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

Stub Shaft Removal

Tools Required

1. J 6125-1B Slide Hammer
2. J 38868 Shaft Remover

1. Remove and discard the snap ring (57) from the end of the stub shaft (58). The stub shaft snap ring is not reusable.
2. Attach the J 6125-1B to the J 38868 . Install the J 38868 into the snap ring groove on the stub shaft (58). Tighten the J 38868 securely to the stub shaft.
3. Pull lightly on the shaft and rotate it until the stub shaft snap ring at the differential seats in the taper on the differential side gear.
4. Pull the stub shaft (58) out with the slide hammer impact.

Output Shaft Speed Sensor Removal

1. Rotate the transmission so that the case side cover is facing upward in order to drain the transmission fluid through the stub shaft end of the transmission.
2. Remove the speed sensor stud (61).
3. Remove the speed sensor assembly (62). Pull the speed sensor assembly straight out from the transmission case in order to prevent damage to the case bore.
4. Remove the O-ring (63).
5. Rotate the transmission with the oil pan facing upward.

Oil Pan and Gasket Removal

1. Remove the twelve oil pan bolts (81).
2. Remove the oil pan (88). The magnet can remain in the oil pan.
3. Remove the oil pan gasket (87). The oil pan gasket is reusable.

Oil Filter/Seal, Oil Level Control Valve Removal

1. Remove the oil level control valve (86). Remove the transmission filter assembly (85).
2. Using a chisel, indent top of seal to relax press fit of seal.
3. Using a small screwdriver remove the filter neck seal (84) from the transmission case. The filter neck seal (84) is not reusable and should be discarded.

Scheme 152

Remove the four oil feed pipe bolts (81) and remove the oil feed pipe assembly (83).

Intermediate/Fourth Servo Removal

1. Remove the three servo cover bolts (25).
2. Remove the servo cover (Intermediate/Fourth) (80) assembly.
3. Remove the servo return spring (75).

Low and Reverse Servo Removal

1. Remove the three servo cover bolts (25).
2. Remove the servo cover assembly (Lo and Reverse) (73).
3. Remove the servo return spring (66).

Case Side Cover Removal

1. Rotate the transmission so that the side cover faces upward.
2. Remove the 11 side cover bolts (3) or studs (4) (model dependent).
3. Remove the transmission side cover (1).
4. Remove the two side cover gaskets (5 and 6) and the side cover to driven support thrust washer (7), if they did not remain with the side cover.

Output Shaft Sleeve Removal

Tools Required

J 41227 Output Shaft Sleeve Puller. See Special Tools .

1. Remove snap ring (57).
2. Insert the legs of J 41227 under the output shaft sleeve (56). See «Special Tools»(ref-200504-S20398696432005102000000) .
3. Tighten the center bolt of the J 41227 down in order to pull the output shaft sleeve (56) off the output shaft (94). See «Special Tools»(ref-200504-S20398696432005102000000) .
4. Remove and discard the output shaft sleeve (56). Use the J 41227 . See «Special Tools»(ref-200504-S20398696432005102000000) . The output shaft sleeve is not reusable.

Oil Pump and Oil Pump Shaft Removal

1. Remove the eight bolts from the oil pump (8, 9 and 12).
2. Remove the oil pump assembly (10).
3. Remove the oil pump shaft (19).

Transmission Fluid Pressure (TFP) Switch Removal

1. Remove the six bolts from the TFP switch assembly (8, 12, and 16).
2. Remove the TFP switch assembly (13) from the control valve body assembly (18). The 4 pressure switch O-rings are reusable and should remain with the TFP switch assembly.

Control Valve Body Assembly and Gasket Removal

1. Remove the remaining twelve bolts (9, 12 and 16) from the control valve body assembly (18).
2. Remove the control valve body assembly (18).
3. Remove and discard the valve body to spacer plate gasket (22).

