Home ReviewsRefund
Home/Saturn/ION/Saturn ION I (2003-2007)/Repair manual/Automatic Trans/Automatic Transaxle Overhaul - 4T40-E/4T45-E: Overhaul
Contents Wiring diagrams Section: Automatic Trans All sections

Automatic Transaxle Overhaul - 4T40-E/4T45-E: Overhaul Saturn ION I

Automatic Trans 12 illustrations ~6438 words

Transmission Holding Fixture Assemble

Tools Required

  1. J 41230 Transmission Support Fixture. See «Special Tools»(ref-200504-S20398696432005102000000) .
  2. J 41230-TEM Drill Template. See «Special Tools»(ref-200504-S20398696432005102000000) .
  3. J 3289-20 Support Fixture. See «Special Tools»(ref-200504-S20398696432005102000000) .
  1. Install the J 41230 transmission support fixture onto the transmission. See «Special Tools»(ref-200504-S20398696432005102000000) .
  2. Install the support fixture bolts. Tighten: Tighten the support fixture bolts to 11 N.m (8 lb ft).
  3. Install the transmission and the support fixture onto the J 3289-20 fixture base. See «Special Tools»(ref-200504-S20398696432005102000000) .
  4. Position the transmission with the side cover facing down.
  5. Insert the pin into the J 3289-20 fixture base in order to lock the unit into place. See «Special Tools»(ref-200504-S20398696432005102000000) .

Final Drive Assembly Disassemble

  1. Remove the differential pinion shaft retaining pin (704). Use a pin punch.
  2. Remove the differential pinion shaft (703).
  3. Remove the snap ring (57) from the end of the output shaft (94).
  4. Remove the output shaft (94) from the differential carrier (702).
  5. Remove the final drive sun gear (115).
  6. Remove the differential pinion gears (707) and the thrust washers (706).
  7. Remove the differential side gears (709) and the thrust washers (708).
  8. Remove the final drive carrier spiral retaining ring (701).
  9. Remove the four planet pinion pins (714).
  10. Remove the four pinion gears (711).
  11. Remove the pinion thrust washers (710).
  12. Remove the needle roller bearings (712).
  13. Remove the needle bearing spacers (713).
  14. Remove the final drive sun gear to carrier thrust bearing (700).
  15. Inspect the needle bearings (712), the thrust washers (710), the pinion gears (711), and the planet pinion pins (714) for excessive wear. Polishing is a normal condition for the pinion pins and the needle bearings.
  16. Inspect the pinion shaft (714) for spalling or for wear.
  17. Inspect the thrust washers (710) for wear and for cracks.
  18. Clean and dry the final drive carrier and the final drive components.

Final Drive Assembly Assemble

Tools Required

J 36850 TRANSJEL™

  1. Install the pinion gear needle bearing spacer (713) onto the planet pinion gear (711).
  2. Place a thrust washer (710) on the bottom of the planet pinion (711) in order to retain the bottom row of needle bearings.
  3. Use J 36850 or equivalent in order to aid in the assembly and in order to keep the needle roller bearings (712) in the race.
  4. Install the needle roller bearings (712) one at a time into the planet pinion (711).
  5. Install the sun gear to final drive carrier thrust bearing (700) onto the final drive carrier (116). Retain the thrust bearing with J 36850 or equivalent.
  6. Assemble the pinion gear thrust washers (710) and the planet pinion gears into the final drive carrier (702).
  7. Install the planet pinion gear pins (714) into the final drive carrier (702) in order to retain the planet pinion gears (711).
  8. Install the final drive carrier spiral retaining ring (701) in order to retain the planet pinion gear pins.
  9. Assemble the thrust washers (708) onto the differential side gears (709).
  10. Install the differential side gears into the final drive carrier (702).
  11. Assemble the thrust washers (706) onto the pinion gears (707). Retain the thrust washers with J 36850 or equivalent.
  12. With the thrust washers (706) attached, install the pinion gears (707) into the final drive carrier (702).
  13. Rotate the pinion gears (707) into position, and install the pinion shaft (703) through the final drive carrier (702) and through the pinion gears (707).
  14. Position the pinion shaft (703) in order to allow installation of the retaining pin.
  15. Install the retaining pin (704) through the final drive carrier (702) and through the pinion shaft (703) in order to retain the pinion shaft (703).

Final Drive and Differential Assembly Install

Tools Required

J 36850 TRANSJEL™

  1. Install the final drive carrier to case thrust bearing (117) onto the final drive carrier. Retain the bearing with J 36850 .
  2. Install the complete final drive carrier assembly (116) into the transmission case (51).
  3. Install the final drive sun gear (115) into the final drive carrier (116).

Forward Clutch Support, Roller Clutch Disassemble

  1. Remove the roller clutch assembly (652) from the forward clutch support (656) by turning the roller clutch assembly (652) clockwise and gently lifting upward.
  2. Remove the thrust bearing (113) from the forward clutch support (656).
  3. Remove the final drive sun gear shaft snap ring (660).
  4. Remove the parking pawl gear (659).
  5. Remove the forward clutch support to parking pawl gear thrust bearing (658).
  6. Remove the forward clutch support (656) from the final drive sun gear shaft (651).
  7. Remove and discard the two seals (654) from the forward clutch support (656).
  8. Inspect the snap ring for overextension (660).
  9. Inspect the seal grooves for damage (656).
  10. Inspect for signs of excessive bearing and bushing wear.
  11. Inspect the splines and the parking gear teeth for cracks or excessive wear.
  12. Inspect the fluid feed holes for the proper opening.
  13. Inspect all other components for excessive wear or damage.
  14. Clean and dry all of the components.

