CTS 2006-2007, CTS-V 2005-2007, DTS 2006-2007

Transaxle Removal & Installation

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4t80-E Transaxle



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the front compartment sight shield.
  6.  
  7. Remove the upper and lower air cleaner assemblies.
  8.  
  9. Disconnect the range selector cable terminal from the transaxle range selector lever.
  10.  
  11. Remove the nuts securing both the range selector cable bracket and heater pipe to the transaxle. Position the range selector cable bracket and heater pipe aside.
  12.  
  13. Remove the Magnasteer wire from the retaining clip.
  14.  
  15. Remove the brake master cylinder from the brake booster and position aside. Do not disconnect the brake lines.
  16.  
  17. Disconnect the master cylinder brake pipe retainers from the side rail.
  18.  
  19. Remove the brake pipe retainers from the side rail and using mechanics wire, support the brake pipes above the side rail.
  20.  
  21. Reposition the main wiring harness to gain access to the upper transaxle to engine bolts.
  22.  
  23. Remove the transaxle to engine bolts. The remaining bolt will temporally retain the transaxle and will be removed from the underside of the vehicle.
  24.  
  25. Place a drain pan under the vehicle.
  26.  
  27. Remove the upper transaxle oil cooler pipe retaining bolt from the radiator fan shroud.
  28.  
  29. Disconnect the upper transaxle oil cooler pipe from the radiator using the J 41623-B cooler quick connect tool . Install plugs in the oil cooler pipe and the radiator to prevent fluid loss and contamination.
  30.  
  31. Disconnect the lower transaxle oil cooler pipe from the transaxle and Install plugs in the oil cooler pipe and the transaxle to prevent fluid loss and contamination.
  32.  
  33. Disconnect the transaxle vent tube from the accelerator bracket.
  34.  
  35. Install the engine support fixture.

    Click image to see an enlarged view

    Fig. Engine Support fixture shown

  36.  
  37. Raise and support the vehicle.
    CAUTION
    To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

  38.  
  39. Secure the vehicle to the front hoist pads.
  40.  
  41. Remove the front tires and wheels.
  42.  
  43. Remove the bolts retaining the steering gear to the engine frame.
  44.  
  45. Remove the ball joints from the steering knuckle.
  46.  
  47. Remove the front air deflector.
  48.  
  49. Remove the brake pressure modulator valve and bracket from the frame.
  50.  
  51. Disconnect the ESC sensor links from the lower control arm ball studs.
  52.  
  53. Do not remove the A.I.R pump assembly from the vehicle. Retain the pump to the body using mechanics wire.
  54.  
  55. Remove the steering gear heat shield fasteners in order to remove the steering gear heat shield and disconnect the electrical harness retainer that is mounted on the heat shield.
  56.  
  57. Disconnect the electrical harness from the heat shield.
  58.  
  59. Remove the brackets retaining the power steering line to the frame.
  60.  
  61. Remove the retainer, retaining the power steering line along the left side of the engine frame.
  62.  
  63. Using mechanics wire, retain the steering gear to the body.
  64.  
  65. Lower vehicle until the engine frame rests on the J 39580 or suitable jack stands .

    Click image to see an enlarged view

    Fig. Engine frame resting on suitable jack stands

  66.  
  67. Remove the fastener retaining the front engine mount to the engine frame.
  68.  
  69. Remove the fasteners retaining the rear transaxle mount to the engine frame.
  70.  
  71. Remove the engine frame insulator bolts.
  72.  
  73. Raise vehicle away from engine frame.
  74.  
  75. Remove the left transaxle mount and bracket from the transmission.
  76.  
  77. Support the transaxle using the J 41160 and a suitable transmission jack.
  78.  
  79. Secure the J 41160 to the transaxle.
  80.  
  81. Remove the bolt securing the left transaxle brace to the transaxle.
  82.  
  83. Loosen the nut securing the left transaxle brace to the engine.
  84.  
  85. Remove the left transaxle brace from the powertrain assembly.
  86.  
  87. Remove the 3 ground connections from the side of the transaxle.
  88.  
  89. Disconnect the transaxle main electrical harness connector.
  90.  
  91. Remove the bolt securing the front transaxle brace to the transaxle.
  92.  
  93. Remove the nut securing the secondary AIR pipe to the transaxle.
  94.  
  95. Remove the nuts securing the vehicle speed sensor heat shield to the transaxle.
  96.  
  97. Remove the vehicle speed sensor heat shield from the vehicle.
  98.  
  99. Disconnect the vehicle speed sensor electrical connector.
  100.  
  101. Remove only the bolts securing the front transaxle brace to the transaxle.
  102.  
  103. Remove only the bolts securing the center transaxle brace to the transaxle.
  104.  
  105. Disengage the right and left drive shafts from the transaxle. The drive shafts do not have to be removed from the wheels.
  106.  
  107. Using mechanics wire, support the wheel drive shafts out of the way by tying them up to the strut spring.
  108.  
  109. Remove the torque converter cover.
    NOTE
    Mark the flywheel to torque converter position so that they can be assembled in the same position.

  110.  
  111. Remove the flywheel to torque converter bolts.
  112.  
  113. Position the power steering gear pressure hose to the right side of the vehicle in order to clear the transaxle during removal.
  114.  
  115. Remove the remaining transaxle to engine bolt.
  116.  
  117. Separate the transaxle from the engine.
  118.  
  119. Tilt the transaxle using the support jack enough to allow clearance for the starter nose cone.
  120.  
  121. Carefully lower the transaxle from the vehicle.
  122.  