Spacer Plate and Gasket Removal

1. Remove the two spacer plate support bolts (20).
2. Remove the spacer plate support (21)
3. Remove the spacer plate (23).
4. Remove and discard the spacer plate to channel plate gasket (24).

Scheme 153

Remove the seven checkballs (26) in the channel plate.

Manual Valve Clip Removal

1. Disconnect the manual valve clip (801) from the manual valve.
2. Disconnect the manual valve link (802) from the manual valve.

Channel Plate and Gasket Removal

1. Remove the ten channel plate bolts (8 and 25).
2. Remove the channel plate assembly (27). Keep the following components with the channel plate: The drive sprocket to channel plate thrust washer (34) The three accumulator pistons (29) The manual valve (800) The detent lever spring (804) and bolt (805)
3. Remove and discard the channel plate to case gasket (28).

Scheme 154

Remove the three accumulator springs (31 and 32) from the case (51).

Drive Sprocket, Driven Sprocket, and Drive Link Removal

1. Remove, as an entire unit, the drive sprocket (37), the turbine shaft (39), the driven sprocket (91) and the drive link assembly (36).
2. If the drive sprocket to drive sprocket support thrust washer (38) has not remained with the drive sprocket assembly (37 and 39), remove the drive sprocket to drive sprocket support thrust washer (38). The driven sprocket to driven sprocket support thrust washer (92) should remain with the driven sprocket support assembly (95).

Input Speed Sensor Removal

1. Remove the wiring harness connector at the input speed sensor (46).
2. Remove the input speed sensor bolt (15) and the input speed sensor (46).
3. Remove the wire retainer clip bolt (15) and retainer clip.

Wiring Harness Removal

Tools Required

J 41101 Pass-Through Connector Remover. See Special Tools .

1. Push the J 41101 onto the pass-through connector from the outside of the transmission case in order to compress the pass-through connector's retaining tabs. See «Special Tools»(ref-200504-S20398696432005102000000) .
2. With the retaining tabs compressed, use a screwdriver in order to remove the pass-through connector through the inside of the transmission case.
3. Remove the wiring harness (11).

Driven Sprocket Support Assembly Removal

1. Remove the driven sprocket to driven sprocket support thrust washer (92).
2. Remove the driven sprocket support assembly (95).

Scheme 155

Remove the following plates

1. 2nd clutch wave plate (96)
2. 2nd clutch steel plates (97)
3. 2nd clutch fiber plates (98)
4. 2nd clutch backing plate (99)

Reverse Input Clutch Housing Removal

1. Remove the driven sprocket support to reverse clutch housing thrust washer (101).
2. Remove the reverse input clutch housing and the 2nd roller clutch assembly (102).

Scheme 156

Remove the intermediate 4th band (100).

Scheme 157

Remove the direct/coast clutch and reaction carrier assembly (105).

Input Carrier and Reaction Gear Assembly Removal

1. Remove the input carrier and reaction internal gear assembly (106). A bearing assembly is permanently inside the input carrier.
2. Remove the input carrier to forward clutch hub thrust bearing (107). The input carrier to forward clutch hub thrust bearing may have remained with the input carrier.

Input Internal Gear, Forward Clutch Hub Removal

1. Remove the input internal gear and forward clutch hub assembly (108).
2. If the forward clutch hub to race thrust washer (109) did not remain with the forward clutch hub, remove the forward clutch hub to race thrust washer (109).

Forward Clutch and Low/Reverse Band Removal

1. Remove the forward clutch assembly (110).
2. Remove the low/reverse band (111).

Forward Clutch Support, Low Roller Clutch Removal

Tools Required

J 28585 Snap Ring Screwdriver

1. Remove the forward clutch support snap ring (112) from the transmission case. Use the J 28585 .
2. Remove the forward clutch support and the low roller clutch assembly (114). Keep the forward clutch housing to the forward clutch support thrust bearing (113) with the forward clutch support assembly (114).

Output Shaft and Final Drive Assembly Removal

1. Remove, as one unit, the output shaft (94), the final drive assembly (116), and the final drive sun gear (115).
2. If the differential carrier to case thrust bearing (117) did not remain with the final drive assembly (116), remove the differential carrier to case thrust bearing (117).