Forward Clutch Support, Low Roller Clutch Assemble

  1. Assemble two new seals (654) on the forward clutch support (656).
  2. Assemble the forward clutch support (656) onto the final drive sun gear shaft (651).
  3. Assemble the roller bearing (658) onto the forward clutch support (656).
  4. Assemble the parking pawl gear (659) onto the final drive sun gear shaft (651) with the raised inner boss facing up, so that the parking pawl properly engages the teeth on the parking pawl gear.
  5. Assemble the snap ring (660) to the final drive sun gear shaft (651) in order to retain the parking pawl gear (659).
  6. Assemble the lo roller clutch assembly (652) onto the forward clutch support (656). The larger tabs on the cage must face down into the forward clutch support (656). Rotate the cage slightly counterclockwise in order to lock the tabs into the grooves in the forward clutch support (656).
  7. Assemble the thrust bearing (113) onto the forward clutch support (656).

Forward Clutch Assembly Disassemble

Tools Required

  1. J 23327 Return Spring Compressor
  2. J 45398 Forward Clutch Inner Seal Puller. See «Special Tools»(ref-200504-S20398696432005102000000) .
  3. J 25031-A Puller/Inner Seal Remover. See «Special Tools»(ref-200504-S20398696432005102000000) .
  1. Remove the snap ring (600) from the housing assembly (609).
  2. Remove the backing plate (601).
  3. Remove the seven fiber plates (602).
  4. Remove the seven steel plates (603).
  5. Remove the wave plate (604).
  6. Compress the forward clutch return spring assembly. Use the J 23327 .
  7. Remove the return spring snap ring (605).
  8. Remove the J 23327 .
  9. Remove the forward clutch return spring assembly (606).
  10. Remove the forward clutch piston and seal assembly (607).
  11. Inspect the forward clutch inner seal assembly (608) for damage.
  12. If the seal is damaged, assemble J 45398-1 (3), which is part of J 45398 , onto the seal. See «Special Tools»(ref-200504-S20398696432005102000000) . Place the J 45398-2 (2), which is part of J 45398 , on the inner hub of the clutch housing.
  13. Use J 25031-A (1) to remove the seal. See «Special Tools»(ref-200504-S20398696432005102000000) .
  14. Inspect the housing, the plates, the bushings, the splines, the band apply surface, the roller clutch race, and the spring assembly.
  15. Inspect fluid feed holes for proper openings.
  16. Inspect the retainer and ball assembly for proper openings.
  17. Inspect the piston and seal assembly for cut seals or other damage. The piston and seal assemblies are reusable, if not damaged.
  18. Clean and dry all of the components.

Forward Clutch Assembly Assemble

Tools Required

  1. J 41231 Inner Seal Installer. See «Special Tools»(ref-200504-S20398696432005102000000) .
  2. J 23327 Return Spring Compressor
  1. Assemble a new inner seal assembly (608) if the old seal was damaged and removed. Use an arbor press and the J 41231 in order to press the inner seal assembly onto the forward clutch housing (609). See «Special Tools»(ref-200504-S20398696432005102000000) .
  2. Assemble the forward clutch piston assembly (607) into the forward clutch housing (609). In order to ease assembly, lubricate the seals with transmission fluid.
  3. With the snap ring tabs facing up, assemble the forward clutch return spring assembly (606) into the forward clutch housing (609).
  4. Compress the return spring assembly. Use the J 23327 .
  5. Assemble the snap ring (605) in order to retain the forward clutch return spring.
  6. Remove the J 23327 .
  7. Install the forward clutch waved plate (604).
  8. Install the seven steel plates (603) and the seven new fiber plates (602) in alternating order beginning with a steel plate (603).
  9. Install the forward clutch backing plate (601).
  10. Install the forward clutch backing plate snap ring (600) in order to retain the clutch pack.

Scheme 162

Scheme 162: Forward Clutch Functional Air Check
Scheme 162: Forward Clutch Functional Air Check

With air pressure set at 20 psi, check the forward clutch to verify proper operation of the seals and clutch assembly.

Scheme 163

Scheme 163: Low/Reverse Band Installation
Scheme 163: Low/Reverse Band Installation

Install the low/reverse band (111) into the transmission case. Align the servo pin apply surface toward the bottom pan and hook the band into the band anchor pin inside the transmission case.

Input Internal Gear, Forward Clutch Hub Disassemble

  1. If the thrust washer (109) has not been removed, remove the thrust washer (109) from the forward clutch hub (577).
  2. Remove the input internal gear to forward clutch hub assembly snap ring (578).
  3. Remove the forward clutch hub (577) from the input internal gear (560).
  4. Inspect the input internal gear (560) for damage or excessive wear.
  5. Inspect the forward clutch hub (577) splines for damage or excessive wear.
  6. Inspect the bushing and the thrust washer (109) for damage or excessive wear.
  7. Clean and dry all of the components.

