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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 >> Transmission 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.
  1. Complete the following if previously removed from the transaxle:
    2. IMPORTANT: Ensure clearance is maintained between the transaxle and the following:
    • The brake pipes
    • The power steering pressure hose
    • The wiring harnesses
  2. Carefully raise the transaxle to the engine in a tilted position in order to clear the starter nose cone.
    3. Fig 1: Identifying Upper Transaxle Bolts
    GM1688267Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  3. Align the transaxle with the engine and position the transaxle onto the engine dowels.

    Install the engine to transaxle lower bolt.

    Tighten:  Tighten the bolt to 75 N.m (55 Ib ft).

    4. Fig 2: View Of Center Transaxle Brace to Transaxle Bolts
    GM820532Courtesy of GENERAL MOTORS CORP.
  4. Install the bolts securing the rear transaxle brace to the transaxle.

    Tighten:  Tighten the bolts to 50 N.m (37 Ib ft).

    5. Fig 3: View Of Vehicle Speed Sensor Heat Shield & Nuts
    GM627402Courtesy of GENERAL MOTORS CORP.
  5. Connect the vehicle speed sensor electrical connector.
  6. Install the vehicle speed sensor heat shield and nuts.

    Tighten:  Tighten the nuts to 50 N.m (37 Ib ft).

    7. Fig 4: View Of Rear Transaxle Mount Bracket Bolts
    GM1687896Courtesy of GENERAL MOTORS CORP.
  7. Install the bolts (2) securing the rear transaxle mount bracket (3) to the transaxle.

    Tighten:  Tighten the bolts to 73 N.m (54 Ib ft).

  8. Remove the transmission jack and the J 41160  . See Special Tools .
    9. Fig 5: View Of Flywheel-To-Torque Converter Bolts
    GM1688240Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Line up the flywheel and converter using the alignment marks made during disassembly.
  9. Install the flywheel to converter bolts (1).

    Tighten:  Tighten the bolts to 60 N.m (44 Ib ft).

    10. Fig 6: View Of Torque Converter Cover
    GM627396Courtesy of GENERAL MOTORS CORP.
  10. Install the torque converter cover. Refer to Torque Converter Cover Replacement .
  11. Install the transmission to engine oil pan 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) .
    12. Fig 7: View Of Wheel Drive Shaft & Transaxle
    GM189013Courtesy of GENERAL MOTORS CORP.
  12. Install the right and left drive shafts (2) to the transaxle (1). Refer to Wheel Drive Shaft Replacement .
    13. Fig 8: View Of AIR Pipe Retaining Nut
    GM1687900Courtesy of GENERAL MOTORS CORP.
  13. Install the nut (3) securing the AIR pipe to the transaxle.
    14. Fig 9: View Of Front Transaxle Brace & Bolt
    GM588757Courtesy of GENERAL MOTORS CORP.
  14. Install the bolt (2) securing the left transaxle brace (1) to the transaxle.

    Tighten:  Tighten the bolt to 120 N.m (89 Ib ft).

    15. Fig 10: View Of Transaxle Ground Connections
    GM627341Courtesy of GENERAL MOTORS CORP.
  15. Install the 3 ground connections to the side of the transaxle.

    Tighten:  Tighten the bolts to 50 N.m (37 Ib ft).

  16. Connect the transaxle main electrical harness connector.
    17. Fig 11: View Of Left Transaxle Brace to Transaxle Bolt
    GM820394Courtesy of GENERAL MOTORS CORP.
  17. Install the left transaxle brace to the powertrain assembly.
  18. Install the bolt securing the left transaxle brace to the transaxle.

    Tighten:  Tighten the bolt to 50 N.m (37 Ib ft).

    Tighten:  Tighten the nut to 50 N.m (37 Ib ft).

  19. Install the front frame assembly to the vehicle. Refer to Front Frame Replacement (3.8L) or Front Frame Replacement (4.6L) .
    20. Fig 12: Identifying Brake Line Retainers
    GM1679761Courtesy of GENERAL MOTORS CORP.
  20. Position the brake pressure modulator valve into the bracket.
  21. Install the mounting bolt (2).

