G6 2005-2007

Transaxle Removal & Installation

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4T40-E & 4T45-E



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Spray penetrating oil on the exposed threads of both lower ball joint bolt to facilitate their removal.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the air intake duct.
  14.  
  15. Disconnect the transaxle wiring harness from the transaxle and the Park Neutral Position (PNP) switch.
  16.  
  17. Remove the shift cable bracket and shift cable from the lever.
  18.  
  19. Remove the transmission wiring harness from the retainer on the transmission.
  20.  
  21. Disconnect the Bank 2 O2 sensor electrical connector.
  22.  
  23. Remove the left exhaust manifold heat shield.
  24.  
  25. Remove the front exhaust pipe nuts.
  26.  
  27. Remove the upper transmission to engine bolts and stud.
  28.  
  29. Install the engine support fixture.
  30.  
  31. Support the radiator and condenser from above using the condenser tabs on each side.
  32.  
  33. Raise the vehicle.
  34.  
  35. Remove the front wheels and tires.
  36.  
  37. Disconnect the Bank 2 O2 sensor electrical sensor.
  38.  
  39. Remove the left catalytic converter to right catalytic converter nuts.
  40.  
  41. Remove the left catalytic converter.
  42.  
  43. Remove the steering gear intermediate shaft .
  44.  
  45. Remove the frame.
    NOTE
    It is only necessary to remove the control arms when the frame is replaced.

  46.  
  47. Disconnect the wheel drive shafts from the transaxle.
  48.  
  49. Remove the 3 bolts from the transmission brace near the right axle shaft.
  50.  
  51. Remove the 3  oil pan to bellhousing bracket bolts.
  52.  
  53. Remove the flywheel inspection cover.
  54.  
  55. Remove the starter.
  56.  
  57. Mark the relationship of the flywheel to the torque converter for reassembly
  58.  
  59. Remove the torque converter to flywheel bolts.
  60.  
  61. Remove the transmission oil cooler lines by removing the nut holding the bracket to the transaxle case.
  62.  
  63. Disconnect the Vehicle Speed Sensor (VSS) wiring harness from the sensor.
  64.  
  65. Disconnect the rear Heated Oxygen Sensor (HO2S) harness from the bracket on the rear transaxle mount
  66.  
  67. Remove the remaining rear bolt from the shift cable bracket.
  68.  
  69. Remove the front transmission mount bracket from the transmission
  70.  
  71. Use a transmission jack in order to support the transmission.
  72.  
  73. Remove the remaining bellhousing bolts and studs and separate the transmission from the engine.
  74.  
  75. Lower the transmission with the transmission jack far enough to remove the transmission.
  76.  
  77. If the transmission is being replace or installed in a holding fixture, remove the rear transmission mount bracket from the transmission.
  78.  
  79. If the transmission is being replaced, remove the PNP switch from the transmission
  80.  
  81. If the transmission is being replaced, remove the transmission mount.
  82.  

To install:

  1. If the transmission is being replaced, install the transmission mount.
  2.  
  3. Install the side cover transmission mount bracket to the transmission.
  4.  
  5. Install the rear transmission mount bracket to the transmission
  6.  
  7. Position the transaxle in the vehicle.
  8.  
  9. Install the lower transmission to engine bolts and nuts, tighten to 66 ft. lbs. (90 Nm).
  10.  
  11. Install the front transmission mount bracket to the transmission.
  12.  
  13. Install the wheel drive shafts to the transaxle.
  14.  
  15. Connect the wiring harness to the VSS.
  16.  
  17. Install the torque converter to flywheel bolts and tighten to 46 ft. lbs. (62 Nm).
  18.  
  19. Install the starter and mounting bolts tighten to 30 ft. lbs. (40 Nm).
  20.  
  21. Install the flywheel inspection cover bolts and tighten to 89 inch. lbs. (10 Nm).
  22.  
  23. Connect the transaxle oil cooler pipes to the transaxle. Tighten the pipes to 71 inch. lbs. (8 Nm).
  24.  
  25. Install the 3 oil pan to bellhousing bracket bolts. Tighten the bolts to 53 ft. lbs. (72 Nm).
  26.  
  27. Install the 3 bolts to the transmission brace at the final drive area and tighten.
  28.  
  29. Remove the transmission jack.
  30.  
  31. Install the frame.
  32.  
  33. Tighten the frame to body bolts to 74 ft. lbs. (100 Nm) plus 90 degrees.
  34.  
  35. Tighten the frame support to body bolts to 74 ft. lbs. (100 Nm).
  36.  
  37. Install the engine splash shields.
  38.  
  39. Install the front wheels and tires.
  40.  
  41. Lower the vehicle.
  42.  
  43. Remove the radiator and condenser support and the engine support fixture.
  44.  
  45. Install the upper transmission to engine bolts and stud. Tighten the bolts and stud to 66 ft. lbs. (90 Nm).
  46.  
  47. Install the shift cable bracket and shift cable to the lever.
  48.  
  49. Install the left catalytic converter exhaust pipe.
  50.  
  51. Connect the Bank 2 O2 sensor electrical connector.
  52.  
  53. Install the left exhaust manifold heat shield.
  54.  
  55. Install the heat shield bolts and tighten to 89 inch. lbs. (10 Nm).
  56.  
  57. Connect the Bank 2 O2 sensor electrical connector
  58.  
  59. Connect the electrical connectors to the PNP switch and transaxle.
  60.  
  61. Connect the negative battery cable.
  62.  
  63. Install the air intake duct.
  64.  
  65. Add automatic transmission fluid DEXRON VI and verify the proper fluid level of the transaxle.
    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.

  66.  
  67. Reset the TAP values.
  68.  
  69. Road test the vehicle.
  70.  

4T65-E



  1. Raise and support the vehicle.
  2.  
  3. Spray penetrating oil on the exposed threads of both lower ball joint bolt to facilitate their removal later in this procedure.
  4.  
  5. Lower the vehicle.
  6.  
  7. Remove the air cleaner outlet duct.
  8.  
  9. Disconnect the negative battery cable.
  10.  
  11. Disconnect the transaxle wiring harness from the transaxle and the park neutral position (PNP) switch.
  12.  
  13. Remove the shift cable bracket and shift cable from the lever.
  14.  
  15. Remove the transmission wiring harness from the retainer on the transmission.
  16.  
  17. Remove the upper transmission to engine bolt and studs.
  18.  
  19. Install the engine support fixture.
  20.  
  21. Convertible ONLY, remove the transmission mount.
  22.  
  23. Support the radiator and condenser from above using the condenser tabs on each side.
  24.  
  25. Raise the vehicle.
  26.  
  27. Remove the front wheels and tires.
  28.  
  29. Remove the steering gear intermediate shaft.
  30.  
  31. Separate the control arm from the frame and the outer tie-rod end from the steering knuckles. Support the lower control arm with mechanic wire.
  32.  
  33. Remove the frame.
  34.  
  35. Remove the bolts from the transmission brace near the right axle shaft.
  36.  
  37. Remove the oil pan to bellhousing bracket bolts.
  38.  
  39. Remove the flywheel inspection cover.
  40.  
  41. Remove the starter.
  42.  
  43. Mark the relationship of the flywheel to the torque converter for reassembly.
  44.  
  45. Remove the torque converter to flywheel bolts.
  46.  
  47. Remove the transmission oil cooler lines by removing the nut holding the bracket to the transaxle case.
  48.  
  49. Disconnect the Vehicle Speed Sensor (VSS) wiring harness from the sensor.
  50.  
  51. Disconnect the rear Heated Oxygen Sensor (HO2S) harness from the bracket on the steering gear.
  52.  
  53. Disconnect the wheel drive shafts from the transaxle.
  54.  
  55. Remove the front transmission mount from the transmission.
  56.  
  57. Use a transmission jack in order to support the transmission.
  58.  
  59. Remove the remaining bellhousing bolts and studs and separate the transmission from the engine.
  60.  
  61. Lower the transmission with the transmission jack far enough to remove the transmission.
  62.  
  63. If the transmission is being replace or installed in a holding fixture, remove the rear transmission mount from the transmission.
  64.  
  65. Remove the PNP switch from the transmission.
  66.  
  67. Remove the transaxle to engine bolts 
  68.  
  69. Separate the engine and the transaxle.
  70.  
  71. Remove the transaxle from the vehicle.