Input Internal Gear, Forward Clutch Hub Assemble

Tools Required

J 36850 TRANSJEL™

  1. Assemble the forward clutch hub (577) onto the input internal gear (560) and retain it with the snap ring (578).
  2. Assemble the thrust washer (109) onto the forward clutch hub (577) with the thrust washer tabs toward the forward clutch hub (577). Retain the thrust washer with J 36850 or equivalent.

Scheme 164

Scheme 164: Input Internal Gear, Forward Clutch Hub Install
Scheme 164: Input Internal Gear, Forward Clutch Hub Install
IMPORTANTInstall the forward clutch hub and input internal gear assembly into the transmission case. Rotate the assembly while installing in order to spline the forward clutch hub (108) to the forward clutch plates (602).

Install the forward clutch hub and input internal gear assembly into the transmission case.

Reaction Internal Gear, Input Carrier Disassemble

  1. Remove the thrust bearing (107) from the reaction carrier (562) if the thrust bearing has not been removed.
  2. Remove the reaction internal gear (560) to input carrier assembly snap ring (563).
  3. Remove the input carrier assembly (562) from the reaction internal gear (560).

Reaction Internal Gear, Input Carrier Assemble

Tools Required

J 36850 TRANSJEL™

  1. Assemble the input carrier assembly (562) to the reaction internal gear (560.
  2. Retain the input carrier assembly with the snap ring (563).
  3. Assemble the thrust bearing (107) onto the input carrier assembly.
  4. Retain the thrust bearing with J 36850 or equivalent. You will find another thrust bearing permanently retained in the input carrier assembly (562).

Scheme 165

Scheme 165: Reaction Internal Gear, Input Carrier Installation
Scheme 165: Reaction Internal Gear, Input Carrier Installation
IMPORTANTWhile installing the reaction internal gear and input carrier assembly, rotate the assembly in order to mesh the input carrier pinion gears to the input internal gear.

Install the reaction internal gear and input carrier assembly (106) into the transmission case.

Direct/Coast Clutch, Reaction Carrier Disassemble

Tools Required

  1. J 23327 Clutch Spring Compressor
  2. J 41232 Direct Clutch Return Spring. See «Special Tools»(ref-200504-S20398696432005102000000) .
  3. J 41236 Coast Cutch Return Spring Compressor. See «Special Tools»(ref-200504-S20398696432005102000000) .
  1. Remove the selective thrust bearing (103) and the thrust washer (104) from the input shaft of the direct and coast clutch assembly (105).
  2. Remove the input sun gear to input sun gear shaft snap ring (534).
  3. Remove the input sun gear (533) from the input sun gear shaft (511).
  4. Remove the thrust bearing (532) from the reaction carrier assembly (531).
  5. Remove the reaction carrier assembly (531). You will find a thrust bearing permanently installed in the reaction carrier assembly under the pinion gears.
  6. Remove the reaction sun gear and shell assembly (529).
  7. Remove the thrust bearing (527) from the reaction carrier shaft and shell assembly (526).
  8. Remove the reaction carrier shaft and shell assembly (526).
  9. Remove the thrust bearing (524) from the top of the sprag race assembly.
  10. Remove the clutch retaining snap ring (517).
  11. Remove the direct clutch plates from the direct coast clutch input housing. The direct clutch consists of a backing plate (523), steel plates (521) and fiber plates (522).
  12. Lift up on the input sun shaft (511) in order to remove the input sun shaft (511) and the sprag (512) as an assembly.
  13. Remove the inner race to input housing thrust bearing (510) if the inner race to input housing thrust bearing did not remain with the input sun shaft and sprag assembly.
  14. Remove the coast clutch plates from the input housing (502). The coast clutch consists of four steel plates (508) and four fiber plates (509).
  15. Compress the direct clutch return spring assembly. Use the J 41232 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  16. Remove the spring retaining snap ring (520).
  17. Remove the J 41232 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  18. Remove the direct clutch return spring (519).
  19. Remove the direct clutch piston and seal assembly (518).
  20. Compress the coast clutch return spring. Use the J 41236 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  21. Remove the spring retaining snap ring (507).
  22. Remove the J 41236 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  23. Remove the coast clutch return spring retainer (506) and the release spring (505).
  24. Remove the coast clutch piston and seal assembly (504).
  25. Remove and discard the four Teflon™ oil seals (500) from the input shaft assembly (502).
  26. Remove the input sprag assembly (512 and 514-516) from the input sun gear shaft (511).
  27. Remove the snap ring (516) from the sprag assembly (515).
  28. Remove the sprag clutch assembly (515) from the sprag outer race (512).
  29. Remove the two end bearings (514) from the sprag clutch assembly (515).
  30. Inspect the piston (518 and 504) and seal assemblies for damage or cut seals.
  31. Inspect the clutch spring assemblies (519 and 505) for distortion or missing springs.
  32. Inspect the direct clutch and coast clutch retainer and ball assemblies for leaks or damage.
  33. Inspect the oil passages for blockage.
  34. Inspect the bushings and bearings for excessive wear.
  35. Inspect the seal grooves on the input shaft for nicks or damage.
  36. Inspect the splines, housings and clutch plates for cracks, excessive wear or damage.
  37. Inspect all other components for damage or excessive wear.

