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

Fastener Tightening Specifications

Fastener Tightening Specifications

End Play Specifications

End Play Specifications (Selective Washer Table)

Clutch Plate Selection Specifications

Direct Clutch Plate Selection Specifications

Reverse Clutch Backing Plate Specifications

Transmission General Specifications

Transmission General Specifications

Fluid Capacity Specifications

Fluid Capacity Specifications (4T40-E)

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Torque Converter Assembly Removal

1. Remove the torque converter assembly (55).
2. Remove the turbine shaft O-ring (41) from the end of the turbine shaft.

Torque Converter Seal Removal

Tools Required

1. J 41103 Torque Converter Seal Remover Set. See «Special Tools»(ref-200504-S20398696432005102000000) .
2. J 41103-1 Torque Converter Seal Puller Legs. See «Special Tools»(ref-200504-S20398696432005102000000) .
3. J 41103-2 Torque Converter Seal Puller Bridge. See «Special Tools»(ref-200504-S20398696432005102000000) .
4. J 41103-3 Torque Converter Seal Support Body. See «Special Tools»(ref-200504-S20398696432005102000000) .

1. Insert the three J 41103-1 puller legs under the Torque Converter Seal (54). See «Special Tools»(ref-200504-S20398696432005102000000) .
2. Insert the J 41103-3 support body over the stator shaft (43). See «Special Tools»(ref-200504-S20398696432005102000000) .
3. Insert the J 41103-2 puller bridge over the J 41103-3 support body. Connect the J 41103-1 puller legs into the slots on the J 41103-2 bridge. See «Special Tools»(ref-200504-S20398696432005102000000) .
4. Tighten the forcing screw on the J 41103-2 puller bridge until the J 41103-1 puller legs remove the torque converter seal (54). See «Special Tools»(ref-200504-S20398696432005102000000) .

Torque Converter Seal Installation

Tools Required

J 28540-A Torque Converter Seal Installer. See Special Tools .

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Note. Install the seal onto the tool before installing into the case to prevent damage to the seal.

Install a new torque converter seal (54). Use the J 28540-A . See Special Tools .

Torque Converter Installation

Tools Required

J 21366 Torque Converter Holding Strap

1. Install a new turbine shaft O-ring (41) on the end of the turbine shaft.
2. Install the torque converter onto the transmission.
3. Install the J 21366 .
4. Remove the transmission from the holding fixture.

Torque Signal Regulating Valve

The torque signal regulating valve regulates the line pressure into the torque signal fluid circuit. Filtered actuator feed fluid pressure from the PCS controls this regulation. Torque signal fluid pressure is routed to the accumulator valves and to the boost valve in order to control shift feel.

Torque Converter/Cooler and Lube Circuits

Refer to reverse range for a complete description of these circuits.

Scheme 147

The torque signal regulating valve regulates the line pressure into the torque signal fluid circuit. Filtered actuator feed fluid pressure from the PCS controls this regulation. Torque signal fluid pressure is routed to the accumulator valves and to the boost valve in order to control shift feel.

Refer to reverse range for a complete description of these circuits.

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Torque Converter

Release fluid pressure is routed to the torque converter in order to keep the TCC released. Fluid leaves the converter in the apply fluid circuit.

Release fluid pressure is routed to the torque converter in order to keep the TCC released. Fluid leaves the converter in the apply fluid circuit.

Torque Converter Clutch

With the TCC control solenoid valve Off, the converter clutch is released in Second gear.

With the TCC control solenoid valve Off, the converter clutch is released in Second gear.

Overdrive Range, Third Gear - Torque Converter Clutch (TCC) Not Applied (W/o Electronic Range Select Mode)

As vehicle speed increases and operating conditions become appropriate, the PCM energized the 2-3 shift solenoid valve in order to shift the transmission into Third gear. The manual valve remains in the Overdrive (D) position, and line pressure continues to feed the drive and the PRND4 fluid circuits.

Torque Converter Clutch (TCC)

Torque Converter Clutch (TCC) Under normal operating conditions the TCC is released in Third gear. However the TCC apply could vary depending upon the vehicle application, and the TCC may be calibrated in order to apply in Overdrive Range - Third gear.

Overdrive Range, Third Gear - Torque Converter Clutch (TCC) Not Applied (With Electronic Range Select Mode)

As vehicle speed increases and operating conditions become appropriate, the PCM energized the 2-3 shift solenoid valve in order to shift the transmission into Third gear. The manual valve remains in the Overdrive (D) position, and line pressure continues to feed the drive and the PRND4 fluid circuits.

Torque Converter Clutch (TCC) Under normal operating conditions the TCC is released in Third gear. However the TCC apply could vary depending upon the vehicle application, and the TCC may be calibrated in order to apply in Overdrive Range - Third gear.

Overdrive Range, Fourth Gear - Torque Converter Clutch (TCC) Applied (W/o Electronic Range Select Mode)

When operating conditions are appropriate, the PCM energizes the 1-2 shift solenoid valve in order to shift the transmission into Fourth gear. In addition, the TCC is applied in Fourth gear. The manual valve remains in the Overdrive position and line pressure continues to feed the Drive and the PRND4 fluid circuits.

Apply fluid is routed to the torque converter at the same time that release fluid exhausts from the converter. Apply fluid pressure applies the TCC.

Overdrive Range, Fourth Gear - Torque Converter Clutch (TCC) Applied (With Electronic Range Select Mode)

When operating conditions are appropriate, the PCM energizes the 1-2 shift solenoid valve in order to shift the transmission into Fourth gear. In addition, the TCC is applied in Fourth gear. The manual valve remains in the Overdrive position and line pressure continues to feed the Drive and the PRND4 fluid circuits.

Apply fluid is routed to the torque converter at the same time that release fluid exhausts from the converter. Apply fluid pressure applies the TCC.

Overdrive Range, 4-3 Downshift - Torque Converter Clutch (TCC) Not Applied (W/o Electronic Range Select Mode)

When the transmission is operating in Overdrive Range - Fourth Gear, a forced 4-3 downshift will occur following a significant increase in throttle position. At minimum throttle, vehicle speed will decrease gradually (coastdown) and the PCM will command a 4-3 downshift. The PCM will also initiate a 4-3 downshift if the engine load is increased while the throttle position remains the same (for example, driving up a steep hill).

The PCM commands TCC release prior to initiating a 4-3 downshift. When the TCC is in the release position, release fluid pressure is routed to the pressure switch assembly. This fluid pressure signals the PCM that the TCC is in the release position. The TCC is not applied under normal operating conditions in Third gear.

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The PCM will release the TCC before downshifting into Manual Second. The TCC will not reapply in Second gear under normal operating conditions.

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The PCM will release the TCC before downshifting into Manual Second. The TCC will not reapply in Second gear under normal operating conditions.

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