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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 >> Removal Procedure

Removal 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: Identifying J 42640
    GM333146Courtesy of GENERAL MOTORS CORP.
    NOTE: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.
  1. Lock the steering column by installing J 42640  into the underside of the steering column.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Replacement .
  3. Remove the front compartment sight shield. Refer to Front Compartment Sight Shields Replacement .
  4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
    5. Fig 2: View Of Range Selector Cable Terminal
    GM820397Courtesy of GENERAL MOTORS CORP.
  5. Remove the range select cable terminal from the transaxle range select lever.
  6. Remove the nuts securing both the range selector cable bracket and heater pipe to the transaxle.
  7. Remove the range selector cable with bracket and heater pipe from the transmission case and position aside.
  8. Remove the Magnasteer wire from the retaining clip.
  9. Disconnect the master cylinder brake pipe retainers from the side rail.
    10. IMPORTANT: Supporting the brake pipes above the body side rail is necessary while removing the transaxle in order to prevent pinching of the brake pipes.
  10. Remove the brake pipe retainers from the side rail and using mechanics wire, support the brake pipes above the side rail.
    11. Fig 3: Identifying Upper Transaxle Bolts
    GM1688267Courtesy of GENERAL MOTORS CORP.
  11. Reposition the main wiring harness to gain access to the upper transaxle to engine bolts.
  12. Remove the transaxle to engine upper bolts. The lower bolt will temporally retain the transaxle and will be removed from the underside of the vehicle.
  13. Place a drain pan under the vehicle.
    14. Fig 4: Identifying Transaxle Oil Cooler Pipe & Retaining Bolt
    GM1687897Courtesy of GENERAL MOTORS CORP.
  14. Remove the upper transaxle oil cooler pipe retaining bolt from the radiator fan shroud.
  15. Disconnect the upper transaxle oil cooler pipe from the radiator using the J 41623-B  . Install plugs in the oil cooler pipe and the radiator to prevent fluid loss and contamination.
    16. Fig 5: View Of Lower Transaxle Oil Cooler Pipe
    GM627386Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the lower transaxle oil cooler pipe from the transaxle using the J 41623-B  . Install plugs in the oil cooler pipe and the transaxle to prevent fluid loss and contamination.
  17. Disconnect the transaxle vent tube from the transaxle.
  18. Install the engine support fixture. Refer to Engine Support Fixture .
  19. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  20. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
    21. Fig 6: Identifying Secondary Air Injection (AIR) Reaction Intake Pipe Retainer
    GM1687898Courtesy of GENERAL MOTORS CORP.
  21. Remove the secondary air injection (AIR) reaction intake pipe retainer (1) from the transaxle.
  22. Disconnect the AIR pump electrical connector.
    23. Fig 7: Identifying AIR Pipe & Hose
    GM1687904Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the AIR hose (2) from the AIR pipe (1).
    24. 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 and strap the vehicle to the hoist.
  24. Secure the vehicle to the front hoist pads.
    25. Fig 8: View Of Front Wheelhouse Liner & Fasteners
    GM1679758Courtesy of GENERAL MOTORS CORP.
  25. Remove the left front wheelhouse liner (1). Refer to Front Wheelhouse Liner Replacement .
    26. Fig 9: View Of Front Air Deflector & Fasteners
    GM1687905Courtesy of GENERAL MOTORS CORP.
  26. Remove the air deflector extension. Refer to Front Wheelhouse Liner Replacement .
  27. Remove the stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement .
  28. Swing the stabilizer shaft downward in order to gain access to the power steering gear retaining bolts.
    29. Fig 10: Locating Steering Rack-To-Intermediate Shaft Pinch Bolt
    GM105357Courtesy of GENERAL MOTORS CORP.
    CAUTION: Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear or to the intermediate shaft. This damage may cause loss of steering control, which could result in an accident and possible personal injury.
  29. Remove the intermediate shaft lower pinch bolt.
  30. Disconnect the intermediate shaft from the power steering gear.
  31. Remove the power steering gear heat shield. Refer to Steering Gear Heat Shield Replacement .
    32. Fig 11: View Of Steering Gear Mounting Bolts
    GM337379Courtesy of GENERAL MOTORS CORP.
  32. Remove the power steering gear mounting bolts.
  33. Remove the power steering line retainers from the frame.
  34. Secure the power steering gear to the exhaust manifold.
    35. Fig 12: Identifying Brake Line Retainers
    GM1679761Courtesy of GENERAL MOTORS CORP.
