GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Malibu 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - 4T40-E/4T45-E 🢒 Transmission Replacement

Removal Procedure
  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical-3.1 L.
  3. Remove the front transmission mount bolts. Refer to Transmission Front Mount Replacement .
  4. Remove the splash shield. Refer to Front Fender Liner Replacement in Body Front End.
  5. Remove the air cleaner and duct assembly from the throttle body. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.1 L.
  6. Remove the wire harness from the upper transaxle mount bracket.
  7. Remove the upper transaxle mount. Refer to Transmission Mount Replacement - Side .
  8. Remove the shifter cable. Refer to Transmission Control Replacement .

    9. Object Number: 439868 Size: SH
  9. Secure the vehicle radiator and condenser to the upper radiator support.

    10. Object Number: 471755 Size: SH
  10. Remove the ground cables from the engine block.

    11. Object Number: 414408 Size: SH
  11. Disconnect the PNP switch connector.
  12. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  13. Support the vehicle with a safety stand.
  14. Drain the transaxle. Refer to Automatic Transmission Fluid Filter and Seal Replacement .
  15. Remove the front suspension crossmember. Refer to Front Suspension Crossmember Replacement In front suspension.
  16. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  17. Remove the left and right front inner splash shield. Refer to Front Fender Liner Replacement in Body Front End.
  18. Remove the lower radiator and condenser support.
  19. Remove the front transmission mount bracket bolts and bracket. Refer to Transmission Front Mount Replacement .

    20. Object Number: 414402 Size: SH
  20. Remove the front Antilock Brake System (ABS) Wheel Speed Sensor (WSS) connectors.

    21. Object Number: 414399 Size: SH
  21. Unroute the ABS WSS harness.
  22. Remove the brake modulator assembly bolts and the brake modulator assembly. Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.

    23. Object Number: 414901 Size: SH
  23. Remove the vehicle speed sensor.
  24. Remove the torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement .
  25. Remove the left and right ball joint nuts.

    26. Object Number: 414906 Size: SH
  26. Separate the ball joint from the control arm. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
  27. Remove the drive axles. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  28. Remove the front transaxle mount. Refer to Transmission Front Mount Replacement .
  29. Remove the ABS module. Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.
  30. Separate the tie rod ends from the steering knuckles. Refer to Power Steering Pressure Pipe/Hose Replacement in Power Steering System.
  31. Disconnect the power steering pressure line from the rack and pinion. Refer to Tie Rod Replacement - Inner - On Vehicle in Power Steering System.
  32. Remove the brake lines from the retainer below the rack and pinion.
  33. Remove the steering column pinch bolt and position the intermediate shaft aside. Refer to Steering Gear Replacement in Power Steering System.

    34. Object Number: 414959 Size: SH
  34. Attach the transaxle case to the support stand.

    35. Object Number: 414961 Size: SH
  35. Remove the transaxle-to-engine mount bolts.
  36. Remove the transaxle:
    37. 36.1. Slide the transaxle away from the engine.
    36.2. Carefully lower the support stand.
  37. Flush the transmission cooler and lines. Refer to Transmission Fluid Cooler Flushing and Flow Test .

Installation Procedure
  1. Install the transaxle:
    2. 1.1. Carefully raise the support stand.
    1.2. Slide the transaxle towards the engine.

    Object Number: 414961 Size: SH
  2. Install the transaxle-to-engine mount bolts.

    3. Object Number: 414959 Size: SH
  3. Detach the transaxle case from the support stand.
  4. Install the steering column pinch bolt and position the intermediate shaft. Refer to Steering Gear Replacement in Power Steering System.
  5. Install the brake lines from the retainer below the rack and pinion.
  6. Connect the power steering pressure line to the rack and pinion. Refer to Tie Rod Replacement - Inner - On Vehicle in Power Steering System.
  7. Install the tie rod ends to the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement in front suspension.
  8. Install the ABS module. Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.
  9. Install the front transaxle mount. Refer to Transmission Front Mount Replacement .
  10. Install the drive axles. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.

    11. Object Number: 414906 Size: SH
  11. Install the ball joint to the control arm. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
  12. Install the left and right ball joint nuts.
  13. Install the torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement .

    14. Object Number: 414901 Size: SH
  14. Install the vehicle speed sensor.
  15. Install the brake modulator assembly bolts and the brake modulator assembly. Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.

    16. Object Number: 414402 Size: SH
  16. Install the front Antilock Brake System (ABS) Wheel Speed Sensor (WSS) connectors.
  17. Install the front transmission mount bracket bolts and bracket. Refer to Transmission Front Mount Replacement .
  18. Install the lower radiator and condenser support.
  19. Install the left and right front inner splash shield. Refer to Front Fender Liner Replacement in Body Front End.
  20. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  21. Remove the safety stand.
  22. Lower the vehicle.

    23. Object Number: 414408 Size: SH
  23. Connect the PNP switch connector.

    24. Object Number: 471755 Size: SH
  24. Install the ground cables from the engine block.

    25. Object Number: 439868 Size: SH
  25. Secure the vehicle radiator and condenser to the upper radiator support.
  26. Install the shifter cable. Refer to Transmission Control Replacement .
  27. Install the upper transaxle mount. Refer to Transmission Rear Mount Replacement .
  28. Install the wire harness from the upper transaxle mount bracket.
  29. Install the air cleaner and duct assembly to the throttle body. Refer to Air Cleaner Assembly Replacement in Engine Controls -3.1 L.
  30. Install the splash shield. Refer to Front Fender Liner Replacement in Body Front End.
  31. Install the front transmission mount bolts. Refer to Transmission Front Mount Replacement .
  32. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical-3.1 L.
  33. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  34. Refill the transmission to the proper level with DEXRON®-III using the following:
    35. •  Fluid Capacity Specifications .
    •  Transmission Fluid Check .