Direct/Coast Clutch, Reaction Carrier Assemble

  1. J 23327 Clutch Spring Compressor
  2. J 41236 Coast Clutch Return Spring Compressor Adapter. See «Special Tools»(ref-200504-S20398696432005102000000) .
  3. J 41232 Direct Clutch Return Spring Compressor Adapter. See «Special Tools»(ref-200504-S20398696432005102000000) .
  4. J 36850 TRANSJEL™
  5. J 41234-1 Input Shaft Seal Installer Pusher. See «Special Tools»(ref-200504-S20398696432005102000000) .
  6. J 41234-2 Input Shaft Seal Installer Protector. See «Special Tools»(ref-200504-S20398696432005102000000) .
  7. J 41234-3 Input Shaft Seal Installer Sizer. See «Special Tools»(ref-200504-S20398696432005102000000) .
  1. In order to aid in the assembly, lubricate the seal with transmission fluid.
  2. Assemble the coast clutch piston and seal assembly (504) into the input housing (502).
  3. Assemble the coast clutch release spring (505) and spring retainer (506) into the input housing (502).
  4. Compress the coast clutch return spring retainer (506). Use the J 41236 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  5. Assemble the coast clutch spring retainer snap ring (507) onto the input housing (502).
  6. Remove the J 41236 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  7. In order to aid in the assembly, lubricate the seal with transmission fluid.
  8. Assemble the direct clutch piston and seal assembly (518) into the input housing (502).
  9. Assemble the direct clutch return spring assembly (519) into the input housing with the snap ring retaining tabs facing up.
  10. Compress the direct clutch spring assembly. Use the J 41232 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  11. Assemble the direct clutch snap ring (520) into the input housing (502).
  12. Remove the J 41232 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  13. Assemble the 4 steel coast clutch plates (508) and the 4 new fiber coast clutch plates (509) into the input housing in alternating order, beginning with a steel plate (508).
  14. Place the sprag outer race (512) on the bench with the flat side down and the side with the snap ring groove up.
  15. Place one end bearing (514) into the outer race.
  16. While rotating the sprag slowly, assemble the sprag clutch (515) into the sprag outer race. Keep the grooved edge up and the flat side down.
  17. Assemble the other end bearing (514) on top of the sprag clutch.
  18. Assemble the snap ring (516) into the sprag outer race (512) in order to retain the sprag clutch and end bearings.
  19. While rotating the input sun gear shaft clockwise in order to help seat the sprags, assemble the sprag clutch and outer race assembly onto the input sun gear shaft (511).
  20. Verify the correct operation of the sprag clutch by holding the sprag clutch outer race (512) and rotating the input sun gear shaft (511).
  21. Assemble the thrust bearing (510) on the underside of the input sun gear shaft.
  22. Retain the thrust bearing with J 36850 or equivalent.
  23. Assemble the input sun gear shaft and sprag clutch assembly (511 and 512) into the input housing. The splines on the input sun gear shaft engage with the coast clutch fiber plates.
  24. Assemble the steel (521) and new fiber 522) direct clutch plates into the input housing in alternating order beginning with a steel plate (521). Refer to «Clutch Plate Selection Specifications»(ref-200504-S25629315422005102000000) .
  25. Assemble the direct clutch backing plate (523) onto the input housing with the flat side down.
  26. Assemble the snap ring (517) in order to retain the input sun shaft and sprag clutch assembly and the direct clutch plates.
  27. Assemble the thrust bearing (524) on the top of the sprag clutch assembly. Retain with J 36850 or equivalent.
  28. Assemble the reaction carrier shaft and shell assembly (526) onto the input housing. The splines on the inside of the shell engage the direct clutch fiber plates.
  29. Assemble the thrust bearing (527) onto the top of the reaction carrier shaft and shell assembly.
  30. Assemble the reaction carrier sun gear and shell assembly (529) onto the reaction shaft shell.
  31. Assemble the reaction carrier assembly (531) onto the reaction sun gear.
  32. Assemble the reaction carrier assembly to input sun gear thrust bearing (532) onto the reaction carrier assembly.
  33. Assemble the input sun gear (533) onto the input sun gear shaft.
  34. Assemble the input sun gear snap ring (534) onto the input sun gear shaft.
  35. Slide the J 41234-2 over the input shaft, and position the J 41234-2 at the seal groove closest to the housing. See «Special Tools»(ref-200504-S20398696432005102000000) . Coat the J 41234-2 with transmission fluid.
  36. Guide a new seal onto the J 41234-2 and slide the seal into the seal groove with the J 41234-1 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  37. Repeat the above procedure for each seal. Adjust the J 41234-2 as necessary for each seal groove. See «Special Tools»(ref-200504-S20398696432005102000000) .
  38. Size the seals with the J 41234-3 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  39. Leave the J 41234-3 in place for at least five minutes. See «Special Tools»(ref-200504-S20398696432005102000000) . If possible, leave the J 41234-3 in place until you install the assembly (105) into the transmission case.