Scheme 158

Remove the final drive internal gear (118).

Manual Shift Shaft, Detent Lever, and Park Lock Removal

1. Remove the manual shaft to transmission case pin (803).
2. Remove the manual shaft and detent lever assembly (806) by pushing the manual shaft into the transmission case (51). The parking lock actuator assembly (807) remains attached to the detent lever until you remove the manual shaft and detent lever assembly.
3. Remove the manual shaft seal (809) from the case (51).

Transmission Cooler Line Seals Removal

Tools Required

1. J 41239-10 Cooler Line Seal Removal. See «Special Tools»(ref-200504-S20398696432005102000000) .
2. J 45201 Cooler Line Seal Removal. See «Special Tools»(ref-200504-S20398696432005102000000) .

1. Install J 41239-10 between the cooler line seal (49) and the case. See «Special Tools»(ref-200504-S20398696432005102000000) .
2. It may be necessary to pivot J 41239-10 back and forth against the case to remove the seal. See «Special Tools»(ref-200504-S20398696432005102000000) .
3. Insert J 45201 collet (2) fully into the cooler line seal bore. See «Special Tools»(ref-200504-S20398696432005102000000) .
4. Insert the forcing screw piece of the J 45201 (1) into J 45201 (2) and tighten. See «Special Tools»(ref-200504-S20398696432005102000000) .
5. Thread the J 45201 collar (2) onto J 45201 (3) and tighten until the tool has removed the seal. See «Special Tools»(ref-200504-S20398696432005102000000) .
6. Use a pair of pliers to remove the cooler line seal from J 45201 . See «Special Tools»(ref-200504-S20398696432005102000000) .

Drive Sprocket Support Removal

1. Remove the six bolts (53) form the drive sprocket support (43).
2. Remove the drive sprocket support (43) from the case (51).

Right Hand Axle Seal Removal

1. J 6125-1B Slide Hammer
2. J 23129 Universal Seal Remover

Scheme 159

Note. Do not damage the case bore when removing the axle seal.

Assemble J 23129 onto J 6125-1B . Use J 6125-1B and J 23129 to remove the axle seal.

Actuator Guide Replacement

1. Remove the actuator guide roll pin (810) from the case.
2. Remove the actuator guide (812) and O-ring seal (811) assembly from the case (51). For easiest removal, tap the actuator guide (812) into the case (51).
3. Install a new O-ring seal (811) on the actuator guide (812).
4. Install the actuator guide (812) and O-ring assembly (811) into the transmission case (51).
5. Install the actuator guide roll pin (810) into the case (51) in order to secure the actuator guide (812).

Drive Sprocket Support Installation

1. Inspect the drive sprocket support (43) for damage to the stator shaft splines, the journals, the bushings, and the roller bearing.
2. Inspect the converter seal drain holes for blockage.
3. Install the drive sprocket support (43) into the bell housing of the transmission case.
4. Install the six drive sprocket support bolts (53) into the drive sprocket support (43).
5. Hand start the bolts. Tighten: Tighten the bolts to 12 N.m (9 lb ft).

Transmission Cooler Line Seals Installation

Tools Required

J 41239-1 Cooler Line Seal Installer. See Special Tools .

1. Lubricate the inside surface of both cooler line seals (49) with automatic transmission fluid DEXRON® III.
2. Place a new cooler line seal (49) in the case bore.
3. Install the J 41239-1 on the transmission case (51) at the cooler line bracket bolt hole. See «Special Tools»(ref-200504-S20398696432005102000000) .
4. Press the new cooler line seal (49) in by tightening the seal pressing bolt on the J 41239-1 until the seal bottoms out in the case bore. See «Special Tools»(ref-200504-S20398696432005102000000) .
5. Repeat steps 2-4 for the second cooler line seal (49).

