AutoZone 2002 Ford Truck Explorer Sport Trac 4WD 4.0L EFI SOHC 6cyl | Repair Guides | Drive Train | Automatic Transaxle | Automatic Transaxle Assembly | AutoZone.com

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    GM Cavalier/Sunfire 1995-2000 Repair Guide

    Automatic Transaxle Assembly

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    REMOVAL & INSTALLATION



    3T40 Automatic Transaxle

    See Figures 1, 2 and 3



    Click image to see an enlarged view

    Fig. Fig. 1: Install a suitable engine support fixture-1995 2.2L engine shown



    Click image to see an enlarged view

    Fig. Fig. 2: Transaxle-to-engine bolt positions-3T40 transaxle shown



    Click image to see an enlarged view

    Fig. Fig. 3: View of the transaxle mount, bracket and bracket-1995 3T40 transaxle shown

    1. Disconnect the negative battery cable.
    2.  
    3. Properly drain the transaxle.
    4.  
    5. Remove the air intake duct.
    6.  
    7. Disconnect the TV cable. Remove the shift cable and bracket.
    8.  
    9. Tag and detach all necessary vacuum lines and electrical connections.
    10.  
    11. Remove the power steering pump and set aside.
    12.  
    13. Remove the transaxle filler tube.
    14.  
    15. Install engine support fixture J 28467-A or equivalent.
    16.  
    17. Remove the top engine-to-transaxle bolts.
    18.  
    19. Raise and safely support the vehicle.
    20.  
    21. Remove both front tire and wheel assemblies. Remove the left splash shield.
    22.  
    23. Remove both front ABS wheel speed sensors and the harness from the left suspension support.
    24.  
    25. As outlined in Suspension & Steering of this guide, remove both lower ball joints.
    26.  
    27. Disconnect the stabilizer shaft links.
    28.  
    29. Remove the front air deflector.
    30.  
    31. Remove the left suspension support and both drive axles.
    32.  
    33. Disconnect the engine-to-transaxle brace, then remove the transaxle converter cover.
    34.  
    35. Remove the starter, as outlined in Engine Electrical of this guide.
    36.  
    37. Unfasten the flywheel-to-torque converter bolts.
    38.  
    39. Disconnect the transaxle cooler pipes.
    40.  
    41. Detach the ground wires from the engine-to-transaxle bolt.
    42.  
    43. Remove the cooler pipe brace and the exhaust brace.
    44.  
    45. Remove the bolts from the engine and transaxle mount.
    46.  
    47. Support the transaxle with a suitable jack.
    48.  
    49. Unfasten the transaxle mount-to-body bolts.
    50.  
    51. Remove the heater core hose pipe brace-to-transaxle nut and bolt.
    52.  
    53. Unfasten the remaining engine-to-transaxle bolts, then remove the transaxle assembly from the vehicle.
    54.  

    To install:

    Whenever the transaxle has been removed, the transaxle cooler lines should be flushed.

    1. Place a thin film of GM part no. 1051344 or equivalent grease on the torque converter pilot knob.
    2.  
    3. Move the transaxle assembly into position with the jack while installing the right drive axle. Make sure to properly seat the torque converter in the oil pump.
    4.  
    5. Install the lower transaxle retaining bolts in their proper positions, as shown in the accompanying figure.
    6.  
    7. Install the transaxle mount-to-body bolts as shown in the accompanying figure.
    8.  
    9. Install the engine and transaxle mount bolts.
    10.  
    11. Fasten the exhaust brace and the cooler pipe brace.
    12.  
    13. Connect the ground wires at the engine-to-transaxle bolt.
    14.  
    15. Attach the transaxle cooler pipes.
    16.  
    17. Apply adhesive/sealing compound GM part no. 12345493 or equivalent on the flywheel-to-torque converter bolts, then install the bolts. Install the converter cover/shield.
    18.  
    19. Install the starter.
    20.  
    21. Fasten the engine-to-transaxle brace.
    22.  
    23. Install the drive axles and the left suspension support.
    24.  
    25. Fasten the front air deflector.
    26.  
    27. Connect the stabilizer shaft links and the lower ball joints.
    28.  
    29. Install both ABS wheel speed sensors.
    30.  
    31. Fasten the left splash shield, then install the heater core pipe brace nut and bolt.
    32.  
    33. Install the front wheel and tire assemblies, then carefully lower the vehicle.
    34.  
    35. Install the top engine-to-transaxle bolts.
    36.  
    37. Remove the engine support fixture.
    38.  
    39. Install the filler tube.
    40.  
    41. Install the power steering pump assembly, then adjust the belt.
    42.  
    43. Attach the electrical connections and vacuum lines, as tagged during removal.
    44.  
    45. Install the shift cable and bracket. Connect the TV cable.
    46.  
    47. Fasten the air intake duct.
    48.  
    49. Connect the negative battery cable, then fill the transaxle to the proper level.
    50.  