Reverse Input and Second Roller Clutch Disassemble

Tools Required

  1. J 23327 Clutch Spring Compressor
  2. J 41232 Return Spring Compressor. See «Special Tools»(ref-200504-S20398696432005102000000) .
  3. J 41097-1 Inner Seal Remover Adapter. See «Special Tools»(ref-200504-S20398696432005102000000) .
  4. J 41097-2 Inner Seal Remover Adapter Ring. See «Special Tools»(ref-200504-S20398696432005102000000) .
  5. J 25031-A Inner Seal Remover. See «Special Tools»(ref-200504-S20398696432005102000000) .
  6. J 4646 Pliers. See «Special Tools»(ref-200504-S20398696432005102000000) .
  1. Remove the reverse clutch snap ring (464).
  2. Remove the reverse clutch plates (one backing plate (463), three steel plates (461), three fiber plates (462), and a waved plate (460).
  3. Compress the reverse clutch return spring. Use the J 41232 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  4. Remove the reverse clutch return spring and the retainer snap ring (459).
  5. Remove the J 41232 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  6. Remove the reverse clutch return spring and retainer assembly (458).
  7. Remove the reverse clutch piston and seal assembly (457).
  8. Inspect the reverse clutch inner seal (456).
  9. If the seal assembly is damaged, perform the following procedure in order to remove the seal assembly: Use the J 4646 or equivalent in order to install the J 41097-1 under the outer lip of the reverse clutch inner seal (456). See «Special Tools»(ref-200504-S20398696432005102000000) . Place the J 41097-2 on the inner hub of the reverse clutch housing (454). See «Special Tools»(ref-200504-S20398696432005102000000) . Use the puller J 25031-A in order to remove the seal. See «Special Tools»(ref-200504-S20398696432005102000000) .
  10. Remove the 2nd roller clutch (452) and roller clutch retainer (450) by prying up on the roller clutch assembly with two screwdrivers. The second roller clutch retainer is pressed onto the reverse clutch housing (454) and is not reusable after removal.
  11. Remove the 2nd roller clutch (452) from the inside of the roller clutch cam (451).
  12. Inspect the reverse housing (454) for excessive band wear and damaged splines.
  13. Inspect the retainer and ball capsule for damage or clogging.
  14. Inspect the fluid feed holes for proper opening.
  15. Inspect the roller clutch for excessive wear (451 and 452).
  16. Inspect the spring assembly for dislocated or damaged springs (458).
  17. Inspect all components for damage and excessive wear.
  18. Clean and dry each of the components.

Reverse Input and Second Roller Clutch Assemble

Tools Required

  1. J 23327 Clutch Spring Compressor
  2. J 41232 Return Spring Compressor. See «Special Tools»(ref-200504-S20398696432005102000000) .
  3. J 41233 Inner Seal Installer. See «Special Tools»(ref-200504-S20398696432005102000000) .
  1. If the reverse clutch inner seal assembly (456) was damaged and removed, install a new reverse clutch inner seal assembly (456). Use the J 41233 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  2. Assemble the reverse clutch piston and seal assembly (456). In order to aid in the assembly, lubricate the seal with transmission fluid.
  3. Assemble the reverse clutch return spring and retainer assembly (458) with the smaller outside diameter down.
  4. Compress the reverse clutch return spring. Use the J 41232 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  5. Assemble the return spring snap ring (459).
  6. Remove the J 41232 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  7. Assemble the wave plate (460).
  8. Assemble the three steel plates (461) and the three new fiber plates (462) in alternating order beginning with a steel plate (461).
  9. Measure the distance between the top of the snap ring groove and the top friction plate (record measurement).
  10. Assemble the reverse clutch backing plate with the beveled edge up.
  11. Assemble the snap ring in the reverse clutch housing in order to retain the reverse clutch plates.

Driven Sprocket Support Assembly Disassemble

Tools Required

  1. J 23327 Clutch Spring Compressor
  2. J 41232 Return Spring Compressor. See «Special Tools»(ref-200504-S20398696432005102000000) .
  1. Remove the two seal rings (403) from the driven sprocket support (401).
  2. Discard the two seal rings (403).
  3. Compress the 2nd clutch spring and retainer assembly (405). Use the J 41232 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  4. Remove the 2nd clutch spring retainer snap ring (406).
  5. Remove the J 41232 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  6. Remove the 2nd clutch spring and retainer assembly (405).
  7. Remove the 2nd clutch piston and seal assembly (404). If not damaged, the piston and seal assembly is reusable.
  8. Inspect the piston and seal assembly (404) for damaged seals
  9. If the seal is cut or damaged replace the seal with a new piston and seal assembly.
  10. Inspect the bushing and bearing for damage or excessive wear.
  11. Inspect the driven sprocket support (401) for plugged feed holes, damaged seal grooves, stripped bolt holes, and a damaged machined surface.
  12. Inspect the reverse intermediate clutch housing valve assembly (407) for free operation.
  13. Using Automatic Transmission fluid, inspect the reverse intermediate clutch housing valve assembly (407) for leaks.
  14. Using a 6.25 mm (1/4 in) drift and a mallet, remove the valve assembly (407) from the driven sprocket support (401).
  15. Using a 6.25 mm (1/4 in) drift and a mallet, install the valve assembly (407) in the driven sprocket support (401).
  16. Inspect the spring assembly (405) for dislocated or damaged springs.
  17. Clean and dry each of the components.