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

  22. Install the brake line retainers (1) onto the frame.
    23. Fig 13: View Of Steering Gear Mounting Bolts
    GM337379Courtesy of GENERAL MOTORS CORP.
  23. Install the power steering gear mounting bolts.

    Tighten:  Tighten the bolts to 75 N.m (55 lb ft).

  24. Install the power steering line retainers onto the frame.
  25. Install the power steering gear heat shield. Refer to Steering Gear Heat Shield Replacement .
    26. Fig 14: Locating Steering Rack-To-Intermediate Shaft Pinch Bolt
    GM105357Courtesy of GENERAL MOTORS CORP.
    CAUTION: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.
  26. Connect the intermediate shaft to the power steering gear.
  27. Install the intermediate shaft lower pinch bolt.

    Tighten:  Tighten the bolt to 45 N.m (33 lb ft).

  28. Install the stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement .
    29. Fig 15: View Of Front Air Deflector & Fasteners
    GM1687905Courtesy of GENERAL MOTORS CORP.
  29. Install the air deflector extension. Refer to Front Air Deflector Replacement .
    30. Fig 16: View Of Front Wheelhouse Liner & Fasteners
    GM1679758Courtesy of GENERAL MOTORS CORP.
  30. Install the left front wheelhouse liner (1). Refer to Front Wheelhouse Liner Replacement .
    31. Fig 17: Identifying AIR Pipe & Hose
    GM1687904Courtesy of GENERAL MOTORS CORP.
  31. Connect the AIR hose (2) to the AIR pipe (1).
    32. Fig 18: Identifying Secondary Air Injection (AIR) Reaction Intake Pipe Retainer
    GM1687898Courtesy of GENERAL MOTORS CORP.
  32. Install the AIR intake pipe retainer (1) to the transaxle.
  33. Connect the AIR pump electrical connector.
  34. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  35. Lower the vehicle.
    36. Fig 19: View Of Lower Transaxle Oil Cooler Pipe
    GM627386Courtesy of GENERAL MOTORS CORP.
  36. Connect the lower transaxle oil cooler pipe to the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .
    37. Fig 20: Identifying Transaxle Oil Cooler Pipe & Retaining Bolt
    GM1687897Courtesy of GENERAL MOTORS CORP.
  37. Install the upper transaxle oil cooler pipe to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .
    38. Fig 21: Identifying Upper Transaxle Bolts
    GM1688267Courtesy of GENERAL MOTORS CORP.
  38. Install the remaining transaxle to engine bolts.

    Tighten:  Tighten the bolts to 75 N.m (55 Ib ft).

  39. Remove the engine support fixture. Refer to Engine Support Fixture .
    40. Fig 22: View Of Range Selector Cable Terminal, Range Selector Lever & Nuts
    GM820397Courtesy of GENERAL MOTORS CORP.
  40. Install the range selector cable bracket to the studs on the transaxle.
  41. Install the heater pipe to the stud on the transaxle.
  42. Install the nuts that retain the heater pipe and the range selector cable bracket to the transaxle.

    Tighten:  Tighten the nuts to 25 N.m (18 Ib ft).

  43. Connect the range selector cable terminal to the transaxle range selector lever.
  44. Install the Magnasteer wire to the retaining clip.
  45. Install the brake pipe retainers to the side rail.
  46. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  47. Install the front compartment sight shield. Refer to Front Compartment Sight Shields Replacement .
  48. Connect the negative battery cable. Refer to Battery Negative Cable Replacement .
    49. Fig 23: Identifying J 42640
    GM333146Courtesy of GENERAL MOTORS CORP.
  49. Remove the J 42640  from the steering column.
  50. Fill the transaxle to the proper level. Refer to Fluid Capacity Specifications .
  51. Add DEXRON® VI transmission fluid as required.
  52. Check the front suspension alignment, adjust the toe as necessary.
  53. Clear the transmission adaptive pressures (TAPS). Refer to Transmission Adaptive Functions .
  54. Check the front end alignment.
  55. Road test the vehicle and check for transaxle leaks.
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