension. Refer to «FRONT FLOOR CONSOLE EXTENSION REPLACEMENT»(ref-652235-S07389571222014082300000) .
  5. Disconnect the transmission range selector lever cable retainers (2) from the support bracket.
  6. Remove the grommet (1) and cable assembly from the floor panel.
  7. Slide the transmission range selector lever cable retainer forward (1) and remove the transmission range selector cable from the transmission control base.
  8. Disconnect the transmission range selector lever cable terminal (2) from the shift lever pin.
  9. Remove the transmission range selector lever cable from the vehicle.

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Scheme 27: Installation Procedure

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Scheme 29
  1. Install the transmission range selector lever cable in the vehicle.
  2. Connect the transmission range selector lever cable terminal (2) to the shift lever pin.
  3. Install the transmission range selector cable to the transmission control base, then slide the transmission range selector lever cable retainer rearward (1) to lock the cable in place.
  4. NOTE: Ensure the grommet is properly oriented with paint dot facing top. Install the grommet (1) and cable assembly into the floor panel.
  5. Connect the transmission range selector lever cable retainers (2) to the support bracket.
  6. Install the front floor console extension. Refer to «FRONT FLOOR CONSOLE EXTENSION REPLACEMENT»(ref-652235-S07389571222014082300000) .
  7. Connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever pin (6).
  8. Install the cable in the bracket, then slide the retainer (4) forward to lock the transmission range selector lever cable in the bracket.
  9. Adjust the cable. Refer to «RANGE SELECTOR LEVER CABLE ADJUSTMENT»(ref-652265-S15692028382014082300000) .

Scheme 30

Scheme 30: Automatic Transmission Range Selector Lever Replacement
CalloutComponent Name
Preliminary Procedures Remove the battery tray. Refer to BATTERY TRAY REPLACEMENT . Ensure that the shift control range select lever is in the park (P) position. Disconnect the shift control cable from the transaxle range switch lever. Depress the shift control cable retainer clip tabs and remove the shift control cable from the shift control cable bracket.
1Automatic Transmission Range Selector Lever Fastener WARNING: Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. Refer to FASTENER CAUTION . Tighten 15 Nm (11 lb ft)
2Automatic Transmission Range Selector Lever Washer
3Automatic Transmission Range Selector Lever
WARNING
Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position.

Scheme 31

Scheme 31: Transmission Control Module Replacement
CalloutComponent Name
Preliminary Procedures Remove the battery tray. Refer to BATTERY TRAY REPLACEMENT . Remove the lever linkage. Refer to AUTOMATIC TRANSMISSION RANGE SELECTOR LEVER REPLACEMENT . Disconnect the TCM electrical connector.
1Transmission Control Module Fastener (Qty: 3) Refer to FASTENER CAUTION . Tighten 25 Nm (18 lb ft)
2Transmission Control Module Procedure Set the inner, rotating section of the control module so that the arrow is pointing towards the marking on the housing. Carry out adaptation, resetting. Refer to TRANSMISSION ADAPTIVE FUNCTIONS . Program the gear selector position sensor in neutral, using the scan tool. NOTE: Twisting or tilting of the transmission control module electrical connector while disconnecting may result in bent or misaligned electrical terminal pins.
NOTE
Twisting or tilting of the transmission control module electrical connector while disconnecting may result in bent or misaligned electrical terminal pins.

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Scheme 32: Removal Procedure

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Scheme 33
  1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-652230-S26645367622014082300000) .
  2. Remove the front transaxle mount through bolt (1).
  3. Remove and discard the three transaxle mount-to-transaxle attachment bolts (2).
  4. Remove the transaxle mount (1) from the vehicle.

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Scheme 34: Installation Procedure

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Scheme 35
  1. Install the transaxle mount (1).
  2. Refer to «FASTENER CAUTION»(ref-652265-S21063658522014082300000) . Install the transaxle NEW brace bolts (2) and tighten to 62 Nm (46 lb ft) .
  3. Install the transaxle bolt (1) and tighten to 105 Nm (77 lb ft) .
  4. Lower the vehicle.

