GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - 4T40-E/4T45-E 🢒 Transmission Replacement

Removal Procedure
  1. Remove the air intake duct from the throttle body and air cleaner assembly.
  2. Remove the battery cover and disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

    3. Object Number: 1233683 Size: SH
  3. Disconnect the transaxle wiring harness from the transaxle and the park/neutral position (PNP) switch.

    4. Object Number: 1239109 Size: SH
  4. Remove the shift cable bracket and shift cable from the lever.
  5. Remove the transmission wiring harness from the retainer on the transmission.

    6. Object Number: 104580 Size: SH
  6. Remove the upper transmission to engine bolts and stud.
  7. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical.
  8. Support the radiator and condenser from above using the condenser tabs on each side.
  9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  10. Remove the front wheel and tire assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  11. Remove the steering gear intermediate shaft .
  12. Separate the control arm from the frame and the outer tie rod ends from the steering knuckles. Support the lower control arm with mechanics wire or a similar method.
  13. Remove the frame. Refer to Frame Replacement in Frame and Underbody.

    14. Object Number: 510437 Size: SH
  14. Remove the 3 bolts from the transmission brace near the right axle shaft.
  15. Remove the oil pan to bell housing bracket (3 bolts).

    16. Object Number: 510441 Size: SH
  16. Remove the flywheel inspection cover.
  17. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.
  18. Mark the relationship of the flywheel to the torque converter for reassembly.
  19. Remove the torque converter to flywheel bolts.
  20. Remove the transmission cooler lines by removing the nut holding the bracket to the transaxle case.

    21. Object Number: 414901 Size: SH
  21. Disconnect the vehicle speed sensor (VSS) wiring harness from the sensor.
  22. Disconnect the rear 02 sensor harness from the bracket on the steering gear.
  23. Disconnect the wheel drive shafts from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts
  24. Remove the front transmission mount bracket from the transmission.
  25. Use a transmission jack to support the transmission.
  26. Remove the remaining bell housing bolts and studs and separate the transmission from the engine.
  27. Lower the transmission with the transmission jack far enough to remove the transmission.
  28. If the transmission is being replaced or installed in a holding fixture, remove the rear transmission mount bracket from transmission.
  29. Remove the PNP switch from the transmission.

Installation Procedure
  1. Install the PNP switch.
  2. Install the torque converter clutch (TCC) lock up clutch O-ring.
  3. Install the torque converter.
  4. Transfer the transaxle from the bench fixture to transmission jack.
  5. Install the side cover transmission mount bracket to the transmission.
  6. Install the rear transmission mount bracket to the transmission.
  7. Position the transaxle in the vehicle.

    8. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 104580 Size: SH
  8. Install the lower transmission to engine bolts and nuts.

    9. Tighten
    Tighten the bolts and nuts to 90 N·m (66 lb ft).

  9. Install the front transmission mount bracket to the transmission.
  10. Connect the wheel drive shafts to the transmission. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.

    11. Object Number: 414901 Size: SH
  11. Connect the VSS wiring harness to the VSS.

    12. Object Number: 475919 Size: SH
  12. Install the torque converter to flywheel bolts.

    13. Tighten
    Tighten the torque converter bolts to 62 N·m (46 lb ft).


    Object Number: 510441 Size: SH
  13. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
  14. Install the flywheel inspection cover bolts.

    15. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  15. Connect the transaxle cooler pipes to the transaxle.

    16. Tighten
    Tighten the cooler pipes to 8 N·m (71 lb in).

  16. Install the oil pan to bell housing bracket (3 bolts).

    17. Tighten
    Tighten to 72 N·m (53 lb ft).

  17. Install the 3 bolts to the transmission brace at final area and tighten.
  18. Remove the transmission jack.
  19. Install the frame. Refer to Frame Replacement Frame and Underbody.
  20. Install the engine splash shields.
  21. Install the front wheel and tire assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  22. Lower the vehicle.
  23. Remove the radiator and condenser support, and the engine support fixture
  24. Install the upper transmission to engine bolts and stud.

    25. Tighten
    Tighten the bolts to 90 N·m (66 lb ft).


    Object Number: 1239109 Size: SH
  25. Install the shift cable bracket and shift cable to the lever.
  26. Install the exhaust pipe upper bolts and heat shield.

    27. Object Number: 1233683 Size: SH
  27. Connect the electrical connectors to the PNP switch and transaxle.
  28. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  29. Install the battery cover.
  30. Install the air intake duct to the throttle body and air cleaner assembly.
  31. Add automatic transmission fluid (ATF) and verify the proper fluid level of transaxle.
  32. Road test the vehicle.