Transaxle (4T80-E): Removal

Tools needed:

• (J 41623-B) Cooler Quick Connect Tool
• (J 41160) Transaxle Jack Adapter

1. Remove the upper and lower air cleaner assemblies.
2. Disconnect the range selector cable terminal from the transaxle range selector lever. See Fig 1.
3. Remove the nuts securing both the range selector cable bracket and heater pipe to the transaxle. Position the range selector cable bracket and heater pipe aside.
4. Remove the Magnasteer wire from the retaining clip.
5. Disconnect the master cylinder brake pipe retainers from the side rail.
6. Remove the brake pipe retainers from the side rail, and using mechanics wire, support the brake pipes above the side rail.
   CAUTION: Supporting the brake pipes above the body side rail is necessary while removing the transaxle in order to prevent pinching of the brake pipes.
7. Reposition the main wiring harness to gain access to the upper transaxle-to-engine bolts (1).
8. Remove the transaxle-to-engine bolts (1). The remaining bolt (2) will temporally retain the transaxle and will be removed from the underside of the vehicle. See Fig 2.
9. Place a drain pan under the vehicle.
10. Remove the upper transaxle oil cooler pipe retaining bolt from the radiator fan shroud. See Fig 3.
11. Disconnect the upper transaxle oil cooler pipe from the radiator using Cooler Quick Connect Tool (J 41623-B). Install plugs in the oil cooler pipe and the radiator to prevent fluid loss and contamination.
    Fig 1: Identifying Range Selector Cable

    Courtesy of GENERAL MOTORS CORP.
    Fig 2: Identifying Transaxle-To-Engine Bolts

    Courtesy of GENERAL MOTORS CORP.
    Fig 3: Disconnecting/Connecting Upper Transaxle Oil Cooler Pipe

    Courtesy of GENERAL MOTORS CORP.
12. Disconnect the lower transaxle oil cooler pipe from the transaxle and install plugs in the oil cooler pipe and the transaxle to prevent fluid loss and contamination. See Fig 4.
13. Disconnect the transaxle vent tube from the accelerator bracket.
14. Install appropriate engine support fixture.
15. Raise and support the vehicle.
    CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.
16. Secure the vehicle to the front hoist pads.
17. Remove the stabilizer shaft links. See appropriate FRONT article in SUSPENSION.
18. Swing the stabilizer shaft downward in order to gain access to the power steering gear retaining bolts.
19. Remove the left front fascia extension.
    WARNING: The following are exceptions while following the frame removal procedure:

    • Do not remove the front stabilizer shaft from the frame.
    • Do not remove the AIR pump assembly from the vehicle. Retain the pump to the body using mechanics wire.
    • Do not remove the insulators from the frame.
    • Do not remove the control arms from the frame.
20. Remove the front frame. See FRAME REPLACEMENT .
    Fig 4: Disconnecting/Connecting Lower Transaxle Oil Cooler Pipe

    Courtesy of GENERAL MOTORS CORP.
21. Remove the bolt securing the left transaxle brace to the transaxle. See Fig 5.
22. Loosen the nut securing the left transaxle brace to the engine.
23. Remove the left transaxle brace from the powertrain assembly.
24. Remove the 3 ground connections from the side of the transaxle. See Fig 6.
25. Disconnect the transaxle main electrical harness connector.
    Fig 5: Removing/Installing Left Transaxle Brace

    Courtesy of GENERAL MOTORS CORP.
    Fig 6: Identifying Harness Ground Connections At Transaxle

    Courtesy of GENERAL MOTORS CORP.
26. Remove the bolt (2) securing the front transaxle brace (1) to the transaxle. See Fig 7.
27. Remove the nut securing the secondary AIR pipe to the transaxle.
28. Remove the nuts (2, 3) securing the vehicle speed sensor heat shield (1) to the transaxle. See Fig 8.
29. Remove the vehicle speed sensor heat shield (1) from the vehicle.
30. Disconnect the vehicle speed sensor electrical connector.
    Fig 7: Removing/Installing Front Transaxle Brace

    Courtesy of GENERAL MOTORS CORP.
    Fig 8: Removing/Installing VSS Heat Shield

    Courtesy of GENERAL MOTORS CORP.
31. Remove only the bolts securing the front transaxle brace to the transaxle. See Fig 9.
32. Remove only the bolts securing the center transaxle brace to the transaxle. See Fig 10.
    Fig 9: Locating Front Transaxle Brace

    Courtesy of GENERAL MOTORS CORP.
    Fig 10: Locating Center Transaxle Brace

    Courtesy of GENERAL MOTORS CORP.
33. Disengage the right and left drive shafts (2) from the transaxle (1). The drive shafts do not have to be removed from the wheels. See Fig 11.
34. Using mechanics wire, support the wheel drive shafts out of the way by tying them up to the strut spring.
35. Remove the torque converter cover.
    WARNING: Mark the flywheel to torque converter position so that they can be assembled in the same position.
36. Remove the flywheel to torque converter bolts. See Figure.
37. Position the power steering gear pressure hose to the right side of the vehicle in order to clear the transaxle during removal.
38. Support the transaxle using Transaxle Jack Adapter (J 41160) and a suitable transaxle jack.
39. Secure the transaxle jack adapter to the transaxle.
40. Remove the nut (1) securing the left transaxle mount to the left transaxle mount bracket. See Fig 12.
    Fig 11: Disengaging Drive Shafts From Transaxle

    Courtesy of GENERAL MOTORS CORP.
    Fig 12: Locating Left Transaxle Mount Bracket

    Courtesy of GENERAL MOTORS CORP.
41. Remove the remaining transaxle-to-engine bolt (2). See Fig 2.
42. Separate the transaxle from the engine.
43. Tilt the transaxle using the support jack enough to allow clearance for the starter nose cone.
    WARNING: Ensure clearance is maintained between the transaxle and the following:

    • The brake pipes.
    • The secondary AIR pipe.
    • The power steering pressure hose.
    • The wiring harnesses.
44. Carefully lower the transaxle from the vehicle.
45. Complete the following if transaxle replacement is necessary:
    • Remove the transaxle cooler pipe.
    • Remove the left transaxle bracket.
    • Remove the rear transaxle bracket.