Scheme 36

Scheme 36: Transmission Rear Mount Replacement
CalloutComponent Name
Preliminary Procedures Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE . Lower the Drivetrain and Front Suspension Frame approx. 10 cm. Refer to DRIVETRAIN AND FRONT SUSPENSION FRAME INSULATOR REPLACEMENT .
1Transmission Rear Mount Fastener (Qty: 3) Refer to FASTENER CAUTION . Tighten 100 Nm (74 lb ft)
2Transmission Rear Mount Fastener Tighten 62 Nm (46 lb ft)
3Transmission Rear Mount Fastener (Qty: 2) Tighten 100 Nm (74 lb ft)
4Transmission Rear Mount

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Scheme 37: Removal Procedure

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Scheme 40
  1. Remove the battery box. Refer to «BATTERY TRAY REPLACEMENT»(ref-652241-S39377734662014082300000) .
  2. Install the engine support fixture. Refer to «ENGINE SUPPORT FIXTURE (ENGINE BRIDGE, RETAINER FRAME)»(ref-652231-S17556864582014082300000) «ENGINE SUPPORT FIXTURE (CENTERING ADAPTER)»(ref-652231-S04641133612014082300000) .
  3. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-652230-S26645367622014082300000) .
  4. Remove the front transmission mount through bolt (1).
  5. Remove the rear transmission mount through bolt (1).
  6. Remove the transmission mount to transmission bolts (1).
  7. Using the engine support, lower the transmission enough to provide clearance for the left transmission mount.
  8. Remove the transmission mount to frame rail bolts (1).
  9. Remove the left transmission mount (2).

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Scheme 41: Installation Procedure

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Scheme 44
  1. Install the left transmission mount (2).
  2. Refer to «FASTENER CAUTION»(ref-652265-S21063658522014082300000) . Install the transmission mount bracket to transmission bolt (1) and tighten to 22 Nm (16 lb ft) .
  3. Using the engine support, raise the transmission until the transmission contacts the left transmission mount.
  4. NOTE: DO NOT reuse the old bolts. Always use NEW bolts when reinstalling the mount. Install the transmission mount bracket to transmission bolts (1) and tighten to 50 Nm (37 lb ft) plus 60-75 degrees .
  5. Install the wheel and tire assembly. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-652234-S18162824462014082300000) .
  6. Raise the vehicle.
  7. Install the rear transmission mount through bolt (1) and tighten to 105 Nm (77 lb ft) .
  8. Install the front transmission mount through bolt (1) and tighten to 100 Nm (74 lb ft) .
  9. Lower the vehicle.
  10. Remove the engine support fixture.
  11. Install the battery box. Refer to «BATTERY TRAY REPLACEMENT»(ref-652241-S39377734662014082300000) .

Scheme 45

Scheme 45: Control Valve Body Cover Replacement
CalloutComponent Name
Preliminary Procedures Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE . Remove the left front wheelhouse liner. Refer to FRONT WHEELHOUSE LINER REPLACEMENT . Remove the transaxle oil cooler lines and seals from the transaxle. Refer to TRANSMISSION FLUID COOLER HOSE REPLACEMENT .
1Control Valve Body Fastener (Qty: 11) Refer to FASTENER CAUTION . Procedure Install the control valve body cover bolts hand tight. Use locking agent on ALL bolts. Refer to ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS . Tighten the control valve body cover bolts in the sequence shown. Tighten 13 Nm (10 lb ft)
2Control Valve Body Cover Procedure Install a 3 mm (0.125 in) bead of RTV sealer on to the control valve body cover. Clean any gasket material from the control valve body cover and inspect the gasket mounting surface. Check the transaxle fluid level. Refer to TRANSMISSION FLUID LEVEL AND CONDITION CHECK . NOTE: Do not pry with a tool on the transaxle control valve body cover, case or sealing surfaces.
NOTE
Do not pry with a tool on the transaxle control valve body cover, case or sealing surfaces.