Manual Shift Shaft, Detent Lever, and Park Lock Installation

Tools Required

J 41229 Manual Shaft to Case Pin Installer. See Special Tools .

1. Install a new manual shaft seal (809) into the case (51). Use a 13 mm socket.
2. With the manual valve to detent lever link (802) and the parking lock actuator assembly (807) attached, install the manual shaft and detent lever assembly (806) into the case.
3. Ensure that the parking lock actuator rod is correctly positioned into the actuator guide.
4. Install the manual shaft pin (803) into the case. Use the J 41229 . See «Special Tools»(ref-200504-S20398696432005102000000) .

Output Shaft Installation

1. Install a new snap ring (57) into the snap ring groove on the final drive end (small machined diameter) of the output shaft (94).
2. Install the output shaft (94) into the final drive assembly. Use a mallet in order to install the shaft (94) through the final drive differential gear.

Forward Clutch Assembly Installation

1. Install the forward clutch assembly (110) into the transmission case.
2. Insert a screwdriver through the reverse servo pin hole in order to verify the correct installation of the lo/reverse band. The screwdriver should compress the band around the forward clutch housing.

Selective Washer Measurement and Installation

Tools Required

J 34673 Gage Block

1. Place the J 34673 across the machined surface of the case.
2. Measure the distance between the top of the direct/coast clutch housing (105) and the machined surface of the case (record measurement).
3. Note the recorded measurement and choose the correct selective washer. Refer to «End Play Specifications»(ref-200504-S07728009782005102000000) .
4. Assemble the selective thrust washer (104) onto the top of the input housing.
5. Assemble the thrust bearing (103) over the input shaft and onto the top of the selective thrust washer (104).

Reverse Input and Second Roller Clutch Installation

1. While rotating the reverse clutch housing (102) in order to align the clutch plates, install the reverse clutch and 2nd roller clutch assembly into the transmission case.
2. Assemble the reverse clutch thrust washer (101) onto the top of the 2nd roller clutch. The tabs must face down onto the housing.

Intermediate Fourth Band Assembly Installation

1. Assemble a new Intermediate/Fourth band (100) into the transmission case.
2. In order to verify the proper positioning of the band, insert a screwdriver through the Intermediate/Fourth servo bore. The screwdriver should press on the servo pin rest and compress the band around the reverse clutch housing.

Second Clutch Plate Installation

1. Inspect the 2nd clutch plates for excessive wear.
2. Clean and dry each of the components.
3. Assemble the 2nd clutch backing plate (99) with the flat side facing up.
4. Assemble the three steel (97) and the three new fiber plates (98) in alternating order beginning with a fiber plate (98).
5. Assemble the 2nd clutch wave plate (96).

Input Speed Sensor Installation

1. Assemble the input speed sensor (46) to the transmission case.
2. Install the input speed sensor bolt (15). Hand start the bolts. Tighten: Tighten the input speed sensor bolt to 12 N.m (9 lb ft).
3. Route the input speed sensor wiring harness in the case channel.
4. Connect the input speed sensor connector to the input speed sensor.
5. Install the wire harness retainer and wire harness retainer bolt. Tighten: Tighten the wire harness retainer bolt to 12 N.m (9 lb ft).

Drive Sprocket, Driven Sprocket, and Drive Link Installation

Tools Required

J 36850 TRANSJEL™

1. Install the drive sprocket to drive sprocket support thrust washer (38) to the drive sprocket (37). Place the tabs on the thrust washer into the holes on the drive sprocket.
2. Retain the thrust washer with J 36850 or equivalent.
3. Install the driven sprocket to driven sprocket support thrust washer (92) onto the driven sprocket support (95).
4. Install the drive link assembly (36) to the drive and driven sprockets (37 and 91).
5. Install as a complete assembly, the drive sprocket (37) the driven sprocket (91), and the drive link assembly (36) onto the transmission.

Accumulator Springs Installation

Install the two remaining accumulator springs into the transmission case accumulator bores.

