2002 Cavalier transmission drop

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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

Disconnect the negative battery cable. Refer to Battery Negative

Cable Disconnection and Connection in Engine Electrical.

1.

Disconnect the air duct hose from the intake plenum.2.

Install the engine support fixture. Refer to Engine Support Fixture in

Engine Mechanical - 2.2L orEngine Support Fixture in Engine

Mechanical - 2.4L orEngine Support Fixture in Engine Mechanical -

2.2L (L61).

Click to Enlarge

3.

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

4.

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Click to Enlarge

Remove the upper transmission to engine bolts and stud.5.

Raise and support the vehicle. Refer to Lifting and Jacking the

Vehicle in General Information.

6.

Remove the front wheel and tire assemblies. Refer to Tire and WheelRemoval and Installation in Tires and Wheels.7.

Remove the left front fender liner. Refer to Front Fender Liner

Replacement in Body Front End.

8.

Disconnect the engine strut from the lower engine mount strut bracket.9.

Remove the wiring harness from the retaining clips.10.

Remove the steering gear mounting bolts and secure the steering

gear with mechanics wire.

11.

Disconnect the wheel speed sensor wires from the both front wheels

and unclip from the frame.

12.

Separate the ball joints from the steering knuckles. Lower ControlArm Ball Joint Replacement in Front Suspension.

13.

Remove the lower suspension support. Refer to Front Suspension

Crossmember Replacement in Front Suspension.

14.


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Click to Enlarge

Remove the 2 bolts from the transmission brace.

Click to Enlarge

15.

Disconnect the shift cable from the shift linkage.16.

Disconnect the cable from the bracket.17.


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Click to Enlarge

Remove the flywheel inspection cover.18.

Remove the starter. Refer to Starter Motor Replacement (Refer To

List 1) in Engine Electrical.

19.

Mark the relationship of the flywheel to the torque converter for

reassembly.

20.


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Remove the torque converter to flywheel bolts.21.

Remove the transmission cooler lines by removing the nut holding the

bracket to the transaxle case.

Click to Enlarge

22.

Disconnect the VSS wiring harness from the sensor.23.

Disconnect the wheel drive shafts from the transaxle. Refer to Wheel

Drive Shaft Replacement in Wheel Drive Shafts

24.


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Lower the vehicle.25.

Remove the body to transmission mount bolts.26.

Lower the transmission and engine with the engine support fixture

enough to remove the transmission.

27.

Raise the vehicle.28.

Remove the oil pan to drain the transmission. Refer to Oil Pan

Replacement .

29.

Install the oil pan. Refer to Oil Pan Replacement .30.

Support the transmission with a suitable jack.

Click to Enlarge

31.

Remove the transaxle to engine nut.32.

Separate the engine and the transaxle.33.

Remove the transaxle from the vehicle.34.

Remove the PNP switch.35.

Remove the shifter cable bracket.36.

Remove the lower transmission to engine stud.37.

Remove the transmission mount.38.

Flush the transmission cooler and the lines. Refer to Transmission

Fluid Cooler Flushing and Flow Test (Refer To List 2) .

39.

Installation Procedure

Install the PNP switch.1.

Install the shifter cable bracket.2.

Install the lower transmission to engine stud.3.

Install the transmission mount.4.


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Click to Enlarge

Position the transaxle in the vehicle.

NOTENotice: Refer to Fastener Notice (Refer To List 3) in thePreface section.

Click to Enlarge

5.

Install the lower transmission to engine bolts and nuts.

Tighten

Tighten the bolts and nuts to 90 Nm (66 lb ft).

6.

Lubricate the transaxle cooler pipes before inserting into seals.7.

Connect the transaxle cooler pipes to the transaxle.

Tighten

Tighten the cooler pipes to 8 Nm (71 lb in).

8.


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Install the torque converter to flywheel bolts.

Tighten

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

9.

Install the wheel drive shafts to the transaxle. Refer to Wheel Drive

Shaft Replacement in Wheel Drive Shafts.

Click to Enlarge

10.

Connect the wiring harness to the VSS.11.


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Click to Enlarge

Install the starter. Refer to Starter Motor Replacement (Refer To List

1) in Engine Electrical.

12.

Install the flywheel inspection cover bolts.

Tighten

Tighten the bolts to 10 Nm (89 lb in).

13.

Lower the vehicle.14.

Use the engine support fixture to raise the engine and transmission

assembly.

15.

Install the transaxle mount to body bolts.

Tighten

Tighten the bolts to 90 Nm (66 lb ft).

16.

Raise the vehicle.17.

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


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Click to Enlarge

Install the front suspension support assembly. Refer to Front

Suspension Crossmember Replacement in Front Suspension.

19.

Connect the ball joints to the steering knuckles. Lower Control Arm

Ball Joint Replacement in Front Suspension.

20.

Route and clip the wheel speed sensor wiring into the proper position

on both sides.

21.

Install the steering gear to the front suspension crossmember.22.

Install the steering gear bolts to the front suspension crossmember.

Tighten


23.


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Install the transmission brace bolts.

Tighten


24.

Install the left front fender liner. Refer to Front Fender Liner

Replacement in Body Front End.

25.

Install the front wheel and tire assemblies. Refer to Tire and Wheel

Removal and Installation in Tires and Wheels.

26.

Lower the vehicle.

Click to Enlarge

27.

Install the upper transmission to engine bolts and stud.

Tighten

Tighten all of the bolts to 90 Nm (66 lb ft).

28.


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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).

29.

Remove the engine support fixture. Refer to Engine Support Fixture

in Engine Mechanical - 2.2L orEngine Support Fixture in Engine

Mechanical - 2.4L orEngine Support Fixture in Engine Mechanical -

2.2L (L61).

Click to Enlarge

30.

Install the shift linkage to the transmission.31.


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Click to Enlarge

Connect the electrical connectors to the PNP switch and transaxle.32.

Connect the air duct hose to the intake plenum.33.

Connect the negative battery cable. Refer to Battery Negative Cable

Disconnection and Connection in Engine Electrical.

34.

Inspect the transmission fluid level. Refer to Transmission Fluid

Check .

NOTEImportant: It is recommended that transmission adaptivepressure (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.

35.

Reset the TAP values. Refer to Adapt Function .36.

REFER TO LIST:

List 1

Engine / Engine Electrical / Repair Instructions / Starter

Replacement (2.2L (L61))


Replacement (2.4L)


Replacement (2.2L)

List 2


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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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2002 Cavalier transmission drop