| Subject: | 2004 Model Year Changes for 4T40E and 4T45E Transmissions |
| Models: | 2004 Chevrolet Cavalier, Classic, Malibu |
| 2004 Pontiac Grand Am, Sunfire |
The purpose of this bulletin is to introduce new changes for the 2004 model
year 4T40E and 4T45E transmissions.
Electronic Range Selector Mode Models (Malibu)
The electronic range selector mode has the following new DTCs:
| • | P0815 - Upshift Switch Circuit |
| • | P0816 - Downshift Switch Circuit |
| • | P0826 - Up and Down Shift Switch Circuit |
| • | P0876 - Up and Down Shift Switch Performance - Range Switch
Not in D3 |
| • | P1877 - Up and Down Shift Switch Performance - Range Switch
in D3 |
New Spacer Plate for Electronic Range Selector Mode Models (Malibu)
The new spacer plate has one (1) notch for TAP models and two (2) notches for
all other models.
New Hydrophobic Filter/Vent and Filler Cap with Case Baffle
A new hydrophobic filter/vent and filler cap (ILL #52) with case baffle (3)
has been added to prevent transaxle splash oil from leaking through the vent. The
cap will be two different colors: red and black. The red cap is only used for the
Malibu models and the black cap is for all other applications, forward
and back. Referring to the graphic above, the top cap (1) is for 2003 and prior and
the bottom cap (2) is for 2004.
Valve Body Assembly, TCC Control Valve
The valve body assembly, TCC control valve (ILL #334) is larger in diameter
and the material changed from anodized aluminum to steel. It will not service past
models.
Decontented Transmission Fluid Pressure (TFP)
Three switches have been eliminated. The three switches that remain are: release,
drive and reverse. The color of the plastic has changed from black to gray.
Two DTCs were also removed -- P1815 Transmission Fluid Pressure (TFP) Valve
Position Switch-Start in Wrong Range and P1817 Transmission Fluid Pressure (TFP)
Valve Position Switch-Reverse with Drive Ratio. In the graphic above, the switch
(1) on the left is the 2003 and prior switch with the black color base. The switch
on the right (2) is the 2004 switch with a gray color base.
New NSBU Switch
A new NSBU switch with one large connector replaces the switch with two connectors.
In the graphic, the two connectors (1) are for 2003 and prior while the one large
connector (2) is for 2004.
