Malibu 2001-2005

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 transmission fluid.
  4.  
  5. Remove the air intake duct from the throttle body and air cleaner assembly.
  6.  
  7. Remove the battery cover and disconnect the negative battery cable.
  8.  
  9. Disconnect the transaxle wiring harness from the transaxle and the Park/Neutral Position (PNP) switch.
  10.  
  11. Remove the shift cable bracket and shift cable from the lever.
  12.  
  13. Remove the transmission wiring harness from the retainer on the transmission.
  14.  
  15. Remove the upper transmission to engine bolts and stud.
  16.  
  17. Install the engine support fixture.
  18.  
  19. Support the radiator and condenser from above using the condenser tabs on each side.
  20.  
  21. Raise and support the vehicle.
  22.  
  23. Remove the front wheel and tire assemblies.
  24.  
  25. Remove the steering gear intermediate shaft .
  26.  
  27. Separate the control arm from the frame and the outer tie rod ends from the steering knuckles. Support the lower control arm with mechanics wire or a similar method.
  28.  
  29. Remove the frame.
  30.  
  31. Remove the 3 bolts from the transmission brace near the right axle shaft.
  32.  
  33. Remove the oil pan to bell housing bracket (3 bolts).
  34.  
  35. Remove the flywheel inspection cover.
  36.  
  37. Remove the starter.
    NOTE
    Mark the relationship of the flywheel to the torque converter for reassembly.

  38.  
  39. Remove the torque converter to flywheel bolts.
  40.  
  41. Remove the transmission cooler lines by removing the nut holding the bracket to the transaxle case.
  42.  
  43. Disconnect the Vehicle Speed Sensor (VSS) wiring harness from the sensor.
  44.  
  45. Disconnect the rear 02 sensor harness from the bracket on the steering gear.
  46.  
  47. Disconnect the wheel drive shafts from the transaxle.
  48.  
  49. Remove the front transmission mount bracket from the transmission.
  50.  
  51. Use a transmission jack to support the transmission.
  52.  
  53. Remove the remaining bell housing bolts and studs and separate the transmission from the engine.
  54.  
  55. Lower the transmission with the transmission jack far enough to remove the transmission.
  56.  
  57. If the transmission is being replaced or installed in a holding fixture, remove the rear transmission mount bracket from transmission.
  58.  
  59. Remove the PNP switch from the transmission.
  60.  

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 transmission jack.
  8.  
  9. Install the side cover transmission mount bracket to the transmission.
  10.  
  11. Install the rear transmission mount bracket to the transmission.
  12.  
  13. Position the transaxle in the vehicle.
  14.  
  15. Install the lower transmission to engine bolts and nuts and tighten to 66 ft. lbs. (90 Nm).
  16.  
  17. Install the front transmission mount bracket to the transmission.
  18.  
  19. Connect the wheel drive shafts to the transmission.
  20.  
  21. Connect the VSS 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 tighten mounting bolts to 30 ft. lbs. (40 Nm). Tighten the cable to starter nut to 7 ft. lbs. (10 Nm).
  26.  
  27. Tighten solenoid S terminal nut to 4 ft. lbs. (5 Nm).
  28.  
  29. Install the flywheel inspection cover bolts and tighten to 89 inch. lbs. (10 Nm).
  30.  
  31. Connect the transaxle cooler pipes to the transaxle and tighten to 71 inch. lbs. (8 Nm).
  32.  
  33. Install the oil pan to bell housing bracket (3 bolts) and tighten to 53 ft. lbs. (72 Nm).
  34.  
  35. Install the 3 bolts to the transmission brace at final area and tighten to 53 ft. lbs. (72 Nm).
  36.  
  37. Remove the transmission jack.
  38.  
  39. Install the frame.
  40.  
  41. Install the engine splash shields.
  42.  
  43. Install the front wheel and tire assemblies.
  44.  
  45. Lower the vehicle.
  46.  
  47. Remove the radiator and condenser support, and the engine support fixture
  48.  
  49. Install the upper transmission to engine bolts and stud tighten to 66 ft. lbs. (90 Nm).
  50.  
  51. Install the shift cable bracket and shift cable to the lever.
  52.  
  53. Install the exhaust pipe upper bolts and heat shield.
  54.  
  55. Connect the electrical connectors to the PNP switch and transaxle.
  56.  
  57. Connect the negative battery cable.
  58.  
  59. Install the battery cover.
  60.  
  61. Install the air intake duct to the throttle body and air cleaner assembly.
  62.  
  63. Add approved Automatic Transmission Fluid (ATF) and verify the proper fluid level of transaxle.
  64.  
  65. Road test the vehicle.
  66.  

 
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