Drive Sprocket Support Assemble

Tools Required

  1. J 23327 Clutch Spring Compressor
  2. J 41232 Return Spring Compressor. See «Special Tools»(ref-200504-S20398696432005102000000) .
  1. In order to aid in the assembly, lubricate the seal with transmission fluid.
  2. Assemble the 2nd clutch piston and seal assembly (404) into the driven sprocket support (401).
  3. Assemble the 2nd clutch spring and retainer assembly (405) into the driven sprocket support.
  4. Compress the 2nd clutch spring assembly. Use the J 41232 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  5. Assemble the 2nd clutch spring retainer snap ring (406).
  6. Remove the J 41232 and J 23327 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  7. Assemble two new seal rings (403) onto the driven sprocket support.

Scheme 166

Scheme 166: Second Clutch Functional Air Check
Scheme 166: Second Clutch Functional Air Check

Air check the 2nd clutch (95) in order to verify proper operation of the seals and piston assembly.

Scheme 167

Scheme 167: Driven Sprocket Support Assembly Installation
Scheme 167: Driven Sprocket Support Assembly Installation

Install the driven sprocket support and 2nd clutch assembly (95) into the transaxle case (51). When installed properly, the driven sprocket support sits slightly below the machined surface of the transaxle case (51).

Drive, Driven Sprockets and Drive Link Disassemble

  1. Remove the turbine shaft to drive sprocket snap ring (35).
  2. Remove the drive sprocket (37) from the turbine shaft (39).
  3. Remove the three Teflon seals (33 and 40) from the turbine shaft.
  4. Discard the Teflon seals (33 and 40).
  5. Inspect the drive sprocket (37), the driven sprocket (91), the drive link assembly (36), and the turbine shaft (39) for damage or excessive wear.
  6. Inspect the seal grooves for damage.
  7. Inspect the thrust washers for damage or excessive wear.
  8. Clean and dry each of the components.

Drive, Driven Sprockets and Drive Link Assemble

Tools Required

  1. J 29569-1 Turbine Shaft Seal Installer. See «Special Tools»(ref-200504-S20398696432005102000000) .
  2. J 29569-2 Turbine Shaft Seal Sizer. See «Special Tools»(ref-200504-S20398696432005102000000) .
  3. J 29829-1 Turbine Shaft Seal Installer. See «Special Tools»(ref-200504-S20398696432005102000000) .
  4. J 29829-2 Turbine Shaft Seal Sizer. See «Special Tools»(ref-200504-S20398696432005102000000) .
  1. Assemble the drive sprocket (37) onto the turbine shaft (39).
  2. Retain the drive sprocket with the turbine shaft to drive sprocket snap ring (35).
  3. In order to assemble three new Teflon seals (33, 40) onto the turbine shaft (39), perform the following procedure: Slide the J 29569-1 over the large spline of the turbine shaft. See «Special Tools»(ref-200504-S20398696432005102000000) . Coat the J 29569-1 with transmission fluid. See «Special Tools»(ref-200504-S20398696432005102000000) . Use your fingers in order to guide the new Teflon™ seals over the J 29569-1 and into the seal ring grooves on the turbine shaft. See «Special Tools»(ref-200504-S20398696432005102000000) . Remove the J 29569-1 when the seals are in place. See «Special Tools»(ref-200504-S20398696432005102000000) . Size the new Teflon™ seals. Use both halves of the J 29569-2 . See «Special Tools»(ref-200504-S20398696432005102000000) . In order to properly size the seals, keep the J 29569-2 in place for five minutes. See «Special Tools»(ref-200504-S20398696432005102000000) . Repeat steps 3.1 thru 3.6 with J 29829-1 and J 29829-2 on the small splined side of the turbine shaft. See «Special Tools»(ref-200504-S20398696432005102000000) .

Channel Plate Assembly Disassemble

  1. Remove the three accumulator pistons (29) from the channel plate (27).
  2. Remove the 1-2 accumulator assist spring (125).
  3. Remove the 2-3 accumulator assist spring (47).
  4. Remove the seals (30) from the accumulator pistons (29).
  5. Discard the accumulator piston seals (30).
  6. Remove the manual valve (800) from the channel plate (27).
  7. Inspect the channel plate (27) for damage.
  8. Inspect the channel plate (27) passages for debris.
  9. Inspect the accumulator pistons (29), the assist springs (47, 125), and the pins for damage.
  10. Inspect the channel plate sleeve for wear from the turbine shaft.
  11. Inspect the channel plate (27) bolt holes for stripped threads and debris.
  12. Inspect the channel plate machined surface for nicks or scratches that could cause a fluid leak.
  13. Inspect the manual valve (800) for freedom of movement.
  14. Inspect the drive sprocket to channel plate thrust washer (34).
  15. Clean and dry each component.