  35. Remove the mounting bolts (2) in order to allow removal of the brake pressure modulator valve from the bracket.
  36. Remove the brake line retainers (1) from the frame.
    37. IMPORTANT: The following are exceptions while following the frame removal procedure:
    • Do not remove the front stabilizer shaft from the frame.
    • Do not remove the insulators from the frame.
    • Do not remove the control arms from the frame.
  37. Remove the frame. Refer to Front Frame Replacement (3.8L) or Front Frame Replacement (4.6L) .
    38. Fig 13: View Of Wheel Drive Shaft & Transaxle
    GM189013Courtesy of GENERAL MOTORS CORP.
  38. Disengage the right and left drive shafts (2) from the transaxle (1). The drive shafts do not have to be removed from the wheels. Refer to Wheel Drive Shaft Replacement .
  39. Using mechanic's wire, support the wheel drive shafts out of the way by tying them up to the strut spring.
    40. Fig 14: View Of Left Transaxle Brace To Transaxle Bolt
    GM820394Courtesy of GENERAL MOTORS CORP.
  40. Remove the bolt securing the left transaxle brace to the transaxle.
  41. Loosen the nut securing the left transaxle brace to the engine.
  42. Remove the left transaxle brace from the powertrain assembly.
    43. Fig 15: View Of Transaxle Ground Connections
    GM627341Courtesy of GENERAL MOTORS CORP.
  43. Remove the 3 ground connections from the side of the transaxle.
  44. Disconnect the transaxle main electrical harness connector.
    45. Fig 16: View Of Front Transaxle Brace & Bolt
    GM588757Courtesy of GENERAL MOTORS CORP.
  45. Remove the bolt (2) securing the left transaxle brace (1) to the transaxle.
    46. Fig 17: View Of AIR Pipe Retaining Nut
    GM1687900Courtesy of GENERAL MOTORS CORP.
  46. Remove the nut (3) securing the AIR pipe to the transaxle.
    47. Fig 18: View Of Vehicle Speed Sensor Heat Shield & Nuts
    GM694213Courtesy of GENERAL MOTORS CORP.
  47. Remove the nuts (2, 3) securing the vehicle speed sensor heat shield (1) to the transaxle.
  48. Remove the vehicle speed sensor heat shield (1) from the vehicle.
  49. Disconnect the vehicle speed sensor electrical connector.
    50. Fig 19: View Of Rear Transaxle Mount Bracket Bolts
    GM1687896Courtesy of GENERAL MOTORS CORP.
  50. Remove the bolts (2) securing the rear transaxle mount bracket (3) to the transaxle.
    51. Fig 20: View Of Center Transaxle Brace To Transaxle Bolts
    GM820532Courtesy of GENERAL MOTORS CORP.
  51. Remove only the bolts securing the rear transaxle brace to the transaxle.
    52. Fig 21: View Of Torque Converter Cover
    GM627396Courtesy of GENERAL MOTORS CORP.
  52. Remove 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) .
  53. Remove the torque converter cover. Refer to Torque Converter Cover Replacement .
    54. Fig 22: View Of Flywheel-To-Torque Converter Bolts
    GM1688240Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Mark the flywheel to torque converter position so that they can be assembled in the same position.
  54. Remove the flywheel to torque converter bolts (1).
  55. Position the power steering gear pressure hose to the right side of the vehicle in order to clear the transaxle during removal.
  56. Support the transaxle using the J 41160  and a suitable transmission jack. See Special Tools .
  57. Secure the J 41160  to the transaxle. See Special Tools .
    58. Fig 23: Identifying Upper Transaxle Bolts
    GM1688267Courtesy of GENERAL MOTORS CORP.
  58. Remove the remaining transaxle to engine bolt.
  59. Separate the transaxle from the engine.
  60. Tilt the transaxle using the support jack enough to allow clearance for the starter nose cone.
    61. IMPORTANT: Ensure clearance is maintained between the transaxle and the following:
    • The brake pipes
    • The power steering pressure hose
    • The wiring harnesses
  61. Carefully lower the transaxle from the vehicle.
  62. Flush the transmission cooler and lines. Refer to Transmission Fluid Cooler Flushing and Flow Test (J 45096)  or Transmission Fluid Cooler Flushing and Flow Test (J 35944-A) .
  63. Complete the following if transaxle replacement is necessary:
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