Channel Plate Assembly Installation

Tools Required

J 36850 TRANSJEL™

1. Install the channel plate to drive sprocket thrust washer (34) onto the channel plate (27).
2. Retain the thrust washer (34) with J 36850 or equivalent.
3. Install a new channel plate to case gasket (28) onto the transmission case (51).
4. Install the channel plate assembly onto the transmission case (51). The channel plate should fit tightly over the guide pins (45) located on the transmission case (51).
5. Install the two channel plate to driven sprocket support bolts (25). Tighten: Tighten the two channel plate to driven sprocket bolts (25) to 14 N.m (10.5 lb ft).
6. Install the six channel plate to case bolts (25). Hand tighten the bolts. Tighten: Tighten the six channel plate to case bolts and the two channel plate to driven sprocket support bolts to 12 N.m (9 lb ft).
7. Install the two channel plate to case bolts (8). Hand tighten bolts. Tighten: Tighten the two channel plate to case bolts (8) to 14 N.m (10.5 lb ft).

Manual Valve Link Installation

1. Connect the manual valve link (802) to both the manual valve and detent lever.
2. Install the manual valve clip (801) onto the manual valve.

Checkballs Installation

Install the seven checkballs into the proper locations on the channel plate.

Spacer Plate and Gaskets Installation

1. Inspect the spacer plate for damage.
2. If damaged, replace the spacer plate (23).
3. Install a new spacer plate to channel plate gasket (24) onto the channel plate.
4. Install the spacer plate (23) on top of the gasket and channel plate.
5. Install the spacer plate support (21) and the two bolts (20) onto the spacer plate. Hand start the bolts. Tighten: Tighten the bolts to 14 N.m (10.5 lb ft).

Control Valve Assembly and Transmission Fluid Pressure (TFP) Switch Installation

1. Install the control valve body to spacer plate gasket (22) onto the spacer plate (23).
2. Install the control valve body assembly (18) onto the gasket (22).
3. Inspect the TFP switch assembly (13) in order to verify the condition and correct location of the 4 pressure switch O-rings.
4. If necessary replace the pressure switch O-rings.
5. Install the TFP switch assembly (13) onto the control valve body assembly.
6. Install the 18 control valve body assembly bolts.
7. Hand start the bolts. Tighten: Tighten the bolts to 14 N.m (124 lb in).

Scheme 160

Connect the wiring harness assembly to the following components

1. The TFP switch assembly (13)
2. The pressure control solenoid (312) - red connector
3. The 1-2 shift solenoid (305) - white connector
4. The 2-3 shift solenoids (305) - white connectors
5. The TCC solenoid (335)

Oil Pump Assembly Installation

1. Install the oil pump shaft (19) into the control valve body assembly (18).
2. Install the oil pump assembly (10) onto the oil pump shaft (19) and the control valve body.
3. Install the eight oil pump bolts (8, 9, 12). Hand start the bolts. Tighten: Tighten the bolts to 12 N.m (9 lb ft).

Side Cover Axle Seal Installation

Tools Required

J 41102 Axle Seal Installer. See Special Tools .

1. Install a new side cover axle seal (2) into the side cover. 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.

Output Shaft Sleeve Assembly Installation

Tools Required

J 41228 Output Shaft Sleeve Installer. See Special Tools .

1. Place a NEW sleeve (56) over the end of the output shaft (94).
2. Install the collet into the output shaft snap ring groove with the collet attached to the threaded collet shaft.
3. Place the NEW sleeve installing tube over the collet. Be sure the small outside diameter of the tube fits securely into the sleeve.
4. Install the bearing and nut onto the threaded collet shaft.
5. In order to move the installing tube and press the sleeve onto the output shaft, hold the end of the threaded collet shaft while tightening the nut down.
6. Remove the J 41228 . See «Special Tools»(ref-200504-S20398696432005102000000) .
7. Install a new snap ring (57) into the output shaft snap ring groove.