Scheme 46

Scheme 46: Removal Procedure

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Scheme 52
  1. Remove control valve body cover. Refer to «CONTROL VALVE BODY COVER REPLACEMENT»(ref-652265-S27932581382014082300000) .
  2. Detach the wiring harness for the solenoid valves. (The illustration shows how to use a screwdriver for detaching the different connectors.) 2.1. Detach 8 connectors from the solenoid valves (1). 2.2. Unplug the 2 connectors from the engine speed sensors (2). 2.3. Remove the wiring harness from the 2 retaining clips (3).
  3. Unplug the engine speed sensor connectors. Detach the connectors from the two mountings (4).
  4. Remove the temperature sensor. 4.1. Remove the screw (1). 4.2. Lift away the attaching plate (2). 4.3. Remove the temperature sensor (3).
  5. Move the wiring harness for the solenoid valves and the wiring harness for the engine speed sensors aside.
  6. Remove the cover (1). 6.1. Remove the screws (2). 6.2. Remove the gasket (3).
  7. Remove the valve housing. 7.1. Undo the fasteners in the specified order. 7.2. Remove the fasteners.
  8. Lower the car to the floor.
  9. Unhook the clutch rod (1).
  10. NOTE: The ducts are filled with oil. Carefully lift the valve housing upwards.

Scheme 53

Scheme 53: Installation Procedure

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Scheme 59
  1. Clean the sealing surfaces.
  2. Clean the threads (arrows).
  3. Install the valve housing. 3.1. Hook in the clutch rod (1). 3.2. Install 6 fasteners.
  4. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-652230-S26645367622014082300000) .
  5. Install the cover. 5.1. Install a new gasket (3). 5.2. Install the cover (1). 5.3. Install two screws (2).
  6. Finish fitting the valve housing.
  7. Refer to «FASTENER CAUTION»(ref-652265-S21063658522014082300000) . Tighten the 8 fasteners (arrows) in the specified order. Tighten 10 Nm (88 lb in)
  8. Install the temperature sensor (3). 8.1. Moisten the temperature sensor O-ring with gearbox oil. 8.2. Install the attaching plate (2). 8.3. Tighten the fastener (1). Tighten 10 Nm (88 lb in)
  9. Plug in the engine speed sensor connectors. Attach the connectors to the two mountings (4).
  10. Plug in the connector for the solenoid valves. 10.1. Secure the wiring harness in the 2 retaining clips (3). 10.2. Plug in the 2 connectors for the engine speed sensors (2). 10.3. Plug in the 8 connectors for the solenoid valves (1).
  11. Install control valve body. Refer to «CONTROL VALVE BODY COVER REPLACEMENT»(ref-652265-S27932581382014082300000) .
  12. Lower the vehicle.

Scheme 60

Scheme 60: Removal Procedure

Scheme 61

Scheme 61
  1. NOTE: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in).
  2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed.
  3. Remove the retaining ring from the quick connect fitting.
  4. Discard the retaining ring.
  5. Pull the cooler line straight out from the quick connect fitting.

Scheme 62

Scheme 62: Installation Procedure

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Scheme 71
  1. NOTE: Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. Ensure the following procedures are performed when installing the new retaining rings onto the fittings. Install a new retaining ring into the quick connect fitting using the following procedure
  2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
  3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting.
  4. Do not install the new retaining ring onto the fitting by pushing the retaining ring.
  5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots.
  6. Install the cooler line into the quick connect fitting.
  7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt.
  8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting.
  9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting.
  10. IMPORTANT: Do not manually depress the retaining clip when installing the plastic cap. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting.
  11. Ensure that the plastic cap is fully seated against the fitting.
  12. Ensure that no gap is present between the cap and the fitting.
  13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting.
  14. A hidden yellow identification band indicates proper joint seating.
  15. Fill the transmission to the proper level. Refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS»(ref-652265-S25988896342014082300000) and «TRANSMISSION FLUID LEVEL AND CONDITION CHECK»(ref-652265-S16994866682014082300000) .

