GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Malibu 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - 4T65-E 🢒 Transmission Replacement

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Spray penetrating oil on the exposed threads of both lower ball joint bolt to facilitate their removal later in this procedure.
  3. Lower the vehicle.
  4. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  5. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  6. Disconnect the transaxle wiring harness from the transaxle and the park neutral position (PNP) switch.

    7. Object Number: 629690 Size: SH
  7. Remove the shift cable bracket and shift cable from the lever.
  8. Remove the transmission wiring harness from the retainer on the transmission.

    9. Object Number: 1580069 Size: SH
  9. Remove the upper transmission to engine bolt (3) and studs (1, 4).
  10. Install the engine support fixture. Refer to Engine Support Fixture .
  11. Support the radiator and condenser from above using the condenser tabs on each side.
  12. Raise the vehicle.
  13. Remove the front wheels and tires. Refer to Tire and Wheel Removal and Installation .
  14. Remove the steering gear intermediate shaft .
  15. Separate the control arm from the frame and the outer tie-rod end from the steering knuckles. Support the lower control arm with mechanic's wire.
  16. Remove the frame. Refer to Frame Replacement .
  17. Remove the bolts from the transmission brace near the right axle shaft. Refer to Transmission Brace Replacement .

    18. Object Number: 1580038 Size: SH
  18. Remove the oil pan to bellhousing bracket bolts (1).

    19. Object Number: 510441 Size: SH
  19. Remove the flywheel inspection cover. Refer to Torque Converter Cover Replacement .
  20. Remove the starter. Refer to Starter Motor Replacement .
  21. Mark the relationship of the flywheel to the torque converter for reassembly.

    22. Object Number: 475919 Size: SH
  22. Remove the torque converter to flywheel bolts. Refer to Flywheel to Torque Converter Bolt Replacement .
  23. Remove the transmission oil cooler lines by removing the nut holding the bracket to the transaxle case.

    24. Object Number: 414901 Size: SH
  24. Disconnect the vehicle speed sensor (VSS) wiring harness from the sensor.
  25. Disconnect the rear heated oxygen sensor (HO2S) harness from the bracket on the steering gear.
  26. Disconnect the wheel drive shafts from the transaxle. Refer to Wheel Drive Shaft Replacement .
  27. Remove the front transmission mount from the transmission. Refer to Transmission Front Mount Replacement .
  28. Use a transmission jack in order to support the transmission.
  29. Remove the remaining bellhousing bolts and studs and separate the transmission from the engine.
  30. Lower the transmission with the transmission jack far enough to remove the transmission.
  31. If the transmission is being replace or installed in a holding fixture, remove the rear transmission mount from the transmission. Refer to Transmission Rear Mount Replacement .
  32. Remove the PNP switch from the transmission.

    33. Object Number: 1580069 Size: SH
  33. Remove the transaxle to engine bolts (2, 5).
  34. Separate the engine and the transaxle.
  35. Remove the transaxle from the vehicle.
  36. Remove the PNP switch.
  37. Remove the shifter cable bracket.
  38. Remove the lower transmission to engine stud.
  39. Remove the left transmission mount bracket. Refer to Transmission Mount Bracket Replacement - Left Side .

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 the transmission jack.
  5. Install the left transmission mount bracket to the transmission. Refer to Transmission Mount Bracket Replacement - Left Side .
  6. Install the rear transmission mount to the transmission. Refer to Transmission Rear Mount Replacement .
  7. Position the transaxle in the vehicle.

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


    Object Number: 1580069 Size: SH
  8. Install the lower transmission to engine bolts (2, 5).

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

  9. Install the front transmission mount to the transmission. Refer to Transmission Front Mount Replacement .
  10. Install the wheel drive shafts to the transaxle. Refer to Wheel Drive Shaft Replacement .

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

    12. Object Number: 475919 Size: SH
  12. Install the torque converter to flywheel bolts. Refer to Flywheel to Torque Converter Bolt Replacement .

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


    Object Number: 510441 Size: SH
  13. Install the starter. Refer to Starter Motor Replacement .
  14. Install the flywheel inspection cover. Refer to Torque Converter Cover Replacement .

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

  15. Connect the transaxle oil cooler pipes to the transaxle.

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


    Object Number: 1580038 Size: SH
  16. Install the oil pan to bellhousing bracket bolts (1).

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

  17. Install the bolts to the transmission brace at the final drive area and tighten.
  18. Remove the transmission jack.
  19. Install the frame. Refer to Frame Replacement .
  20. Install the engine splash shields.
  21. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation .
  22. Lower the vehicle.
  23. Remove the radiator and condenser support.
  24. Remove the engine support fixture.

    25. Object Number: 1580069 Size: SH
  25. Install the upper transmission to engine bolt (3) and studs (1, 4).

    26. Tighten
    Tighten the bolt/stud to 90 N·m (66 lb ft).


    Object Number: 629690 Size: SH
  26. Install the shift cable bracket and shift cable to the lever.
  27. Install the exhaust pipe upper bolts and heat shield.
  28. Connect the electrical connectors to the PNP switch and transaxle.
  29. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  30. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

    31. Important: It is recommended that the transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the ECM, PCM or TCM will need to relearn the TAP values. Transmission performance may be affected as new TAP values are learned. Reset the TAP values. Refer to Transmission Adaptive Functions .

  31. Add automatic transmission fluid (ATF) and verify the proper fluid level of the transaxle.
  32. Road test the vehicle.