    4T40E Transaxle
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the air cleaner assembly.
    4.  
    5. Disconnect the shift linkage from the transaxle.
    6.  
    7. Detach the wiring connections from the transaxle.
    8.  
    9. Install J 28467-A or equivalent engine support fixture.
    10.  
    11. Unfasten the upper engine-to-transaxle bolts.
    12.  
    13. Raise and safely support the vehicle.
    14.  
    15. Remove both front tire and wheel assemblies. Remove the left and right splash shields.
    16.  
    17. Remove both front ABS wheel speed sensors and the harness from the left suspension support.
    18.  
    19. Using tool J 24319-B or equivalent, remove both outer tie rods from the steering knuckle.
    20.  
    21. Separate both ball joints from the steering knuckle using tool J 38892 or equivalent.
    22.  
    23. Remove the front suspension support brace, then remove the engine mount strut from the strut mount bracket.
    24.  
    25. Support the suspension support assembly, then remove the bolts. Loosen the suspension support assembly enough to disconnect the steering coupling and both power steering fluid lines.
    26.  
    27. Remove both drive axles (halfshafts) from the transaxle, then support them.
    28.  
    29. Unfasten the engine-to-transaxle brace.
    30.  
    31. Remove the shift cable bracket.
    32.  
    33. As outlined in Engine Electrical of this guide, remove the starter.
    34.  
    35. Unfasten the retaining bolts, then remove the transaxle converter cover/shield.
    36.  
    37. Matchmark the flywheel-to-torque converter for reassembly, then unfasten the torque converter-to-flywheel bolts.
    38.  
    39. Disconnect the transaxle cooler pipes. Remove the brake hose bracket-to-body.
    40.  
    41. Unfasten the transaxle mount pipe expansion bolt.
    42.  
    43. Unfasten the transaxle mount-to-body bolts.
    44.  
    45. Carefully lower the vehicle.
    46.  
    47. Lower the transaxle with the engine support fixture enough to remove the transaxle.
    48.  
    49. Raise and safely support the vehicle.
    50.  
    51. Support the transaxle with a suitable jack.
    52.  
    53. Unfasten the remaining transaxle-to-engine bolts, then remove the transaxle from the vehicle.
    54.  

    To install:

    Whenever the transaxle has been removed, the transaxle cooler lines should be flushed.

    1. Place a thin film of GM part no. 1051344 or equivalent grease on the torque converter pilot knob. Make sure to properly seat the torque converter in the oil pump.
    2.  
    3. Position the transaxle in the vehicle, then secure with the lower transaxle-to-engine bolts. Tighten to the specifications shown in the accompanying figure.
    4.  
    5. Carefully lower the vehicle. Raise the transaxle with the engine support fixture.
    6.  
    7. Raise and safely support the vehicle.
    8.  
    9. Fasten the transaxle mount-to-body bolts.
    10.  
    11. Attach the brake hose bracket to body.
    12.  
    13. Connect the transaxle cooler pipes.
    14.  
    15. Fasten the torque converter-to-flywheel bolts. Hand start the bolts, then tighten them to 46 ft. lbs. (62 Nm). Install the converter cover/shield.
    16.  
    17. Install the starter.
    18.  
    19. Connect the shift cable bracket. Tighten the bolt to 18 ft. lbs. (25 Nm) and the nut to 37 ft. lbs. (50 Nm).
    20.  
    21. Install the engine-to-transaxle brace.
    22.  
    23. Install both drive axles (halfshafts).
    24.  
    25. Raise the suspension support assembly enough to connect the steering coupling and both power steering fluid lines.
    26.  
    27. Support the suspension support assembly, then install the retaining bolts.
    28.  
    29. Fasten the engine mount strut to the suspension support. Install the front suspension support brace. Tighten the retaining bolt to 49 ft. lbs. (66 Nm).
    30.  
    31. Attach both ball joints to the steering knuckle assembly, then connect both outer tie rods to the steering knuckle.
    32.  
    33. Attach both front ABS wheel speed sensors and fasten the harness to the left suspension support.
    34.  
    35. Install the right and left splash shields and the front tire and wheel assemblies.
    36.  
    37. Carefully lower the vehicle.
    38.  
    39. Install the upper transaxle-to-engine bolts, the remove the engine support fixture.
    40.  
    41. Attach the wiring connections to the transaxle, then connect the shift linkage to the transaxle.
    42.  
    43. Install the air cleaner assembly, then connect the negative battery cable.
    44.  
    45. Check the transaxle fluid lever, and fill with the proper type of oil, if necessary.
    46.  
    47. Apply the brakes, start the engine, then shift the transaxle from Reverse to Drive. Fasten the transaxle mount pipe expansion bolt.
    48.  

    ADJUSTMENTS



    Throttle Valve (TV) Cable

    Setting of the TV cable must be done by rotating the throttle lever at the throttle body. Do not use the accelerator pedal to rotate the throttle lever.

    1. With the engine OFF, depress and hold the reset tab at the engine end of the TV cable.
    2.  
    3. Move the slider until it stops against the fitting.
    4.  
    5. Release the rest tab.
    6.  
    7. Rotate the throttle lever to its full travel.
    8.  
    9. The slider must move (ratchet) toward the lever when the lever is rotated to its full travel position.
    10.  
    11. Recheck after the engine is hot and road test the vehicle.
    12.  

     
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