Channel Plate Assembly Assemble

Tools Required

J 36850 TRANSJEL™

  1. Assemble the new accumulator piston seals (30) on the three accumulator pistons (29).
  2. Install the 1-2 and 2-3 accumulator assist springs (47, 125).
  3. Install the accumulator pistons (29) into the channel plate over the guide pins. The pistons are identical. You can assemble the pistons in any of the three accumulator bores.
  4. In order to retain the pistons, apply J 36850 onto the piston seals.
  5. Install the manual valve (800) into channel plate.

Control Valve Body Disassemble

IMPORTANTRetainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement.
  1. Remove the 3-4 shift valve retainer clip (304), the bore plug (321), with O-ring (320), the 3-4 shift valve (319) and the 3-4 shift valve spring (318).
  2. Remove the actuator feed limit valve retainer clip (304), the bore pug (317), the actuator feed limit spring (316) and the actuator feed limit valve (315).
  3. Remove the actuator oil filter retainer clip (304), and the actuator oil filter (314) with O-ring (313).
  4. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308).
  5. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306).
  6. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301).
  7. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340).
  8. Remove the TCC control valve retainer clip (304), the bore plug (317), the spring (333), and the TCC control valve (334).
  9. Remove the pressure regulator valve retainer clip (304), the bushing (324), the pressure regulator boost valve (325), the isolator spring (326), the pressure regulator valve spring (327), and the pressure regulator valve (328).
  10. Remove the 1-2/3-4 accumulator valve retainer clip (304), the plug (341), and the accumulator valve (323).
  11. Inspect the valve body passages for debris.
  12. Inspect the machined surfaces for nicks or scratches. Some polish is normal for the machined surfaces.
  13. Inspect the valves for nicks or scratches that could cause sticking valves or fluid leaks.
  14. Inspect the springs, bushings, O-rings, screens and solenoids for damage.
  15. Clean and dry the valve body and valve body components.

Control Valve Body Assemble

  1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304).
  2. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304).
  3. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304).
  4. Install the actuator oil filter (314), with the O-ring (313) and the actuator oil filter retainer clip (304).
  5. Install the actuator feed limit valve (315), the actuator feed limit spring (316), the bore plug (317) and the actuator feed limit valve retainer clip (304).
  6. Install the 3-4 shift valve spring (318), the 3-4 shift valve (319), the bore plug (321), with O-ring (320) and the 3-4 shift valve retainer clip (304).
  7. Install the accumulator valve (323), the plug (341) and the 1-2/3-4 accumulator valve retainer clip (304).
  8. Install the pressure regulator valve (328), the pressure regulator valve spring (327), the isolator spring (326), the pressure regulator boost valve (325), the bushing (324) and the pressure regulator valve retainer clip (304).
  9. Install the TCC control valve (334), the spring (333), the bore plug (317) and the TCC control valve retainer clip (304).
  10. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304).

Side Cover/Gaskets, Disassemble, Assemble, Install

Tools Required

J 36850 TRANSJEL™

  1. Remove the side cover gaskets (5 and 6) and the thrust washer (7) from the side cover (1).
  2. Remove the side cover axle seal (2). Use the handle end of a hammer.
  3. Inspect the side cover for cracks or damage to the seal grooves and mounting bosses.
  4. Inspect the side cover seals for damage. The side cover seals are reusable if not damaged.
  5. Thoroughly clean the side cover and the side cover seals.
  6. Clean and dry the seal grooves and the axle seal bore.
  7. Install the side cover gaskets (5 and 6) into the grooves on the side cover (1).
  8. Retain the seals with J 36850 or equivalent.
  9. Install the side cover to drive sprocket thrust washer (7) onto the side cover.
  10. Retain the thrust washer with J 36850 or equivalent.
  11. Install the side cover assembly onto the transmission case.
  12. Install the 11 side cover bolts (3) or studs (4) (model dependent).
  13. Refer to the graphic in order to find the correct installation points of the bolts and the stud.
  14. Hand start the bolts. Tighten: Tighten the side cover bolts and stud to 28 N.m (22 lb ft).

Right Hand Axle Seal Assemble

Tools Required

J 41102 Axle Seal Installer. See Special Tools .

  1. Install a new right hand axle seal (2) into the transmission case. Use the J 41102 . See «Special Tools»(ref-200504-S20398696432005102000000) .
  2. In order to prevent damage to the shaft splines during vehicle operation, add Polyurea grease (part number 7843867) to the splines on the output shaft.

Intermediate/Fourth Servo Disassemble

  1. Remove the piston and pin assembly (76 and 77) from the servo cover (80).
  2. Remove the snap ring (70) from the servo pin (76).
  3. Remove the piston (77) and the servo cushion springs (68) from the servo pin (76).
  4. Remove the servo piston seals (78, 79) from the servo cover (80).
  5. Discard the servo piston seals (78 and 79). Do not reuse the servo piston seals.
  6. Inspect all components for damage.
  7. Inspect the fluid feed holes for proper opening.
  8. Inspect the bolt hole threads for debris and stripping.
  9. Inspect the seal grooves for damage.
  10. Clean and dry each component.