Scheme 72

Scheme 72: Removal Procedure
  1. Drain the cooling system. Refer to «DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) , «DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) or «DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .
  2. Remove the transaxle oil cooler hoses from the oil cooler fittings on the radiator. Refer to «TRANSMISSION FLUID COOLER HOSE/PIPE QUICK-CONNECT FITTING DISCONNECTION AND CONNECTION»(ref-652265-S09980399162014082300000) .
  3. NOTE: Do not remove the upper and lower transaxle oil cooler fittings from the radiator at the same time other wise the transaxle oil cooler will fall inside the radiator end tank. Remove the oil cooler fitting from the radiator.

Scheme 73

Scheme 73: Installation Procedure
  1. Inspect the new O-ring seals for cracks, cuts or damage. Replace if necessary.
  2. Refer to «FASTENER CAUTION»(ref-652265-S21063658522014082300000) . NOTE: The correct thread engagement is critical. Cross-threaded fittings can achieve proper tightness and still leak. Install the oil cooler fitting to the radiator and tighten to 38 Nm (28 lb ft) .
  3. Install the transaxle oil cooler hoses to the oil cooler fittings on the radiator. Refer to «TRANSMISSION FLUID COOLER HOSE/PIPE QUICK-CONNECT FITTING DISCONNECTION AND CONNECTION»(ref-652265-S09980399162014082300000) .
  4. Fill the cooling system. Refer to «DRAINING AND FILLING (GE 47716)»(ref-652237-S23590170992014082300000) , «DRAINING AND FILLING (STATIC FILL LAU)»(ref-652237-S36839240752014082300000) , or «DRAINING AND FILLING (STATIC FILL LF1)»(ref-652237-S01219592032014082300000) .
  5. Adjust the transmission fluid level.
  6. Inspect for fluid leaks.
  1. DT-41239-1A Cooler Line Seal Installer
  2. DT-45201 Cooler Line Seal Remover

For equivalent regional tools, refer to SPECIAL TOOLS .

Scheme 74

Scheme 74: Removal Procedure

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Scheme 77
  1. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-652230-S26645367622014082300000) .
  2. WARNING: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. Place a drain pan or suitable container under the vehicle.
  3. Remove the transaxle oil cooler line assembly nut from the transaxle.
  4. Disconnect the transaxle oil cooler lines from the vehicle.
  5. NOTE: Ensure that the J 45201 is fully seated into the transaxle seal bore. Insert the collet piece (2) of the DT-45201 Cooler Line Seal Remover into the cooler line seal.
  6. Insert the forcing screw piece (1) of the DT-45201 Cooler Line Seal Remover into the collet (2).
  7. Tighten the forcing screw (1) until snug.
  8. Thread the collar piece (1) of the DT-45201 Cooler Line Seal Remover onto the collet (3) until snug.
  9. Turn the collar clockwise in order to remove the cooler line seal (87).
  10. Discard the seal (87).
  11. Clean the case bores for the cooler line seals.

Scheme 78

Scheme 78: Installation Procedure

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Scheme 80

Scheme 80
  1. Insert a new transaxle cooler line seal into the case bore.
  2. Remove the nub from the DT-41239-1A Cooler Line Seal Installer.
  3. Install the nub of the DT-41239-1A Cooler Line Seal Installer on the transaxle cooler line seal.
  4. Tap the new transaxle cooler line seal into the case bore.
  5. Install the transaxle oil cooler line assembly to the transaxle.
  6. Refer to «FASTENER CAUTION»(ref-652265-S21063658522014082300000) . Install the transaxle oil cooler line assembly nut and tighten to 9 Nm (80 lb in) .
  7. Lower the vehicle.
  8. NOTE: DEXRON® VI automatic transmission fluid is not compatible with this transaxle. If DEXRON® VI ATF is used, transaxle failure will result. This transaxle uses GM AW-1 fluid P/N 19256039. Add fluid to the transaxle. Refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS»(ref-652265-S25988896342014082300000)
  9. Start the engine and check for leaks.