Stub Shaft Sleeve Assembly Installation

1. Inspect the stub shaft (58) for damage to the splines, the snap ring grooves, and the journals.
2. Inspect the sleeve (56) for excessive wear, scratches or nicks the could cause a leak or damage the seal portion.
3. Clean and dry the stub shaft and sleeve assembly.
4. Place a NEW sleeve (56) over the end of the stub shaft (58).
5. Install the collet into the stub shaft snap ring groove with the collet attached to the threaded collet shaft.
6. Place the sleeve installing tube over the collet. Be sure the small outside diameter of the tube fits securely into the sleeve.
7. Install the bearing and nut onto the threaded collet shaft.
8. In order to move the installing tube and press the sleeve onto the stub shaft, hold the end of the threaded collet shaft while tightening the nut down.
9. Remove the J 41228 . See «Special Tools»(ref-200504-S20398696432005102000000) .
10. Install the two new snap rings (57) on the stub shaft (58). The snap rings (57) are not reusable after you remove the shaft (58).
11. Install the stub shaft into the transmission. Use a mallet in order to install the shaft through the final drive differential gear.

Output Shaft Speed Sensor Installation

1. Inspect the vehicle speed sensor (62) for damage to the sensor, the electrical connector, or the O-ring (63).
2. Clean and dry the vehicle speed sensor (62).
3. Install the O-ring (63) onto the speed sensor (62).
4. Install the speed sensor (62) into the transmission case.
5. Install the speed sensor stud (61). Tighten: Tighten the speed sensor stud to 12 N.m (9 lb ft).

Intermediate/Fourth Servo Assemble and Installation

1. Install the servo cushion springs (68) and the servo piston (77) onto the servo pin (76).
2. Install the snap ring (70) onto the servo pin (76) in order to retain the springs (68) and piston (77).
3. Install the new seals (78 and 79) onto the servo piston (77) and the servo cover (80).
4. Install the servo piston assembly into the servo cover (80). Lubricate the piston seals with transmission fluid in order to aid in assembly.
5. Install the servo return spring (75) into the transmission case (51).
6. Install the servo cover (80) and the piston assembly over the servo return spring (75).
7. Install the three servo cover bolts (25). Hand start the bolts. Tighten: Tighten the bolts to 12 N.m (9 lb ft).

Low and Reverse Servo Assemble and Installation

1. Assemble the servo cushion springs (68) and the servo piston (69) onto the servo pin (67).
2. Install the snap ring onto the servo pin (67) in order to retain the servo cushion springs (68) and the servo piston (69).
3. Assemble the new seals (71, 72) onto the servo piston (69) and the servo cover (73).
4. Assemble the servo piston assembly (67-70) into the servo cover (73). Lubricate the piston seals with transmission fluid in order to aid in assembly.
5. Install the servo return spring (66) into the transmission case (51).
6. Install the servo cover and piston assembly over the servo return spring (66).
7. Install the three servo cover bolts (25). Hand start the bolts. Tighten: Tighten the bolts to 12 N.m (9 lb ft).

Filter Assembly and Seal Installation

1. Lubricate the oil filter seal (84) with transmission fluid.
2. Install a new oil filter seal (84) into the transmission case (51). You may use a large socket as an installer in order to tap on the seal.
3. Install a new filter assembly (85) into the filter seal (84). If necessary, twist the filter slightly during installation.

Scheme 161

Install the oil level control valve into the transmission case (51). Push straight down on the center of the oil level control valve in order to prevent damage to the case bore.

Oil Pan and Gasket Installation

1. Inspect the oil pan (88) for cracks, dents or damage to the gasket sealing surface.
2. Inspect the gasket (87) for cuts or other damage. The bottom pan gasket is reusable if not damaged.
3. Clean and dry the bottom pan, gasket and magnet (89).
4. Install the gasket (87) and bottom pan (88) onto the transmission case.
5. Install the twelve bottom pan bolts (81).
6. Hand start the bolts. Tighten: Tighten the bottom pan bolts to 14 N.m (124 lb in).