    Click image to see an enlarged view

    Fig. 4T65-E transaxle removal

  72.  
  73. Remove the PNP switch.
  74.  
  75. Remove the shifter cable bracket.
  76.  
  77. Remove the lower transmission to engine stud.
  78.  
  79. Remove the left transmission mount bracket.
  80.  

To install:

  1. Install the PNP switch.
  2.  
  3. Install the torque converter clutch (TCC) lock up clutch O-ring.
  4.  
  5. Install the torque converter.
  6.  
  7. Transfer the transaxle from the bench fixture to the transmission jack.
  8.  
  9. Install the left transmission mount bracket to the transmission.
  10.  
  11. Install the rear transmission mount to the transmission.
  12.  
  13. Position the transaxle in the vehicle.
  14.  
  15. Install the lower transmission to engine bolts and tighten to 66 ft. lbs. (90 Nm).
  16.  
  17. Install the front transmission mount to the transmission.
  18.  
  19. Install the wheel drive shafts to the transaxle. Tighten the shaft nuts to 159 ft. lbs. (215 Nm).
  20.  
  21. Connect the wiring harness to the VSS.
  22.  
  23. Install the torque converter to flywheel bolts and tighten to 46 ft. lbs. (62 Nm).
  24.  
  25. Install the starter and mounting bolts tighten to 30 ft. lbs. (40 Nm).
  26.  
  27. Install the flywheel inspection cover bolts and tighten to 89 inch. lbs. (10 Nm).
  28.  
  29. Connect the transaxle oil cooler pipes to the transaxle. Tighten the pipes to 71 inch. lbs. (8 Nm).
  30.  
  31. Install the 3 oil pan to bellhousing bracket bolts. Tighten the bolts to 53 ft. lbs. (72 Nm).
  32.  
  33. Install the 3 bolts to the transmission brace at the final drive area and tighten.
  34.  
  35. Remove the transmission jack.
  36.  
  37. Install the frame.
  38.  
  39. Tighten the frame to body bolts to 74 ft. lbs. (100 Nm) plus 90 degrees.
  40.  
  41. Tighten the frame support to body bolts to 74 ft. lbs. (100 Nm).
  42.  
  43. Install the engine splash shields.
  44.  
  45. Install the front wheels and tires.
  46.  
  47. Lower the vehicle.
  48.  
  49. Convertible ONLY, install the transmission mount.
  50.  
  51. Remove the radiator and condenser support and the engine support fixture.
  52.  
  53. Install the upper transmission to engine bolts and stud. Tighten the bolts and stud to 66 ft. lbs. (90 Nm).
  54.  
  55. Install the shift cable bracket and shift cable to the lever.
  56.  
  57. Install the exhaust pipe upper bolts and heat shield.
  58.  
  59. Connect the electrical connectors to the PNP switch and transaxle.
  60.  
  61. Connect the negative battery cable.
  62.  
  63. Install the air cleaner outlet duct.
  64.  
  65. Add automatic transmission fluid DEXRON VI and verify the proper fluid level of the transaxle.
    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.

  66.  
  67. Reset the TAP values.
  68.  
  69. Road test the vehicle.
  70.  

