GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Cavalier 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - 3T40 🢒 Transmission Replacement

Removal Procedure
  1. Remove the battery. Refer to Battery Replacement in Engine Electrical.
  2. Disconnect the IAT sensor and loosen the air duct hose from the intake plenum.
  3. Remove the push pin from the relay center, lift the relay center.
  4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-2.2 L.
  5. Remove the upper radiator filler panel.

    6. Object Number: 104328 Size: SH
  6. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical-2.2 L.

    7. Object Number: 104580 Size: SH
  7. Disconnect the transaxle wiring harness from the transaxle and the PNP switch.
  8. Remove the screw from the front coolant pipe bracket to allow the freedom of movement.
  9. Remove the 3 upper transaxle to engine bolts and the 1 stud.
  10. Remove the 2 top bolts from the transaxle mount.
  11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  12. Remove the tire and the wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  13. Remove the front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
  14. Disconnect the engine strut from the lower engine mount. Refer to Engine Mount Strut Replacement in Engine Mechanical-2.2 L.
  15. Disconnect the front and rear oxygen senors and wiring harness from the shift cable bracket.
  16. Remove the wiring harness from the retaining clips.
  17. Remove the front exhaust pipe.
  18. Disconnect the wheel speed sensor wires from the both front wheels and unclip the clips from the frame.
  19. Remove the lower steering intermediate shaft pinch bolt.
  20. Remove the tie rod from the steering knuckle. Refer to Rack and Pinion Outer Tie Rod End Replacement in Front Suspension.
  21. Remove the ball joint from the steering knuckle. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
  22. Remove the drive axles from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  23. Unclip the brake line from the retainers on the suspension support frame clips.
  24. Place a suitable drain pan in position to catch the power steering fluid as you remove the power steering lines from the rack and pinion assembly.
  25. Remove the bolt which retains the power steering line to the right side of the suspension support brace.
  26. Remove the front suspension support brace bolts.
  27. Remove the support brace.
  28. With the aid of an assistant remove the lower suspension support.

    29. Object Number: 510437 Size: SH
  29. Remove the 2 bolts which hold the transaxle to engine support brace to the transmission at the right side of the transaxle output shaft.

    30. Object Number: 494775 Size: SH
  30. Disconnect the shift cable from the shift linkage.
  31. Disconnect the cable from the bracket.

    32. Object Number: 510441 Size: SH
  32. Remove the flywheel inspection cover.
  33. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.
  34. Mark the relationship of the flywheel to the torque converter for reassembly.

    35. Object Number: 475919 Size: SH
  35. Remove the torque converter to flywheel bolts.
  36. Remove the transaxle cooler lines by removing the nut holding the bracket to the transaxle case.
  37. Disconnect the VSS wiring harness from the sensor.
  38. Disconnect the transaxle output shafts from the transaxle and support in an out of the way position with mechanics wire.
  39. Remove the 2 bolts which retain the transaxle bracket to the body.
  40. Remove the 2 bolts retaining the bracket to the transaxle.
  41. Remove the wiring harness from the body.
  42. Lower the vehicle.
  43. Remove the 2 bolts from the transaxle to body bracket.
  44. Lower the transaxle with the engine support fixture enough to remove the transaxle.
  45. Raise the vehicle.
  46. Remove the two retaining bolts and the bracket.
  47. Remove the 2 transaxle to engine bolts.
  48. Support the transaxle with a suitable jack.

    49. Object Number: 104581 Size: SH
  49. Separate the engine and the transaxle.
  50. Remove the transaxle from the vehicle.
  51. Flush the transmission cooler and lines. Refer to Transmission Fluid Cooler Flushing and Flow Test .

Installation Procedure
  1. Place a thin film of chassis grease GM P/N 1051344, or the equivalent, on the torque converter pilot hub.
  2. Ensure that the torque converter is properly seated in the oil pump.

    3. Object Number: 104581 Size: SH
  3. Position the transaxle in the vehicle.

    4. Object Number: 104580 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the lower transaxle to engine bolts and 2 studs.