Scheme 81

Scheme 81: Transmission Fluid Cooler Hose Replacement
CalloutComponent Name
Preliminary Procedures Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE . Disconnect the transmission lines from the radiator. Refer to TRANSMISSION FLUID COOLER HOSE/PIPE QUICK-CONNECT FITTING DISCONNECTION AND CONNECTION .
1Transmission Fluid Cooler Pipe Bracket Nut Refer to FASTENER CAUTION . Tighten 10 Nm (89 lb in)
2Transmission Fluid Cooler Hose Procedure Discard the hose and install NEW seals prior to installation of the pipe. Refer to TRANSMISSION FLUID COOLER PIPE SEAL REPLACEMENT

Scheme 82

Scheme 82: Front Axle Shaft Seal Replacement - Left Side
CalloutComponent Name
WARNING: Always use the proper automatic transmission fluid listed. Using incorrect automatic transmission fluid may damage the vehicle. Preliminary Procedures Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE . Place a drain pan under the transaxle to catch any spilled transaxle fluid. Remove the left front wheel drive shaft from the transmission. Refer to FRONT WHEEL DRIVE SHAFT REPLACEMENT . Clean the seal bore in the transaxle housing. Inspect the transaxle fluid level. Refer to TRANSMISSION FLUID LEVEL AND CONDITION CHECK .
1Front Axle Shaft Seal Special Tools DT-519 Installer EN-45000 Seal Remover
WARNING
Always use the proper automatic transmission fluid listed. Using incorrect automatic transmission fluid may damage the vehicle.

Scheme 83

Scheme 83: Torque Converter Replacement
CalloutComponent Name
Preliminary Procedures Remove the transmission. Refer to TRANSMISSION REPLACEMENT . Place a drain pan under the vehicle.
1Torque Converter WARNING: Only install the lift assist handles until it stops. Do not tighten. Over tightening the lift assist handles can cause damage to the torque converter. WARNING: Lower the torque converter straight down. Failure to lower the torque converter straight down could damage the torque converter clutch lip seal inside the torque converter clutch assembly. Procedure Check that the torque converter has reached the correct position by placing a steel ruler on the torque converter shell's mating surface and measure the surface between the mating surface and the driving plate contact surface on the torque converter. The distance for the 2.8L LAU and 3.0L LF1 engines should be a minimum of 9 mm (0.35 in).
WARNING
Only install the lift assist handles until it stops. Do not tighten. Over tightening the lift assist handles can cause damage to the torque converter.
WARNING
Lower the torque converter straight down. Failure to lower the torque converter straight down could damage the torque converter clutch lip seal inside the torque converter clutch assembly.

Scheme 84

Scheme 84: Torque Converter Fluid Seal Replacement
CalloutComponent Name
Preliminary Procedures Remove the torque converter. Refer to TORQUE CONVERTER REPLACEMENT . Special Tools EN-328-B Remover EN-469-A Remover/installer DT-674-A Installer DT-6328 Adapter For equivalent regional tools, refer to SPECIAL TOOLS .
1Torque Converter Fluid Seal WARNING: Support the back side of the torque converter housing while installing the seal. Install the seal until it stops moving. Applying excessive pressure to the seal once it is seated could cause damage to the torque converter housing casting.
WARNING
Support the back side of the torque converter housing while installing the seal. Install the seal until it stops moving. Applying excessive pressure to the seal once it is seated could cause damage to the torque converter housing casting.
  1. CH-49290 Engine fixture
  2. CH-49289 Support frame fixture
  3. CH-904 Basic tool
  4. DT-47648 Transmission fixture
  5. EN-47649 Engine Bridge
  6. EN-47650 Retainer Frame

For equivalent regional tools, refer to SPECIAL TOOLS .