To install:

  1. Carefully raise the transaxle to the engine in a tilted position in order to clear the starter nose cone.
  2.  
  3. Align the transaxle with the engine and position the transaxle onto the engine dowels.
  4.  
  5. Install the engine to transaxle bolt (2), tighten to 55 ft. lbs. (75 Nm).

    Click image to see an enlarged view

    Fig. Transaxle to engine bolts (1) and (2)

  6.  
  7. Connect the vehicle speed sensor electrical connector.
  8.  
  9. Install the engine to transaxle center brace and heat shield.
  10.  
  11. Install the bolts securing the front transaxle brace to the transaxle. Tighten the bolts to 37 ft. lbs. (50 Nm).
    NOTE
    Line up the flywheel and converter using the alignment marks made during disassembly.

  12.  
  13. Install the flywheel to converter bolts. Tighten the bolts to 44 ft. lbs. (60 Nm).
  14.  
  15. Install the torque converter cover assembly.
  16.  
  17. Install the engine to transaxle bracket lower bolt and tighten to 37 ft. lbs. (50 Nm).
  18.  
  19. Install the right and left drive shafts to the transaxle.
  20.  
  21. Install the 3 ground connections to the side of the transaxle. Tighten the bolts to 37 ft. lbs. (50 Nm).
  22.  
  23. Connect the transaxle main electrical harness connector.
  24.  
  25. Install the left transaxle brace to the powertrain assembly.
  26.  
  27. Install the bolt securing the left transaxle brace to the transaxle. Tighten the left transaxle brace bolt to 37 ft. lbs. (50 Nm). Tighten the left transaxle brace nut to 30 ft. lbs. (41 Nm).
  28.  
  29. Remove the transmission jack and the J 41160.
  30.  
  31. Install the left transaxle mount and bracket to the transmission.
  32.  
  33. Lower the vehicle onto the engine frame.
  34.  
  35. Using dowel pins in the alignment holes, align the engine frame with the vehicle.
  36.  
  37. Install the engine frame insulator retainer bolts in order to retain the engine frame to the vehicle.
  38.  
  39. Tighten the retainers to 133 ft. lbs. (181 Nm).
  40.  
  41. Raise the vehicle away from the jack stands supporting the engine frame.
  42.  
  43. Install the fasteners in order to retain the rear transaxle mount to the bracket. Tighten the retainers to 37 ft. lbs. (50 Nm).
  44.  
  45. Install the fastener in order to retain the front engine mount to the engine frame. Tighten the fastener to 52 ft. lbs. (70 Nm).
  46.  
  47. Install the fasteners in order to retain the steering gear to the engine frame. Tighten the fastener to 70 ft. lbs. (95 Nm).
  48.  
  49. Install the bracket to retain the power steering line to the engine frame.
  50.  
  51. Install the clips retaining power steering line along engine frame rail.
  52.  
  53. Connect the wiring harness to the heat shield.
  54.  
  55. Install the steering gear heat shield to the vehicle. Tighten the retainers to 80 inch lbs. (9 Nm).
  56.  
  57. Install the brake pressure modulator valve.
  58.  
  59. Install the ESC sensor links to the lower control arm ball studs.
  60.  
  61. Install the front air deflector.
  62.  
  63. Install the ball joints to the steering knuckle.
  64.  
  65. Tighten the ball joint nut to 22 ft. lbs, (30 Nm). Then tighten the nut an additional 210 degrees.
  66.  
  67. Install the front tires and wheels.
  68.  
  69. Install the stabilizer shaft links.
  70.  
  71. Lower the vehicle.
  72.  
  73. Connect the lower transaxle oil cooler pipe to the transaxle.
  74.  
  75. Install the upper transaxle oil cooler pipe to the radiator.
  76.  
  77. Install the remaining transaxle to engine bolts (1), tighten to 55 ft. lbs. (75 Nm).

    Click image to see an enlarged view

    Fig. Transaxle to engine bolts (1) and (2)

  78.  
  79. Remove the engine support fixture.
  80.  
  81. Install the range selector cable bracket to the studs on the transaxle.
  82.  
  83. Install the heater pipe to the stud on the transaxle.
  84.  
  85. Install the nuts that retain the heater pipe and the range selector cable bracket to the transaxle. Tighten the nuts to 18 ft. lbs. (25 Nm).
  86.  
  87. Connect the range selector cable terminal to the transaxle range selector lever.
  88.  
  89. Install the Magnasteer wire to the retaining clip.
  90.  
  91. Connect the transaxle vent tube to the accelerator bracket.
  92.  
  93. Install the Magnasteer wire to the retaining clip.
  94.  
  95. Connect the transaxle vent tube to the accelerator bracket.
  96.  
  97. Install the brake pipe retainers to the side rail.
  98.  
  99. Install the brake master cylinder to the brake booster.
  100.  
  101. Install the upper and lower air cleaner assemblies.
  102.  
  103. Install the front compartment sight shield.
  104.  
  105. Flush the transmission cooler.
  106.  
  107. Add DEXRON®VI transmission fluid as required.
  108.  
  109. Check the front suspension alignment, adjust the toe as necessary.
    NOTE
    It is recommended that Transmission Adaptive Pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned.

  110.  
  111. Clear the TAP values.
  112.  
  113. Connect the negative battery cable.
  114.  
  115. Check the front wheel alignment.
  116.  
  117. Road test the vehicle and check for transaxle leaks.
  118.  

 
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