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2002 Chevrolet Cavalier - Transmissions > Automatic Tr...

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2002 Chevrolet Cavalier : Transmissions > Automatic Transaxle > Automatic Transaxle - 4T40-E/4T45-E > Repair Instructions > Transmission Replacement

Transmission Replacement
TRANSMISSION REPLACEMENT Removal Procedure 1. 2. 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical. Disconnect the air duct hose from the intake plenum. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 2.2L or Engine Support Fixture in Engine Mechanical - 2.4L or Engine Support Fixture in Engine Mechanical 2.2L (L61).

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4.

Disconnect the transaxle wiring harness from the transaxle and the PNP switch.

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5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Remove the upper transmission to engine bolts and stud. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. Remove the front wheel and tire assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Remove the left front fender liner. Refer to Front Fender Liner Replacement in Body Front End. Disconnect the engine strut from the lower engine mount strut bracket. Remove the wiring harness from the retaining clips. Remove the steering gear mounting bolts and secure the steering gear with mechanics wire. Disconnect the wheel speed sensor wires from the both front wheels and unclip from the frame. Separate the ball joints from the steering knuckles. Lower Control Arm Ball Joint Replacement in Front Suspension. Remove the lower suspension support. Refer to Front Suspension Crossmember Replacement in Front Suspension.

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15.

Remove the 2 bolts from the transmission brace.

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16. 17.

Disconnect the shift cable from the shift linkage. Disconnect the cable from the bracket.

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18. 19. 20.

Remove the flywheel inspection cover. Remove the starter. Refer to Starter Motor Replacement (Refer To List 1) in Engine Electrical. Mark the relationship of the flywheel to the torque converter for reassembly.

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21. 22.

Remove the torque converter to flywheel bolts. Remove the transmission cooler lines by removing the nut holding the bracket to the transaxle case.

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23. 24.

Disconnect the VSS wiring harness from the sensor. Disconnect the wheel drive shafts from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts

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2002 Chevrolet Cavalier - Transmissions > Automatic Tr...


25. 26. 27. 28. 29. 30. 31. Lower the vehicle. Remove the body to transmission mount bolts.

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Lower the transmission and engine with the engine support fixture enough to remove the transmission. Raise the vehicle. Remove the oil pan to drain the transmission. Refer to Oil Pan Replacement . Install the oil pan. Refer to Oil Pan Replacement . Support the transmission with a suitable jack.

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32. 33. 34. 35. 36. 37. 38. 39.

Remove the transaxle to engine nut. Separate the engine and the transaxle. Remove the transaxle from the vehicle. Remove the PNP switch. Remove the shifter cable bracket. Remove the lower transmission to engine stud. Remove the transmission mount. Flush the transmission cooler and the lines. Refer to Transmission Fluid Cooler Flushing and Flow Test (Refer To List 2) .

Installation Procedure 1. 2. 3. 4. Install the PNP switch. Install the shifter cable bracket. Install the lower transmission to engine stud. Install the transmission mount.

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5.

Position the transaxle in the vehicle.

NOTE
Notice: Refer to Fastener Notice (Refer To List 3) in the Preface section.

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6.

Install the lower transmission to engine bolts and nuts. Tighten Tighten the bolts and nuts to 90 Nm (66 lb ft).

7. 8.

Lubricate the transaxle cooler pipes before inserting into seals. Connect the transaxle cooler pipes to the transaxle. Tighten Tighten the cooler pipes to 8 Nm (71 lb in).

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9.

Install the torque converter to flywheel bolts. Tighten Tighten the torque converter bolts to 62 Nm (46 lb ft).

10.

Install the wheel drive shafts to the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.

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11.

Connect the wiring harness to the VSS.

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12. 13.

Install the starter. Refer to Starter Motor Replacement (Refer To List 1) in Engine Electrical. Install the flywheel inspection cover bolts. Tighten Tighten the bolts to 10 Nm (89 lb in).

14. 15. 16.

Lower the vehicle. Use the engine support fixture to raise the engine and transmission assembly. Install the transaxle mount to body bolts. Tighten Tighten the bolts to 90 Nm (66 lb ft).

17. 18.

Raise the vehicle. Reposition the wiring harness into its clips on the body rail.

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19. 20. 21. 22. 23.

Install the front suspension support assembly. Refer to Front Suspension Crossmember Replacement in Front Suspension. Connect the ball joints to the steering knuckles. Lower Control Arm Ball Joint Replacement in Front Suspension. Route and clip the wheel speed sensor wiring into the proper position on both sides. Install the steering gear to the front suspension crossmember. Install the steering gear bolts to the front suspension crossmember. Tighten Tighten the bolts to 110 Nm (81 lb ft).

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24.

Install the transmission brace bolts. Tighten Tighten the bolts to 72 Nm (53 lb ft).

25. 26. 27.

Install the left front fender liner. Refer to Front Fender Liner Replacement in Body Front End. Install the front wheel and tire assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Lower the vehicle.

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28.

Install the upper transmission to engine bolts and stud. Tighten Tighten all of the bolts to 90 Nm (66 lb ft).

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2002 Chevrolet Cavalier - Transmissions > Automatic Tr...


29.

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Install the engine wiring harness grounds to the transaxle to engine mount stud and nut. Tighten Tighten the nut to 8 Nm (71 lb in).

30.

Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 2.2L or Engine Support Fixture in Engine Mechanical - 2.4L or Engine Support Fixture in Engine Mechanical 2.2L (L61).

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31.

Install the shift linkage to the transmission.

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32. 33. 34. 35.

Connect the electrical connectors to the PNP switch and transaxle. Connect the air duct hose to the intake plenum. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical. Inspect the transmission fluid level. Refer to Transmission Fluid Check .

NOTE
Important: 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. 36. Reset the TAP values. Refer to Adapt Function .

REFER TO LIST: List 1 Engine / Engine Electrical / Repair Instructions / Starter Replacement (2.2L (L61)) Engine / Engine Electrical / Repair Instructions / Starter Replacement (2.4L) Engine / Engine Electrical / Repair Instructions / Starter Replacement (2.2L) List 2

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2002 Chevrolet Cavalier - Transmissions > Automatic Tr...

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Transmission/Transaxle / Automatic Transaxle - 4T40-E/4T45-E / Diagnostic Information And Procedures / Transmission Fluid Cooler Flushing And Flow Test (J 45096) Transmission/Transaxle / Automatic Transaxle - 4T40-E/4T45-E / Diagnostic Information And Procedures / Transmission Fluid Cooler Flushing And Flow Test (J 35944-A) List 3 Preface / Cautions And Notices / Introduction / Fastener Notice Unsorted / Fastener Notice

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