GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Sunfire 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - 4T40-E/4T45-E 🢒 Transmission Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Disconnect the air duct hose from the intake plenum.
  3. 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).

    4. Object Number: 414408 Size: SH
  4. Disconnect the transaxle wiring harness from the transaxle and the PNP switch.

    5. Object Number: 104580 Size: SH
  5. Remove the upper transmission to engine bolts and stud.
  6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  7. Remove the front wheel and tire assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  8. Remove the left front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
  9. Disconnect the engine strut from the lower engine mount strut bracket.
  10. Remove the wiring harness from the retaining clips.
  11. Remove the steering gear mounting bolts and secure the steering gear with mechanics wire.
  12. Disconnect the wheel speed sensor wires from the both front wheels and unclip from the frame.
  13. Separate the ball joints from the steering knuckles. Lower Control Arm Ball Joint Replacement in Front Suspension.
  14. Remove the lower suspension support. Refer to Front Suspension Crossmember Replacement in Front Suspension.

    15. Object Number: 510437 Size: SH
  15. Remove the 2 bolts from the transmission brace.

    16. Object Number: 494775 Size: SH
  16. Disconnect the shift cable from the shift linkage.
  17. Disconnect the cable from the bracket.

    18. Object Number: 510441 Size: SH
  18. Remove the flywheel inspection cover.
  19. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.
  20. Mark the relationship of the flywheel to the torque converter for reassembly.

    21. Object Number: 475919 Size: SH
  21. Remove the torque converter to flywheel bolts.
  22. Remove the transmission cooler lines by removing the nut holding the bracket to the transaxle case.

    23. Object Number: 414901 Size: SH
  23. Disconnect the VSS wiring harness from the sensor.
  24. Disconnect the wheel drive shafts from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts
  25. Lower the vehicle.
  26. Remove the body to transmission mount bolts.
  27. Lower the transmission and engine with the engine support fixture enough to remove the transmission.
  28. Raise the vehicle.
  29. Remove the oil pan to drain the transmission. Refer to Oil Pan Replacement .
  30. Install the oil pan. Refer to Oil Pan Replacement .
  31. Support the transmission with a suitable jack.

    32. Object Number: 104581 Size: SH
  32. Remove the transaxle to engine nut.
  33. Separate the engine and the transaxle.
  34. Remove the transaxle from the vehicle.
  35. Remove the PNP switch.
  36. Remove the shifter cable bracket.
  37. Remove the lower transmission to engine stud.
  38. Remove the transmission mount.
  39. Flush the transmission cooler and the lines. Refer to Transmission Fluid Cooler Flushing and Flow Test .

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

    5. Object Number: 104581 Size: SH
  5. Position the transaxle in the vehicle.

    6. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 104580 Size: SH
  6. Install the lower transmission to engine bolts and nuts.

    7. Tighten
    Tighten the bolts and nuts to 90 N·m (66 lb ft).

  7. Lubricate the transaxle cooler pipes before inserting into seals.
  8. Connect the transaxle cooler pipes to the transaxle.

    9. Tighten
    Tighten the cooler pipes to 8 N·m (71 lb in).


    Object Number: 475919 Size: SH
  9. Install the torque converter to flywheel bolts.

    10. Tighten
    Tighten the torque converter bolts to 62 N·m (46 lb ft).

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

    11. Object Number: 414901 Size: SH
  11. Connect the wiring harness to the VSS.

    12. Object Number: 510441 Size: SH
  12. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
  13. Install the flywheel inspection cover bolts.

    14. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  14. Lower the vehicle.
  15. Use the engine support fixture to raise the engine and transmission assembly.
  16. Install the transaxle mount to body bolts.

    17. Tighten
    Tighten the bolts to 90 N·m (66 lb ft).

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

    19. Object Number: 104578 Size: SH
  19. Install the front suspension support assembly. Refer to Front Suspension Crossmember Replacement in Front Suspension.
  20. Connect the ball joints to the steering knuckles. Lower Control Arm Ball Joint Replacement in Front Suspension.
  21. Route and clip the wheel speed sensor wiring into the proper position on both sides.
  22. Install the steering gear to the front suspension crossmember.
  23. Install the steering gear bolts to the front suspension crossmember.

    24. Tighten
    Tighten the bolts to 110 N·m (81 lb ft).


    Object Number: 510437 Size: SH
  24. Install the transmission brace bolts.

    25. Tighten
    Tighten the bolts to 72 N·m (53 lb ft).

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

    28. Object Number: 104580 Size: SH
  28. Install the upper transmission to engine bolts and stud.

    29. Tighten
    Tighten all of the bolts to 90 N·m (66 lb ft).

  29. Install the engine wiring harness grounds to the transaxle to engine mount stud and nut.

    30. Tighten
    Tighten the nut to 8 N·m (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).

    31. Object Number: 494775 Size: SH
  31. Install the shift linkage to the transmission.

    32. Object Number: 414408 Size: SH
  32. Connect the electrical connectors to the PNP switch and transaxle.
  33. Connect the air duct hose to the intake plenum.
  34. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  35. Inspect the transmission fluid level. Refer to Transmission Fluid Check .

    36. 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 .