    5. Tighten
    Tighten the bolts and studs to 90 N·m (66 lb ft).

  5. Install the transaxle to body bracket bolts.

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

  6. Lower the vehicle.

    7. Object Number: 104328 Size: SH
  7. Use the engine support fixture to raise the transaxle.
  8. Install the 2 bolts through the unibody frame into the transaxle to engine mount bracket.
  9. Raise the vehicle.
  10. Reposition the wiring harness into its clips on the body rail.
  11. Install the drive axles to the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  12. Install the wiring harness to the VSS.
  13. Connect the transaxle cooler pipes to the transaxle.

    14. Tighten
    Tighten the cooler pipes to 8 N·m (71 lb ft).


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

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


    Object Number: 510441 Size: SH
  15. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.

    16. Tighten
    Tighten the starter bolts to 50 N·m (37 lb ft).

  16. Install the battery cable to the starter and the nut.

    17. Tighten
    Tighten the nut to 15 N·m (11 lb ft).

  17. Install the starter wire and the nut to the starter solenoid.

    18. Tighten
    Tighten the nut to 11 N·m (8 lb ft).

  18. Install the flywheel inspection cover.

    19. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  19. Connect the shift cable to the bracket and the lever.

    20. Object Number: 104578 Size: SH
  20. With the aid of an assistant install the front suspension support assembly, rack and pinion assembly into place with the 6 bolts.

    21. Tighten
    Tighten the 6 bolts to 110 N·m (71 lb ft).

  21. Install the left side suspension support brace and bolts.

    22. Tighten
    Tighten the brace bolts to 72 N·m (53 lb ft).

  22. Install and tighten the power steering lines to the rack and pinion steering gear.

    23. Tighten
    Tighten the power steering bolts to 27 N·m (20 lb ft).

  23. Install the bolt that secures the power steering lines to the front suspension support assembly.

    24. Tighten
    Tighten the bolt to 8 N·m (71 lb ft).

  24. Reconnect the ball joints to the steering knuckles and the nuts.

    25. Tighten
    Tighten the nuts to 60 N·m (50 lb ft) plus 180 degrees.

  25. Install the cotter pin in both the balls joints.
  26. Reconnect the tie rod ball stud and nut to the steering knuckle.

    27. Tighten
    Tighten the tie rod ball stud nut to 45 N·m (33 lb ft).

  27. Install the lower steering column pinch bolt.

    28. Tighten
    Tighten the pinch bolt to 40 N·m (30 lb ft).

  28. Reroute and clip the wheel speed sensor wiring into the proper position on both sides.
  29. Install the catalytic converter flange attaching bolts.

    30. Tighten
    Tighten the bolts to 30 N·m (22 lb ft).

  30. Install the front pipe to the manifold exhaust and the nuts.

    31. Tighten
    Tighten the nuts to 45 N·m (33 lb ft).

  31. Route and clip the rear oxygen senor and wires in there proper position.
  32. Lower the vehicle to loosen the J 28476-B and allow the engine to assume its proper position.
  33. Raise the vehicle.

    34. Object Number: 510437 Size: SH
  34. Install the right side suspension support bolts.

    35. Tighten
    Tighten the bolts to 72 N·m (53 lb ft).

  35. Install the front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
  36. Install the tire and the wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  37. Lower the vehicle.

    38. Object Number: 104580 Size: SH
  38. Install the upper transmission to engine bolts.

    39. Tighten
    Tighten all of the bolts to 90 N·m (66 lb ft).

  39. Install the upper transaxle to engine bolts and stud.

    40. Tighten
    Tighten the bolts and stud to 90 N·m (66 lb ft).

  40. Install the engine wiring harness grounds to the transaxle to engine mount stud and nut.

    41. Tighten
    Tighten the nut to 8 N·m (71 lb in).


    Object Number: 104328 Size: SH
  41. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical-2.2 L.
  42. Install the heater pipe screw.

    43. Object Number: 494775 Size: SH
  43. Connect the electrical connectors to the PNP switch.
  44. Install the shift linkage to the transaxle.
  45. Install the radiator filler panel to the vehicle.
  46. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-2.2 L.
  47. Connect the IAT sensor.
  48. Install the battery. Refer to Battery Replacement in Engine Electrical.
  49. Inspect the transmission oil level. Refer to Transmission Fluid Check .
  50. Apply the brakes. Start the engine. Shift the transaxle from R (Reverse) to D (Drive).
  51. Road test the vehicle.