Scheme 85

Scheme 85: Removal Procedure

Scheme 86

Scheme 86

Scheme 87

Scheme 87

Scheme 88

Scheme 88

Scheme 89

Scheme 89
  1. Remove the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000) .
  2. Remove the battery tray. Refer to «BATTERY TRAY REPLACEMENT»(ref-652241-S39377734662014082300000) .
  3. Disconnect the connector (1) from the transmission control module.
  4. Remove the shift lever cable from the selector on the transmission. Refer to «RANGE SELECTOR LEVER CABLE REPLACEMENT»(ref-652265-S30276357842014082300000) .
  5. Remove upper transmission fasteners (1).
  6. Install the engine support fixture. Refer to «ENGINE SUPPORT FIXTURE (ENGINE BRIDGE, RETAINER FRAME)»(ref-652231-S17556864582014082300000) and «ENGINE SUPPORT FIXTURE (CENTERING ADAPTER)»(ref-652231-S04641133612014082300000) .
  7. Raise the vehicle.
  8. Drain the transmission fluid.
  9. Remove the exhaust front pipe. Refer to «EXHAUST FLEXIBLE PIPE REPLACEMENT (LAU)»(ref-652240-S22994477482014082300000) or «EXHAUST FLEXIBLE PIPE REPLACEMENT (LF1-SERVICE)»(ref-652240-S39572498132014082300000) .
  10. Install CH-49290 Engine fixture and CH-49289 Support frame fixture.
  11. Remove the frame. Refer to «DRIVETRAIN AND FRONT SUSPENSION FRAME INSULATOR REPLACEMENT»(ref-652247-S00711622472014082300000) .
  12. Remove the transmission front mount. Refer to «TRANSMISSION FRONT MOUNT REPLACEMENT»(ref-652265-S39316327472014082300000) .
  13. Remove the transmission rear mount bracket. Refer to «TRANSMISSION REAR MOUNT REPLACEMENT»(ref-652265-S41712967522014082300000) .
  14. Remove the right wheel driveshaft. Refer to «FRONT WHEEL DRIVE SHAFT REPLACEMENT»(ref-652249-S17747125552014082300000) .
  15. Remove the left wheel drive shaft. Refer to «FRONT WHEEL DRIVE SHAFT REPLACEMENT»(ref-652249-S17747125552014082300000) .
  16. Remove the transfer case from the transmission. Refer to «TRANSFER CASE REPLACEMENT»(ref-652248-S04533415112014082300000)
  17. Remove the starter. Refer to «STARTER REPLACEMENT (LAU)»(ref-652241-S14690624992014082300000) or «STARTER REPLACEMENT (LF1)»(ref-652241-S08189275452014082300000) .
  18. Remove the six fasteners (1) from the flywheel to the torque converter.
  19. Remove the oil cooler hose connection (1) from the transmission.
  20. Remove the fasteners to the transmission mount bracket left side. Refer to «FRONT AXLE SHAFT SEAL REPLACEMENT - LEFT SIDE»(ref-652265-S27598727142014082300000) .
  21. Lower the vehicle.
  22. Adjust the settings of the CH-904 Basic tool and lower the engine enough to access the transmission.
  23. Raise the vehicle.
  24. Support the transmission with DT-47648 Transmission fixture and a transmission jack. graphic here
  25. Remove the lower transmission fasteners.
  26. Separate the transmission from the engine.
  27. Secure the torque converter in the transmission to prevent it from falling.
  28. Lower the transmission.