6T70/6T75



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the battery tray.
  4.  
  5. Remove the transmission range select lever cable and bracket.
  6.  
  7. Drain the transmission fluid.
  8.  
  9. Remove the wire harness retainer from the control valve body cover stud.
  10.  
  11. Disconnect the control valve body Transmission Control Module (TCM) electrical connector.
  12.  
  13. Remove the transmission fluid cooler pipe retainer nut.
  14.  
  15. Remove the transmission fluid cooler inlet hose and seal from the transmission.
  16.  
  17. Plug and/or cap the hose and transmission to prevent contamination.
  18.  
  19. Remove the transmission fluid cooler pipe retainer nut.
  20.  
  21. Remove the transmission fluid cooler outlet hose and seal from the transmission.
  22.  
  23. Plug and/or cap the hose and transmission to prevent contamination.
  24.  
  25. Remove the upper transmission to engine bolts.
  26.  
  27. Remove the frame.
  28.  
  29. Disconnect the wheel drive shafts from the transmission.
  30.  
  31. Remove the intermediate drive shaft.
  32.  
  33. Remove the transmission brace bolts.
  34.  
  35. Remove the transmission brace.
  36.  
  37. Remove the rear transmission mount from the transmission.
  38.  
  39. Remove the front transmission mount from the transmission.
  40.  
  41. Remove the starter.
  42.  
  43. Mark the relationship of the flywheel to the torque converter for reassembly.
  44.  
  45. Remove the torque converter to flywheel bolts.
  46.  
  47. Use a transmission jack in order to support the transmission.
  48.  
  49. Remove the flywheel inspection cover bolts.
  50.  
  51. Remove the flywheel inspection cover.
  52.  
  53. Remove the remaining transmission bolts.
    NOTE
    Insure the torque converter remains securely in place on the transmission input shaft while separating and removing the transmission.

  54.  
  55. Separate the transmission from the engine.
  56.  
  57. Lower the transmission with the transmission jack far enough to remove the transmission.
  58.  

To install:

  1. Raise the transmission with the transmission jack and position the transmission to the engine.
  2.  
  3. Install the transmission bolts and tighten to 55 ft. lbs. (75 Nm).
  4.  
  5. Install the flywheel inspection cover and bolts, tighten to 55 ft. lbs. (75 Nm).
  6.  
  7. Remove the transmission jack.
  8.  
  9. Install the torque converter to flywheel bolts at starter motor hole. Tighten the bolts to 46 ft. lbs. (62 Nm).
  10.  
  11. Install starter motor and tighten the mounting bolts to 37 ft. lbs. (50 Nm).
  12.  
  13. Install the front transmission mount to the transmission.
  14.  
  15. Install the rear transmission mount to the transmission.
  16.  
  17. Install the transmission brace.
  18.  
  19. Install the transmission brace bolts tighten to 37 ft. lbs. (50 Nm).
  20.  
  21. Install the intermediate drive shaft.
  22.  
  23. Install the wheel drive shafts to the transmission. Tighten the shaft nuts to 159 ft. lbs. (215 Nm).
  24.  
  25. Install the frame
  26.  
  27. Install the upper transmission to engine bolts and tighten to 55 ft. lbs. (75 Nm). 
  28.  
  29. Install the transmission fluid cooler outlet hose and seal to the transmission.
  30.  
  31. Install the transmission fluid cooler pipe retainer nut and tighten to 16 ft. lbs. (22 Nm).
  32.  
  33. Install the transmission fluid cooler inlet hose and seal to the transmission.
  34.  
  35. Install the transmission fluid cooler pipe retainer nut and tighten to 16 ft. lbs. (22 Nm).
  36.  
  37. Connect the control valve body TCM electrical connector.
  38.  
  39. Install the wire harness retainer to the control valve body cover stud. Tighten the nut to 106 lb inch. lbs. (12 Nm).
  40.  
  41. Install the transmission range select lever cable and bracket.
  42.  
  43. Install the battery tray.
  44.  
  45. Connect the negative battery cable.
  46.  
  47. Adjust the automatic transmission range selector lever cable.
  48.  
  49. Add automatic transmission fluid DEXRON VI and verify the proper fluid level of the transaxle.
    WARNING
    Use DEXRON VI transmission fluid only. Failure to use the proper fluid may result in transmission internal damage.


    NOTE
    After an internal transmission repair or internal part replacement the service fast learn adapt procedure should be performed.

  50.  
  51. Perform the service fast learn adapt procedure. Use the scan tool to navigate to service fast learn adapts.
  52.  
  53. Road test the vehicle.
  54.  

 
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