Low and Reverse Servo Disassemble

  1. Remove the piston pin assembly (67-70) from the servo cover (73).
  2. Remove the snap ring (70) from the servo pin (67).
  3. Remove the piston (69) and the servo cushion springs (68) from the servo pin (67).
  4. Remove the servo piston seals (71, 72) from the cover (73).
  5. Discard the servo piston seals (71 and 72).
  6. Inspect all the components for damage.
  7. Inspect the fluid feed holes for the proper opening.
  8. Inspect the bolt hole threads for debris or stripping.
  9. Inspect the seal grooves for damage.
  10. Clean and dry each component.

Oil Feed Pipes Assemble

  1. Inspect the oil feed pipes (83) for plugged passages, bent pipes, or cracks.
  2. Inspect the oil feed pipe seal rings (82) in order to verify the proper location of the seal rings (82).
  3. Replace the seal rings (82) only if they are cut, swelled or damaged.
  4. Clean and dry the oil feed pipes.
  5. Install new oil feed pipe seal rings (82) if necessary.
  6. Retain any newly installed oil feed pipe seal rings (82) with J 36850 or equivalent.
  7. Install the oil feed pipe assembly (83) onto the transmission case (51).
  8. Install the four oil feed pipe bolts (81). Hand start the bolts. Tighten: Tighten the bolts to 12 N.m (9 lb ft).

Automatic Transmission Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly

PRND4 fluid is routed to the PRND4 fluid pressure switch in the TFP Val. Position Sw. Assembly, which signals the PCM that the transmission is in the Park (P) position. Line pressure is routed to the A/T Fluid Temperature Sensor in the TFP Val. Position Sw. Assembly.

1-2, and 3-4 Accumulator Assemblies

Accumulator fluid is routed to each of the accumulator assemblies in preparation for upshifts. The fluid which is routed to the 1-2 and to the 3-4 accumulators is orificed by the #4 and the #7 checkballs. The 2-3 accumulator fluid circuit does not use a checkball in order to orifice accumulator fluid to the 2-3 accumulator.

PRND4 fluid is routed to the PRND4 fluid pressure switch in the TFP Val. Position Sw. Assembly, which signals the PCM that the transmission is in the Park (P) position. Line pressure is routed to the A/T Fluid Temperature Sensor in the TFP Val. Position Sw. Assembly.

Accumulator fluid is routed to each of the accumulator assemblies in preparation for upshifts. The fluid which is routed to the 1-2 and to the 3-4 accumulators is orificed by the #4 and the #7 checkballs. The 2-3 accumulator fluid circuit does not use a checkball in order to orifice accumulator fluid to the 2-3 accumulator.

A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly

Reverse fluid pressure exhausts from the TFP Val. Position Sw. Assembly. This action signals the PCM that the transmission is either in Neutral (N) or Park (P) position.

Reverse fluid pressure exhausts from the TFP Val. Position Sw. Assembly. This action signals the PCM that the transmission is either in Neutral (N) or Park (P) position.

Reverse fluid is routed through the 1-2 shift valve and to the TFP Val. Position Sw. Assembly, which signals the PCM that the transmission is in Reverse position.

Reverse fluid is routed through the 1-2 shift valve and to the TFP Val. Position Sw. Assembly, which signals the PCM that the transmission is in Reverse position.

Drive fluid is routed to the TFP Val. Position Sw. Assembly, which signals the PCM that the transmission is in the Overdrive range.

Scheme 168

Scheme 168: A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly
Scheme 168: A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly

Drive fluid is routed to the TFP Val. Position Sw. Assembly, which signals the PCM that the transmission is in the Overdrive range.

Scheme 169

Scheme 169: A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly
Scheme 169: A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly

Release fluid pressure routed to the TFP Val. Position Sw. Assembly signals to the PCM that the TCC is released.

Scheme 170

Scheme 170: A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly
Scheme 170: A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly

Release fluid pressure routed to the TFP Val. Position Sw. Assembly signals to the PCM that the TCC is released.

Scheme 171

Scheme 171: A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly
Scheme 171: A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly

Release fluid also exhausts from the TFP Val. Position Sw. Assembly, which signals to the PCM that the TCC is released.

Scheme 172

Scheme 172: A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly
Scheme 172: A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly

Release fluid also exhausts from the TFP Val. Position Sw. Assembly, which signals to the PCM that the TCC is released.

Scheme 173

Scheme 173: A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly
Scheme 173: A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly

PRND4 fluid exhausts from the TFP Val. Position Sw. Assembly, which signals to the PCM that the manual valve is in the Manual Third position.

PRND4 fluid exhausts from the TFP Val. Position Sw. Assembly, which signals to the PCM that the manual valve is in the Manual Third position.

The D21 fluid from the 2-3 shift valve is routed to the TFP Val. Position Sw. assembly, which signals to the PCM that the manual valve is in the Manual Second position.

The D21 fluid from the 2-3 shift valve is routed to the TFP Val. Position Sw. assembly, which signals to the PCM that the manual valve is in the Manual Second position.

Low fluid pressure is routed to the TFP Val. Position Sw. Assembly, which signals to the PCM that the manual valve is in the Manual First position.

Low fluid pressure is routed to the TFP Val. Position Sw. Assembly, which signals to the PCM that the manual valve is in the Manual First position.

More articles — Automatic Transaxle Overhaul - 4T40-E/4T45-E