Scheme 90

Scheme 90: Installation Procedure

Scheme 91

Scheme 91

Scheme 92

Scheme 92

Scheme 93

Scheme 93
  1. Lubricate the centering pin on the converter and the two guiding sleeves.
  2. Check torque converter for correct transmission positioning.
  3. Position the transmission to the engine.
  4. Refer to «FASTENER CAUTION»(ref-652265-S21063658522014082300000) . Install the one lower transmission fastener (1) and tighten to 60 Nm (44 lb ft) .
  5. Install the four lower transmission fasteners (2) and tighten to 40 Nm (30 lb ft) .
  6. Install the transfer case to the transmission. Refer to «TRANSFER CASE REPLACEMENT»(ref-652248-S04533415112014082300000)
  7. Remove the DT-47648 Transmission fixture and the transmission jack.
  8. Lower the vehicle.
  9. Raise the engine to the correct level with the engine support fixture.
  10. Install the fasteners to the transmission mount bracket left side. Refer to «TRANSMISSION MOUNT REPLACEMENT - LEFT SIDE»(ref-652265-S23166069232014082300000)
  11. Install the upper transmission fasteners (1) and tighten to 60 Nm (44 lb ft) .
  12. Connect the shift lever cable to the selector lever on the transmission. Refer to «RANGE SELECTOR LEVER CABLE REPLACEMENT»(ref-652265-S30276357842014082300000) .
  13. Connect the electrical connector to the transmission control module.
  14. Raise the vehicle.
  15. Install the fasteners to the converter. Apply locking agent on the bolts and tighten to 60 Nm (44 lb ft) .
  16. Install the starter. Refer to «STARTER REPLACEMENT (LAU)»(ref-652241-S14690624992014082300000) or «STARTER REPLACEMENT (LF1)»(ref-652241-S08189275452014082300000) .
  17. Install the oil cooler hose connection (1) to the transmission and tighten to 10 Nm (89 lb in) .
  18. Install the transmission rear mount bracket. Refer to «TRANSMISSION REAR MOUNT REPLACEMENT»(ref-652265-S41712967522014082300000) .
  19. Install the transmission front mount. Refer to «TRANSMISSION FRONT MOUNT REPLACEMENT»(ref-652265-S39316327472014082300000) .
  20. Install the right driveshaft. Refer to «FRONT WHEEL DRIVE SHAFT REPLACEMENT»(ref-652249-S17747125552014082300000) .
  21. Install the left driveshaft to the transmission. Refer to «FRONT WHEEL DRIVE SHAFT REPLACEMENT»(ref-652249-S17747125552014082300000) .
  22. Install the CH-49290 Engine fixture with the engine guiding pins.
  23. Install the frame. Refer to «DRIVETRAIN AND FRONT SUSPENSION FRAME INSULATOR REPLACEMENT»(ref-652247-S00711622472014082300000) .
  24. Remove the CH-49290 Engine fixture and the CH-49289 Support frame fixture
  25. Install the exhaust front pipe. Refer to «EXHAUST FLEXIBLE PIPE REPLACEMENT (LAU)»(ref-652240-S22994477482014082300000) or «EXHAUST FLEXIBLE PIPE REPLACEMENT (LF1-SERVICE)»(ref-652240-S39572498132014082300000) .
  26. Lower the vehicle.
  27. Remove the engine support fixture.
  28. Install the battery tray and battery. Refer to «BATTERY TRAY REPLACEMENT»(ref-652241-S39377734662014082300000) .
  29. Check the transmission fluid. Refer to «TRANSMISSION FLUID LEVEL AND CONDITION CHECK»(ref-652265-S16994866682014082300000) .
  30. Install the intake manifold cover. Refer to «INTAKE MANIFOLD COVER REPLACEMENT»(ref-652231-S15941694392014082300000) .

Scheme 94

Scheme 94: Removal Procedure
  1. Remove control valve body cover. Refer to «CONTROL VALVE BODY COVER REPLACEMENT»(ref-652265-S27932581382014082300000) .
  2. Remove control valve body. Refer to «CONTROL VALVE BODY REPLACEMENT»(ref-652265-S16463239452014082300000) .
  3. Remove the transmission control module, see «TRANSMISSION CONTROL MODULE, REPLACEMENT»(ref-652265-S07524743032014082300000) .
  4. Remove the wiring harness. Remove the clip (1). Lift out the wiring harness (2).

Scheme 95

Scheme 95: Installation Procedure

Scheme 96

Scheme 96
  1. Fit the wiring harness. Fit a new seal (2) in the gearcase and an O-ring (1) on the connection.
  2. Fit in the wiring harness (2). Make sure that the connector's guide pin locates in the groove and fit the clip (1).
  3. Fit the transmission control module. Refer to «TRANSMISSION CONTROL MODULE REPLACEMENT»(ref-652265-S07524743032014082300000) .
  4. Fit the control valve body. Refer to «CONTROL VALVE BODY REPLACEMENT»(ref-652265-S16463239452014082300000) .
  5. Fit the control valve body cover. Refer to «CONTROL VALVE BODY COVER REPLACEMENT»(ref-652265-S27932581382014082300000) .

Scheme 97

Scheme 97: Power, Ground, Data Communication, Malfunction Indicator, and Tap Up/Tap Down

Scheme 98

Scheme 98: Speed Sensors, Transmission Fluid Temperature, Pressure Controls and Shift Controls