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Home >> Chevrolet >> 2005 >> Malibu LS >> Repair and Diagnosis >> External Pages >> Different car >> Section 707 (Automatic Transaxle - 4T80-E - Removal & Installation, Service, Overhaul, Troubleshooting & Diagnosis) >> Repair Instructions - On Vehicle >> Case Extension Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2008 Buick Lucerne. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Scavenge Tube
    GM15512Courtesy of GENERAL MOTORS CORP.
  1. Inspect the scavenge tube (54) for damage and clogging.
    2. Fig 2: Identifying Scavenge Tube
    GM97498Courtesy of GENERAL MOTORS CORP.
  2. Install the scavenge tube seal into the case.
  3. Install the scavenge tube into the scavenge tube seals located in the case and in the driven sprocket support. Tap the scavenge tube lightly with a plastic hammer to ensure a tight fit in both seals.
    4. NOTE: Refer to Fastener Notice .
  4. Install the scavenge tube bolt.

    Tighten:  Tighten the bolt to 8-14 N.m (6-10 lb ft).

    5. Fig 3: View Of Case Extension Seal
    GM15514Courtesy of GENERAL MOTORS CORP.
  5. Inspect the case to case extension seal (126).
  6. Inspect the case extension mating surface for damage.
    7. Fig 4: View Of Case Extension Components
    GM687612Courtesy of GENERAL MOTORS CORP.
  7. Install the following parts:
    • The selective washer (133)
    • The thrust washer (132)
    • The case extension seal (126)
    • The case extension (134)
    8. Fig 5: Identifying Case Extension Bolts
    GM15520Courtesy of GENERAL MOTORS CORP.
  8. Apply pipe thread sealant GM P/N 12346004 to bolt threads before installation. Install the case extension bolts (128, 129).
  9. Hand tighten the bolts (128, 129) until the case extension is seated onto the case.
    10. Fig 6: Measuring End Play Clearance Using J 25025-7A, J 8001, & J 28585
    GM15522Courtesy of GENERAL MOTORS CORP.
  10. Install the long J 25025-7A  and the J 8001  . See Special Tools .
  11. Position the dial indicator with the stem contacting the output shaft (112). Set the dial indicator to zero.
  12. Insert the J 28585  through the vehicle speed sensor bore and lift the speed sensor rotor for measurement. Protect the bore with a piece of wood or a suitable piece of plastic.
  13. Proper end play clearance is 0.15-0.65 mm (0.006-0.026 in).
  14. Record the measured specification and, if necessary, adjust the clearance with the proper thickness selective thrust washer and reassemble. Refer to step  3.
  15. Remove the dial indicator set and the post.
    16. Fig 7: Identifying Case Extension Bolts & Studs
    GM15516Courtesy of GENERAL MOTORS CORP.
  16. Install the stud (127).

    Tighten: 

    • Tighten the bolt (128) and the stud (127) to 50-55 N.m (37-40 lb ft).
    • Tighten the bolt (129) to 20-27 N.m (15-20 lb ft).

  17. Install the transmission brace. Refer to Transmission Brace Replacement (Transmission Converter Housing to Eng)  or Transmission Brace Replacement (Transmission to Engine Oil Pan)  or Transmission Brace Replacement (Trans Extension Housing to Engine)  or Transmission Brace Replacement (Transmission to Engine Head) .
  18. Install the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement .
  19. Install the ground wire to case.
  20. Install the wiring harness.
  21. Install the right drive axle. Refer to Wheel Drive Shaft Replacement .
  22. Remove the safety stands.
  23. Lower the vehicle.
  24. Fill the transmission with fluid.
  25. Check the fluid level.
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